our expertise in your industry SPRING 2009

BOWERS IN AEROSPACE • OUR EXPERTISE IN YOUR INDUSTRY Partners in Precision

Welcome toBowers inAerospaceLong recognised as the world’s leadingbore gauge manufacturer, the BowersMetrology Group is a respected globalleader in the field of precisionmeasurement for the Aerospaceindustry.

In this, the latest edition of Bowers in

Aerospace, we bring you up-to-date withall the latest developments from Bowers foryour industry. Take a look at how just someof the solutions from Bowers have helpedrevolutionise the working practices of theseorganisations:

APPH Basingstoke: flying high with Bowers Bore Gauges pg 1

Flight Refuelling: improving theirinspection methods using ultra-accurate Bowers SmartPlug technology pg 3

JWST Project: avoid failure in service of vital components with a Bowers Portable Hardness Tester pg 6

FR Hi-Temp: puts Bowers MetrologySystems to the test pg 7

In response to customer demand, and as aresult of the company’s continuedinvestment in cutting-edge technology,Bowers produces an increasinglycomprehensive range of affordable, qualitybore gauging and material testing solutions.Products in Focus in this issue include:

Shave Height and Countersink Gauges pg 2

SmartPlugs pg 3

Universal Gauge pg 4

Electronic Bore Gauge - Ultima pg 5

Rangemaster Plus Hardness Tester pg 6

Intex Beam Gauge pg 7

Bowers Bore Gauges FlyingHigh With APPH Basingstoke

system should have the ability to take precise

‘blind’ measurements 2 metres down inside our

components without leaving any kind of

blemish on the fine surface finish of our bores.”

Robin found the answer in Bowers Metrology’s

impressive, XT Xtreme Bore Gauging range.

Ideal for use within inspection departments or

in close proximity to Machine Tools, Bowers’

advanced new electronics boast a very

impressive IP65 rating, rendering them

resistant to coolant, water and airborne

particles. Amongst a long list of useful features

incorporated into the tough new instruments

are a clear digital display, metric/inch

conversion, an RS 232 output and hardwearing

extended travel carbide measuring anvils.

Robin continues, “Having been extremely

impressed by the standard XT Xtreme Bore

Gauge range, Bowers was able to grind a

radius on our instrument’s contact anvils

guaranteeing the integrity of our components

surface finish, whilst retaining the gauge’s

micron capability. Modular, long-reach 2 metre

extensions were also supplied ensuring that we

are able to accurately measure even our

deepest bores. We will be adding further

Bowers measuring heads to our range as the

need arises. Our new Bore Gauges have proven

a great success and are now helping us to

maintain APPH’s excellent reputation for the

high-quality of our work.”

Part of BBA Aviation PLC, APPH

Basingstoke Ltd provides its growing

international customer base with a

highly skilled multi-disciplined

engineering capability from its

impressive 70,000 sq/ft facility situated

in Basingstoke, Hampshire. Boasting

a long list of international approvals,

this well-known company undertake

manufacturing, repair and overhaul work

across an impressive spectrum of Aerospace

related areas such as, Cargo Systems, Electrical

Harness, Rotary Wing and Landing Gear.

As one of Europe’s leading landing gear repair

and overhaul engineering organisations, APPH

Basingstoke has a comprehensive in-house

Grinding, Boring, Milling and Turning capability

and is able to accommodate the vast majority

of landing gear currently in service. When

tasked with finding a flexible gauging system

with the ability to accurately measure the bores

in these safety critical parts, Robin White,

company Inspector found that the wide

diversity in the sizes of landing gear work

undertaken by the company raised an awkward

problem. “Because of our broad range of tight

tolerance bores, we needed to find a system

with the potential to gauge sizes of up to

300mm, in both our production and inspection

areas. The nature of our larger components also

dictated that any new company bore gauging

BOWERS IN AEROSPACE • OUR EXPERTISE IN YOUR INDUSTRY Partners in Precision

The Bowers Metrology Group is continually working to develop products specificallydesigned for the Aerospace industry.

As tolerances are constantly being tightened, the industry is demanding increasingly accurategauging instruments and systems. Our Shave Height Gauge and Countersink Gauge are just two examples:

22

Shave Height Gauge

Digital Countersink Gauge

The Bowers Shave Height Gauge has

been specially designed to measure the

height of rivets used on aircraft outer skin. If

the top of the rivet is too high above or too

low below the level of the rivet-hole, the

streamlining of the aircraft will be affected.

