A Comparative Study of Measuring Devices Used During Space Shuttle Processing for Inside Diameters

During Space Shuttle processing, discrepancies between vehicle dimensions and per print dimensions determine if a part should be refurbished, replaced or accepted "as-is." The engineer's job is to address each discrepancy by choosing the most accurate procedure and tool available, sometimes with up to ten thousands of an inch tolerance. Four methods of measurement are commonly used at the Kennedy Space Center: 1) caliper, 2) mold impressions, 3) optical comparator, 4) dial bore gage. During a problem report evaluation, uncertainty arose between methods after measuring diameters with variations of up to 0.0004" inches. The results showed that computer based measuring devices are extremely accurate, but when human factor is involved in determining points of reference, the results may vary widely compared to more traditional methods. iv