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Measuring with multiple tip angles

We are currently working on a cylindrical part which is fixtured with the center of the cylinder parallel to the X axis.

The length of the part is 27.45mm and verified by calipers.

We measure a plane on the edge of the cylinder with tip T1A90B-90 then we measure a plane on the other side of the cylinder with tip T1A90B90.

When reporting the distance from plane 1 to plane 2, it reports at 27.724.

When we measure this distance with T1A0B0, we get 27.488, much closer to nominal and what we are measuring with calipers.

I'm assuming we're missing something regarding the change in tip angles?

Can anyone point out what we're doing wrong? We need to be able to measure this feature, along with all the internal features, using these angles.

Thanks.
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  • We have re-calibrated the angles. Same result.

    We are reporting 3D distance.

    Yes, the A0B0 is just a point to point.

    We are measuring this in Xplus workplane, if that's a factor. I don't see how.

    When reporting distance between 2 planes, is it taking an average? Centroid to centroid?

    When measuring using calipers, the distance does not change.
  • Centroid to centroid. And if those centroids are at different locations in Y and Z the 3D distance is going to report longer than a caliper which is measuring 2D. If the cylinder axis is parallel to machine X then I'd report 2D and tick parallel to machine X if I wanted to replicate a caliper measurement.
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