This wind-resistance will be magnified many

times depending on the number of rivets

present in the outer hull of the aircraft. The

rivet-height gauge measures the height of

the top of the rivet in relation to the level

of the surrounding aircraft skin, enabling

tolerances to be maintained and providing a

valuable reference measurement to help

determine the streamlining of the aircraft

and the consequent effects on it’s

aerodynamics and fuel efficiency.

The Bowers Countersink Gauge

can be used to check the major

diameters of countersinks in the

aircraft outer skin, prior to the

application of rivets. The gauge can

also be used for countersink

measurement in general

applications within the aerospace,

automotive and other related

industries. The unit shown here is

with a digital indicator but can also

be fitted with a digital readout and

probe.

Bowers can deliver innovative and cost-effective solutions to the most demanding measurement challenge. If you have a

specific requirement that you would like Bowers to assist with, please contact info@bowers.co.uk.

Features• Rivet diameters : 3/16", 1/4", 5/16", 3/8"

available as standard

• Other rivet diameters available on

request

• Digital display with mm / inch conversion

and preset function

• Resolution : 0.0005" / 0.001mm

• Repeatablility +/- 0.003µm

• RS-232 data ouput

• Scalloped base to facilitate visual location

over the rivet

• Very easy to use

• Small portable format

• Robust construction

Features• Standard range diameter 6 - 16mm /

1/4" - 5/8"

• Switchable resolution - inch/metric true

conversion

• Preset facility

• Tolerance mode

• All digital indicator features can be locked for

security

• RS-232 data ouput

• Robust construction, hardened plunger,

induction hardened body

• Standard plungers available to measure 90º,

100º and 110º

• Other angles available on request

• Setting master supplied as standard

Bowers is at the forefront of deliveringinnovative and cost-effective solutions

For more information visit www.bowers.co.uk Partners in Precision 3

Renowned for the quality of their manufactured products,well-known aerospace company, Flight Refuelling Ltd, tookdelivery of a series of Bowers SmartPlug Heads linked to highaccuracy Sylvac transducer probes feeding into a Sylvac D100sreadout unit. The ingenious system now helps measure thecritical concentricity of a series of vital parts within acomplex Airborne Weapons Firing Mechanism.

Company Manufacturing Manager Steve Grindey explained“The safety critical nature of these tight tolerance,

complex components meant that our previousinspection methods, involving a CoordinateMeasuring Machine, was exceptionally timeconsuming and caused a bottle-neck for otherinspection work at the CMM. Although ourspecification for this gauging project wasextremely demanding, Bowers fully understood

the brief and supplied on time, on budget and,most importantly, our new gauging equipment

actually exceeds our accuracy expectations. OurBowers SmartPlug/Sylvac system sends its dimensional

findings to a PC instantly updating our records and asinspection times have now been slashed the system is well

on its way to paying for itself.”

‘Smart’ Thinking from Bowers

SmartPlugs & D100

BOWERS SMARTPLUGSThe robust, easy to use SmartPlug range is designed to give the operator greater speed of use, unmatched measuring

accuracy and superb repeatability, especially in harsh shop-floor environments. Advanced hand held ergonomics allied to

an ingenious mechanical / electronic system render SmartPlugs the easiest to operate Bowers bore gauging system to

date. The flexible nature of Bowers SmartPlugs range means that they can be supplied fitted with easy to read electronic

indicators (ideal for automatic data collection), conventional analogue indicators, or transducer probes linked to remote

digital readout units.

Features• Range 6 - 280mm

• Tough, robust construction

• High accuracy dedicated plug-gauges

• Hand-held measurement

• Protective indicator shroud (with some

indicators)

• Repeatability ≤1 µm

• 2 - point measurement as standard

• Depth-stops available

• Extensions available for deeper bores

• Guide chamfer for easy entry into bore

• Plug body coatings: Hard-chrome

(standard), T.i.N., Plain steelSmartPlug with TiN

coated body

SmartPlug with ceramic contacts

SmartPlug with

depth stop

SmartPlug with transducer holder

and standalone display

For more information on our range of SmartPlugs Email: smartplugs@bowers.co.uk

BOWERS IN AEROSPACE • OUR EXPERTISE IN YOUR INDUSTRY Partners in Precision4

Universal Gauging from Bowers

Keeping You in The KnowBowers Metrology has been manufacturing high quality bore gauging

systems for over 50 years and the demand for ‘special’ gauging systems

to suit our customers’ specific requirements has never been greater.

