Lecture 1 Chapter 10

Measurement, Inspection and Testing

MECH 311
Dr John Cheung
Dr.

MECH311 Manufacturing Processes

Section CC

Instructor: Dr. John Cheung

Office:

EV 3.276
Phone:
514-848-2424 ext
ext. 3462
Email:
cheung@encs.concordia.ca
Schedule
Lecture:

Monday and Wednesday (8.45 11-15am)

Tutorial: Tuesday and Thursday (8
(8.45
45 10.25am)
10 25am)
Labs: Once a week

Marking Scheme
Labs: 15%
Assignments: 10
Quizzes: 10%
Midterm: 15%
Final exam: 50%

Lecture Outline
Measurement & Quality Control (Week 1)
Machining (Weeks 2 8)
Other manufacturing process (Weeks 9 13)
Each lecture will cover 1 to 4 chapters
Lecture will NOT cover all the material that

you are responsible for

You are responsible for all the material in the
textbook
4

About Lectures
The lecture contents are about
Tabulation of facts, different processes, different
technologies, different techniques
Lectures will offer a roadmap of knowledge rather
the list of knowledge.
Feed back (good/bad) on the lecture is

welcome.
Good time management.

About Tests
Multiple choice, short questions calculations

and case study.

Based
ased o
on ass
assignments,
g e s, tutorial,
u o a , lectures
ec u es a
and
d
textbook.
No content specific
p
to the lab work

My Expectation

Knowledge from
textbook and lectures
- Important
- Conceptual
- Analytical

Engineers

Needs
- Abstraction
- Imagination
- Insight

Vs.

Knowledge from labs

- Practical
- Hands-on
Hands on
- Lots of specific details

Operators
7

Factors in Manufacturing
Factors
Product

design
Materials
Labour
L b
costs
t
Equipment
Manufacturing costs

Strategies to reduce cost

Figure 1-2
Manufacturing cost is
the largest part of the
selling price, usually
around 40%. The
largest part of the
manufacturing cost is
materials, usually 50%.

Lean

manufacturing
Systems approach
Key message:
How the manufacturing process
is managed can greatly affect the
cost
8

Roles of Engineers in
Manufacturing
Design engineer responsibilities
What the design is to accomplish
Assumptions that can be made
Service environments the product must withstand
Final appearance
pp
of the p
product
Product designed with the knowledge that certain
manufacturing processes will be used (you cannot
design something that cannot be made.)

Roles of Engineers in
Manufacturing
Manufacturing engineer responsibilities
Select and coordinate specific processes and
equipment
Supervise and manage their use (the cost)
Industrial ((Manufacturing)
g) engineer
g
Manufacturing systems layout
Materials engineers
g
Specify ideal materials
Develop new and better materials
10

Introduction
Measurement
Fundamental activity of testing and inspection
Inspection
Ensures product will meet specifications
Testing
Evaluates product quality or performance

11

Manufacturing Principles
Products are manufactured to standard sizes

and shapes
Interchangeable
e c a geab e pa
parts
s beca
became
e co
common
o in the
e
early 1900s
Design
g engineer
g
may
y have to design
g or alter
specifications to ease manufacturing, assembly
and inspection or lower costs
These

changes should not sacrifice functionality,

product reliability or performance
Example:
E
l gett a hole
h l with
ith diameter
di
t 0
0.93
93 iinch
h
12

Standards of Measurement
Fundamental measures
Length

(sort-of), time, mass, temperature

Candela, ampere, mole

All other
th measurements
t can b
be made
d using
i a

combination of the fundamental measures

Linear standards
International

meter is the standard

Inch is based off of the meter standard as 0.0254m

41 929 399 wavelengths of orange

41,929.399
orange-red
red light from krypton
krypton-86
86

13

Attributes vs.
vs Variables
Inspection of a product can be done in two

main ways
Attributes

(
(Gauging)
g g)

Uses gauges
Reported as YES/NO, GO/NO GO

Variables

(Measurements)

Uses calibrated instruments

Reported
R
t d iin actual
t l di
dimensions
i

14

Allowance and Tolerance

What to inspect

Allowance - intentional,, desired difference

between two mating parts

Determines

the condition of tightest fit

May be specified for clearance or interference
Tolerance- undesirable but permissible

deviation from a desired dimensions

No

part can be made exactly to a specified

dimension
Necessary to permit the actual dimension to
deviate from the theoretical (nominal) dimension
15

Allowance and Tolerance

Cl
Clearance
or interference?
i t f
?

Figure 10-7 When mating parts are designed, each shaft must be smaller than each
hole for a clearance fit.

