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Educational Consultant/ Dr. R.S. MahashabdeTechnical Regional Project Teachers' Training Institute, Coordinator Extension Centre, Pune
Govt. Polytechnic, Aurangabad April 2002 - March 2003 Principal, Shri P V. Sarode Shri R. D. Virdhe, HOD, Mechanical Engineering, Govt. Polytechnic, Aurangabad Shri. S. S. Lakade, LME Govt. Polytechnic Aurangabad 1) Shri. K. R. Patil, LME Govt. Polytechnic Dhule. 2) Shri. V. M. Bukka, LME Govt. Polytechnic Jalna 3) Shri. P. U. Garge, LME Govt. Polytechnic, Nanded
Course Coordinator
Subject Experts
1) Shri. S. S. Lakade, LME Govt. Polytechnic Aurangabad 2) Shri. V. M. Bukka, LME Govt. Polytechnic Jalna 3) Shri S. S. Deshpande, LME, Govt. Polytechnic Aurangabad ---
Subject Editor
2004,Maharashtra State Board of Technical Education, 49, Kherwadi, Aliyawar Jung Road, Bandra (East), Mumbai-400051, Maharashtra State, India. No part of this laboratory manual may be reproduced, in any form or by any means, without permission in writing from MSBTE Mumbai
the term work satisfactorily in Metrology And Quality Control (1544) for the academic year 200 to 200
Place : Date :
Subject Teacher
Principal
Seal of Institution
LEARNING OVERVIEW
IMPORTANCE OF THE SUBJECT
Metrology is the science of engineering measurements. It is concerned with the methods, execution, & estimation of accuracy of measurements & measuring instruments. In an industrial organization, it is necessary to determine the process capabilities & ensure that these are better than the relevant component tolerances. In addition, it is necessary to determine the measuring instrument capabilities and ensure that they are adequate for their respective measurements. Experiences in Metrology and Quality Control Laboratory will be useful to the Mechanical engineering Diploma holder in industries under various job situations such as, Selection of appropriate measuring instrument for the measurement of a given job. Handle the measuring instrument to judge the accuracy of the component. Take care and maintenance of the measuring instruments. Determine the dimensional accuracy of different machine tools. Inculcate Quality mindedness at all levels of work. Implement the Quality management systems at the work place. This subject is related with other subjects as - manufacturing process for the measurements of jobs produced by various machining processes such as lathe, milling, grinding, honing, lapping also jobs produced by forging, casting and press work. In Mechanical engineering Drawing and machine design subject for the representation of tolerances, surface finish symbols and other geometrical symbols. In tool design and production engineering subject for the measurement of jigs, fixtures and dies. In CAD/CAM subject for the representation of various symbols in drawings, etc. This laboratory manual covers areas of linear & angular measurements, limits, fits and gauges, comparators, screw thread measurements, gear measurements, surface finish measurements, machine tool alignment testing, geometrical feature testing. It also highlights the important aspects of quality such as - control charts, process capability & quality management systems.
CURRICULUM PHILOSOPHY
The Maharashtra State Board of Technical Education has conducted a survey of industries in Maharashtra to find out the job functions of the Mechanical Engineering Diploma Holders in the Industries. The curriculum document explicitly describes technical skills, social skills and attitudes to be developed in industries. While designing this subject; the principles under theories of learning have been used. The link diagram and graphical structure is provided, which helps the students to learn systematically and also helps the teachers to use different strategies for teaching. Job description and role of technician Curriculum objectives drawn from job analysis Personal development domain Social development Life Long Learner Industry related professional role Curriculum areas to develop / achieve curriculum objectives
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Graphical structure of the subject area Teaching learning process at curriculum level Approach student evaluation
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LINK / BLOCK DIAGRAM SHOWING INTER RELATIONSHIP OF SUBJECT AREAS, CURRICULUM OBJECTIVES & JOB PROFILE.
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GRAPHICAL STRUCTURE OF SUBJECT AREA Third year- Mechanical Engineering METROLOGY AND QUALITY CONTROL (1544)
To select and use the various measuring instruments to measure the quality characteristic of different industrial components. To statistically analyze the data. To take decisions from quality control point of view.
Problems
Procedures
To select the proper instrument for a specific measurement problems To measure the dimension of different components using measuring instruments. To accept or reject the components using gauges
To collect and analyse the data in view of frequency distribution control charts process capability sampling inspection
Principles
Concepts
Quality cost and value of quality Quality characteristics Measurement quality control
Facts
Vernier caliper, vernier height gauge, vernier depth gauge, inside and outside micrometer, slip gauges, dial indicators, comparators, comparators, autocollimator, gauges, gear tooth vernier, screw thread micrometer, floating carriage micrometer, tool maker's microscope, optical profile projector, surface finish measuring instruments, frequency histograms, quality control charts, quality management systems
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DEVELOPMENT OF SKILLS
Intellectual Skills :1. 2. 3. 4. 5. 6. 7. To understand principle, construction and working of various measuring instruments Selection of proper instruments for measurement Calculation of least count of instrument Take reading using the instrument Interpret the observations & results Collection & recording of data Analysis of data
Motor Skills :1. 2. 3. 4. 5. 6. 7. Setting the instruments for zero error adjustment Proper alignment of the instrument with work-piece Handling of instruments Care & maintenance of instrument Measure the dimensions from the instruments Calibration of the instruments Graphical representation of data
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GRID TABLE
Expr. No. 01 Name Of Experiment Study of basic measuring instruments: surface plate, angle plate, `V' block, spirit level, combination set, straight edge, filler gauge, screw pitch gauge, radius gauge. Use of vernier caliper & micrometer to measure dimensions of given jobs. Use of Slip Gauges to find the unknown gap. To find unknown angle of component using sine bar. Study and use of optical flat for flatness measurement. Study and use of angle dekkor as a comparator. Measurement of screw thread elements by using screw micrometer. Measurement of screw thread elements by using floating carriage micrometer. Measurement of screw thread elements by using Toolmaker's microscope. Study and use of dial indicators as a mechanical comparator. Study & use of pneumatic comparator Measurement of surface finish elements by using Taylor Hobson Talysurf. Measurement of gear tooth elements by using optical profile projector. Measurement of gear tooth elements using Gear tooth vernier caliper. Testing of machine tools for flatness, parallelism, perpendicularity for lathe and drilling machine. Visit to industry which has got ISO-9000 / ISO14000 certificate & submit a report consisting of a) Certificate norms b) Quality Control System Draw the frequency histogram, frequency polygon & ogive curve for given samples. To draw the normal distribution curve & find standard deviation, variance & range. To draw & interpret the control limits for variable measurement (X bar & R Chart). To draw & interpret the control limits for attribute measurement (P & C chart). - Identified Skills Intellectual skills 1 2 3 4 5 6 7 1 2 Motor skills 3 4 5 6 7
02 03 04 05 06 07 08 09 10 11 12 13 14 15
16
17 18 19 20
NOTE :
4)
5) 6) 7) 8) 9)
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2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
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