To help keep you up-to-date with all our latest Special Applications, a new

brochure has been released. With the use of simple line drawings, the brochure

describes some of the most popular applications based around our standard

range of flexible gauging systems. By changing either the measuring anvils or

the measuring head, our products can be converted economically into

‘special’ gauges to solve our customers’ specific problems.

To request your copy of the brochure, simply email your details to:

specials@bowersmetrology.com or why not download it now at

www.bowersmetrology.com.

The Bowers Universal Gauge’singenious modular formatenables it to be quicklyconfigured to suit almost anymeasuring challenge. Whethermeasuring internally orexternally, the Universal’s cleverconstant pressure device ensuresaccuracy and consistency ofreading. The gauge’s findings aredisplayed on its built in cleardigital readout.

The unique modular construction ofthe Bowers Universal Gauge allowsthe fitting of a large variety ofmeasuring contacts and adaptors,enabling countless measuring tasksto be completed with ease.Accessories for the measurement ofthreads, grooves, splines, gears, holecentres, and many others areavailable as standard, whilst specialadaptations for more unusualapplications can be quoted onrequest.

Features

• Range 30 - 250mm internal / 0 - 215mmexternal 15mm anvil travel

• Constant measuring pressure

• Digital or mechanical readout

• 150mm and 500mm extensionsavailable. Can be screwed together in multiples (up to maximum 3m recommended)

• Measuring table and supports availablefor conversion to bench gauge for themeasurement of small components

• Covers approx 90% of all applications

TGUDEMO2

Special ApplicationsFabrications Spéciales

Sonderanfertigungen

For more information visit www.bowers.co.uk Partners in Precision 5

Bowers Gauges AerospaceThanks to its continued investment in cutting edge technology anddrawing from over 50 years of experience, Bowers Metrology is in anenviable position of being able to deliver innovative and cost-effective solutions to the most demanding of measurementchallenges.

Following a detailed discussion of requirements, and with the rigorousinspection processes associated with the Aerospace industry always at theforefront of the design considerations, Bowers developed a range of gaugesfor a leading name in Aerospace. Presented in a tough, portable case perfectfor the harsh shop-floor, the Bowers gauge kit includes; a Drivematic SlugRivet Gauge, two different sized Shave Height Gauges for measuring rivetheight on an aircraft outer skin and a Digital Countersink Gauge forchecking countersink diameters in the outer skin prior to the application ofrivets.

The gauges shown are with a digital indicator but can also be fitted with astandard probe and readout unit.

For more information on how Bowers can help you find your idealmeasuring solution, email info@bowers.co.uk.

The Ultima inBore GaugingBowers’ Ultima Bore Gauge offers achoice of resolutions up to 0.0001mm.Featuring the Bowers ‘FASTFIT’measuring heads with extendedmeasuring range (above 14mm), theUltima boasts a simple lever operationand a constant measuring force,ensuring outstanding ease of use andrepeatability under laboratory orshop-floor conditions.

The Ultima Features:• UKAS certificates standard for allmeasuring heads and setting rings

• Measuring range 2 - 310mm (0.080" - 12.000")

• Resolution: 0.0001mm (0.00001") • Constant spring pressure for improvedrepeatability

• Good positive feel as heads self-centrein the bore

• Bowers Fastfit measuring heads forrapid changeover

• Ceramic anvils on heads above 12mm • Blind-bore measurement standardabove 12mm

• Possible to connect several probeholders to one single readout tomeasure different bore sizes at onemeasuring station

• The complete range of Bowers specialheads is available for the Ultima(grooves, threads, splines, deep-bores etc)

• Depth stops available for all heads • Available without digital readout unit(if not required)

• Alternative Sylvac digital readoutsavailable

• Interchangeable probe option, allowsuse of other manufacturers probes anddisplays

For more information email ultima@bowers.co.uk.

