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This paper discusses calibration uncertainty and linearity issues of the typical back-pressure air gauge. In this sort of air gauge, the correlation between the measured dimension (represented by the slot width) and the air pressure in the measuring chamber is used in a proportional range. However, when high linearity is required (e.g., nonlinearity less than 1%), the measuring range should be shortened. In the proposed method, based on knowledge of the static characteristics of air gauges, the measuring range is kept unchanged but the nonlinearity is decreased. The static characteristics may be separated into two sections, each of them approximated with a different linear function. As a result, the nonlinearity is reduced from 5% down to 1% and even below.

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The paper presents a method for checking the geometry of stamped car body parts using a 3D optical measurement system. The analysis focuses on the first forming operation due to the deformation and material flow associated with stall thresholds. An essential element of the analysis is determining the actual gap occurring between the forming surfaces based on the die and punch geometry used in the first stamping operation. The geometry of car body elements at individual production stages was analyzed using an optical laser scanner. The control carried out in this way allowed one to correctly position the tools (punch and die), thus introducing the correction of technological parameters, having a fundamental influence on the specific features of the final product. This type of approach has not been used before to calibrate the technological line and setting of shaping tools. The influence of the manufactured product geometry in intermediate operations on the final geometry features was not investigated.

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