16

Specifying Tolerance
Bilateral
Plus or minus deviation from the nominal size
Unilateral
Deviation in one direction from the nominal
size
Limits
Maximum and minimum dimensions
Geometric
Shape
p and p
position of a feature
17

ANSI Classes of Fits

Class 1: Loose fit
Class 2: Free fit
Class 3: Medium fit
Class 4: Snug fit
Class 5: Wringing fit
Class 6: Tight fit
Class
Cl
7:
7 Medium
M di
fforce
Class 8: Heavy force and shrink fits
18

ISO System of Limits and Fits

Far more complicated then ANSI standard
A basic size and limit are defined
Three classes of fits
Clearance, Transition and Interference
ii.e.
e H8/g7
Letter is the tolerance grade
# is tolerance WRT zero deviation
Capital letter is hole, lower case is shaft
Tables are used to look up actual sizes
19

Geometric Tolerances
Maximum allowable deviation of a form or position

from the perfect geometry

Geometric tolerances are specified with respect to
a datum or reference surface
Maximum material condition indicates that a part
i made
is
d with
ith the
th maximum
i
allowable
ll
bl material
t i l
Least material condition indicates that a part is
made with the minimum allowable material
Four form tolerances
Flatness,,

straightness,
g
, roundness,, and cylindricity
y
y
20

Geometric Tolerances

Figure 10-11 (a) Geometric tolerancing symbols;

(b) feature control symbols for part drawings; (c)
how a geometric tolerance for flatness is specified;
(d) what the specification means.

21

Measuring Instruments
Common Types
Linear measuring devices
Optical measuring devices
Angular measuring devices
Coordinate measuring
g machines

22

Gauge Blocks

23

Vernier Callipers

24

Micrometer

25

Tool Makers Microscope

26

Interferometer
Uses light
g

interference bands to
determine distance
and thickness of
objects
Constructive

interference- beams
interference
returning are in
phase
Destructive

interference- beams
returning are out of
phase
27

Sine Bar

28

Gauges for Attributes Measuring

It is not always necessary to know exact

dimensions
Attribute-type
bu e ype instruments
s u e sa
are
e ca
called
ed gauges
Fixed-type gauges

Gauge only one dimension and indicate

whether it is larger or smaller than some
standard
Plug gauge, go/no go gauge, step-type gauge,
snap gauge, ring gauge
29

Ring Gauge
Used to check the size of a shaft
One for the upper limit and one for the lower
limit

30

Plug Gauge
Double sided, a go and no-go
no go ends

31

10 10 Testing
10.10
Destructive testing
Components

are subjected to conditions to induce failure

Proof testing
Product

is subjected to a load or pressure of some known

and determined magnitude to simulate product life

Hardness tests
Test

the hardness of materials

Nondestructive testing
Products

are examined in a way that it can still be used

32

Liquid Penetrant Inspection

33

Liquid Penetrant Inspection

Clean and dry
y component
p
thoroughly.
g y
Apply Liquid penetrant (mixed with colour dyes glow

under ultraviolet light) to component surface.

Remove excessive penetrant from surface.
Cover surface with thin film of developer which draws
penetrant from defects
defects.
Check component under ultraviolet light to find
surface cracks if any.
y
Clean component after inspection.

34

Magnetic Particle Inspection

(a) Magnetic field disrupted by a crack
(b) magnetic particles are preferentially

a ac ed to
attracted
o field
e d leakage
ea age
(c) subsurface defects can also produce
surface-detectable disruptions
p

35

Ultrasonic Inspection
Distortions in the sound indicate a defect in

the product

36

Radiographic Inspection
X
X-rays,
rays, gamma rays, neutron beams can be

used to inspect for defects

37

Eddy
Eddy Current Testing

38

Eddy
Eddy Current Testing

39

Eddy
Eddy Current Testing
Electrically
y conductive material exposed
p
to

alternating magnetic field induced small electric

current near surface (eddy currents).
Edd currentt affected
Eddy
ff t d by
b defects
d f t - changing
h
i th
the
induced magnetic field characteristics.
Use to detect components with various hardness
hardness,
case depth, residual stresses.
Simple, portable units with hand held probes.
Not as sensitive as penetrant testing and magnetic
particle inspection for small surface cracks.
40

Summary
Measurement and inspection are an important

aspect of quality control

There
eea
are
e a wide
de variety
a eyo
of techniques
ec ques that
a
can be employed to make measurements
The correct technique
q depends
p
on the
application, available equipment and necessary
accuracy
Cost may play a role in determining which
technique is appropriate
41