Product Focus:

Drivematic Slug Rivet

Gauge

ShaveHeight Gauge

DigitalCountersink

Gauge

ShaveHeight Gauge

BOWERS IN AEROSPACE • OUR EXPERTISE IN YOUR INDUSTRY Partners in Precision

The prevention of failure in serviceof vital components, is often theprincipal motivation for stringentquality control regimes, this wasnever truer than in the case of theJames Webb Space Telescope project. Scheduled to be launched in2013, the JWST will be a giant stepforward in the human quest tounderstand our place in the universe.With its infrared-optimised telescopecooled to tens of degrees aboveabsolute zero, hanging in the darknessof space far from earth, JWST willexamine every phase of our history, fromthe first luminous glows following thebig bang, to the formation of solarsystems capable of supporting life onplanets such as Earth. Following itslaunch, JWST will be the premier spaceobservatory for astronomers world wide,extending the tantalising discoveries ofthe Hubble Space Telescope, the SpitzerSpace Telescope, and the giantground-based telescopes.

Maximising the mission’s potential tomake new scientific discoveries, JWSTwill have a large 6.5-meter primarymirror, passively cooled to approximately45K by a sunshield. It will be sensitive tolight from 0.6 to 27 micrometers. JWSTwill contain four advanced scientificinstruments on its Integrated ScienceInstrument Module (ISIM), the NearInfrared/Visible Camera (NIRCAM), NearInfrared Spectrograph (NIRSPEC), MidInfrared Instrument (MIRI) and FineGuidance Sensor (FGS). Missioninnovations include a folding segmentedprimary mirror, adjusted to shape afterlaunch, ultra-lightweight berylliumoptics, detectors that are able to record

extremely weak signals, microshuttersthat enable programmable objectselection for the spectrograph, and acryocooler for cooling the mid-IRdetectors to 7K.

The JWST project represents aninternational collaboration amongNASA, the European Space Agency andthe Canadian Space Agency. WithNorthrop Grumman Space Technologiesas prime contractor and Goddard FlightCentre managing the hugedevelopment effort, on completionJWST will be operated by the SpaceTelescope Science Institute.

Enjoying an excellent internationalreputation in its field, the University ofLeicester Space Research Centreprovides the project mechanicalengineering lead for the MidInfrared Instrument (MIRI) and isresponsible for the design andprovision of the MIRI PrimaryStructure in collaboration withthe Danish National SpaceCentre, whilst also providingsupport for MIRI test andcalibration activities.

As failure in service of any of theMIRI components could provedisastrous to the JWST mission, theUniversity of Leicester SpaceResearch Centre applies stringentquality control regimes at everystage of the MIRImanufacturing process. Whenfaced with the need for ahigh quality, portablehardness tester that wouldbe able to give accurateresults over a wide crosssection of components, JonSykes (MIRI European ConsortiumMechanical Engineering Lead)purchased a CV Rangemaster fromBowers Metrology. John enthused, “TheRangemaster allows us to make anassessment of material yield strength atvarious stages of the Primary Structuremanufacturing process. This informationis critical, as it provides confirmation thatthe structural performance will bewithin our predicted limits, andtherefore that structural failure will notoccur during test or in flight. Theportability, range, ease of calibrationand measurement repeatability of theBowers device renders it entirely suitablefor this application.”

6

PortableHardnessTesting forAerospaceThe Bowers CV Rangemaster PlusHardness Tester represents an idealsolution to the problems associatedwith portable hardness testing inaerospace. Its clear digital display,ease of use and ability to operate inall major international scales make itthe most comprehensive unit of itstype currently available. The optionalsturdy bench stand adds further to the

flexible nature of thisergonomic gauge.

Rangemaster Features:

• Dynamic test indicator

• Large digitalreadout

• Hardness valuesin all majorinternationalscales with simple

conversion facilities fromone to the other

• RS232 output forconnection to PC orserial printer

• Memory storagecapacity for in excess

of 400 readings

• Statistical summary

• Integral icon facility providesoperator with easy visual

identification of mode in which unit isoperating

• Operates in temperatures from -5ºC to+35ºC

• Upper and lower control limits

• Last reading recall

• Supplied with two UKAS certified testblocks, adjuster key and carrying case

For more information contact

rangemaster@bowers.co.uk.

Bowers Material Help ForJWST Science Mission

Product Focus:

For more information visit www.bowers.co.uk Partners in Precision 7

Bowers Go ToGreat Lengths

Product Focus:

Intex: A Closer LookDeveloped to measure both internal and external diameters andlengths, the Bowers Intex Beam Gauge’s aluminium extrusionbeam gives it a rigid, yet lightweight quality – making it ideal forshop-floor environments. The simple release of a locking thumb screwenables the gauge’s measuring direction to be changed easily and quickly.The four gauges in the Intex range have been designed to measurecomponents from 200mm up to 1m long – extended lengths are availableon request.

Features of the Intex Beam Gauge:• Lightweight and rigid - typically weighing less than 2kg• Internal and external measurement • 2mm travel on moving contacts• Adjustable fixed contacts with a range of adjustment up to 250mm• Digital or mechanical readout display• Hardened steel wear pads locate gauge on to the

component aiding accuracy, repeatability and prolonging the life of the instrument

For more information email intex@bowers.co.uk.

In an effort to further improvetheir already stringent inspectionroutines, one of the country’sleading suppliers to theaerospace industry, FR Hi-Temphas taken delivery of twoinnovative 3 meter lengthmeasuring machines, designedand manufactured by BowersMetrology Systems. Unable tofind an ’off the shelf’ solutioncapable of accommodating parts ofsuch great lengths and able to matchthe company’s demandingspecification, FR Hi-Temp, mindful ofthe Bowers reputation within thechallenging Aerospace industry,approached Bowers MetrologySystems. Following a shortconsultation period, an innovativemachine design evolved, giving theuser the high accuracy andrepeatability (0.001 inch over 10 feet)and the many useful facilitiesrequired when in use.

Plant Manufacturing Engineer MarkSheath enthuses, “FR Hi-Temp enjoysa reputation second to none withinthe Aerospace industry for thequality of our output. Our new largecapacity acquisitions are alreadyproving a great success, allowing usto measure, amongst many otherlarge parts, our entire range of flapoperating shafts and fuselagestrengthening struts. The newBowers machines now enable us tomatch and exceed the dimensionaltolerances demanded by ourcustomers and have significantlyspeeded up previously long andlaborious measuring routines”.

THE NEW BOWERS

INTEX BEAM GAUGE

Designed to accurately perform a staggering variety of measuring tasks, Bowers Metrology has launched its long awaited UniCal multi-purpose digitalcaliper range.

Available in standard 300mm, 600mm and 1000mm capacities, with larger versionsavailable upon request, Bowers’ revolutionary new technology boasts tough, lightweightreinforced beams, giving them incredible strength and an amazing weightlessness.

Bowers’ flexible UniCal’s advanced features include a large, easy to read digital display, apreset facility, a constant measuring force, a metric inch conversion and a RS232 data outputport.

Although a wide range of standard UniCal accessories enable a multitude of measuringtasks to be performed, for more unusual applications Bowers will manufacture ‘one-off’adaptations allowing the most difficult of gauging routines to be undertaken.

For more information about the UniCal email unical@bowers.co.uk

BOWERS IN AEROSPACE • OUR EXPERTISE IN YOUR INDUSTRY Partners in Precision8

Measuring contacts for face-groove and V-groove

ø measurement

Shoulder anvils Code: TGUA 011

Semi-cylindrical anvils Code: TGUA 012

Disc anvils Code: TGUA 013

Cylindrical measuring pins

UniCal: Flexibility at Your Fingertips

Product Focus:

A TOTALLY NEW

SOLUTION FROM BOWERS

BowersLaunchesNew Website!Bowers Metrology has launchedits new, all-inclusive, user-friendlywebsite; www.bowers.co.uk.

Claimed by Bowers to feature thelargest selection of measuring andmaterial testing instruments, thecomprehensive new website isdesigned specifically with ease ofnavigation in mind, enabling allvisitors to access information quicklyand easily.

Users of the new site now enjoyimproved access to a full range ofcompany technical support and areable to instantly download productdata sheets, installation manuals,free software, dimensional drawingsetc.

Company Managing Director SteveWhite explained, “The phenomenalrise in visitor numbers to the oldwebsite, together with the largeincrease in the range of products andservices offered by Bowers,prompted us to totally re-design ourwebsite. The improved architectureenables visitors to find exactly theinformation they are looking for –quickly. We are hoping that thecomprehensive nature of our new,user-friendly site will give anenhanced experience to visitors,further increase company web-trafficand help give an improved service toall of our many valued customers.”

Keep up-to-date with news anddevelopments from Bowers byregistering your details online atwww.bowers.co.uk/register