Inspection and Quality Control - me.iitb.ac.inramesh/courses/ME338/ssp2.pdf · Outline • Need for...
Transcript of Inspection and Quality Control - me.iitb.ac.inramesh/courses/ME338/ssp2.pdf · Outline • Need for...
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Inspection and Quality Control1
Prof. S. S. Pande
Mechanical Engineering DepartmentIndian Institute of Technology, Bombay
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Outline
• Need for Inspection and Quality Control
• Modes of Inspection• Accuracy Testing of Machine Tools• Part / Product inspection• Process Quality Control
• Basics of Metrology• Definitions• Metrology Instruments.
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Inspection
Watchdog of a Manufacturing Process
Product cost = Material + Production + Inspection
Cost of inspection is Significantly High.
Inspection Process is mostly manual.
Design Manufacturing Inspection Part
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Inspection Process
Objective• Assess Conformity with Design Specifications• Improve Product Quality and Reliability
Constraints on Inspection • Product Volume• Product Cost• Product Functional Performance
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Global Manufacturing Scenario
Challenges
• Miniaturization • High Precision and Accuracy • High Productivity and Reliability• Shortest Time to market• Quick Turn-around
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Machining Accuracy
Ref: Taniguchi
Normal machining
Precision machining
0.1mm
1 µm
1 nm
Mac
hini
ng a
ccur
acy
capa
bilit
y (µ
m)
Ultra-precisionmachining
1940 1960 1980 2000
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Cost – Tolerance relation
Tolerance (in.)
Rel
ativ
e co
st
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Production Time - Surface Finish
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Stages in Product - Process Inspection
Product Development
• Part Production and Inspection• Assembly Testing• Prototype Testing
• Kinematic (No load) Testing• Performance Testing
• Roll Out
Process Monitoring• Process inspection and control
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Modes of Inspection
• Accuracy Testing of Machine Tools
• Part / Product inspection
• Process Quality Control
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Accuracy Testing of Machine Tools
Objective
• To Test kinematic and Geometric accuracy of Machine Tool• Alignment, Location, Orientation errors
between Spindle, Slides, Tool/ work Holders
• Certification, Maintenance tasks, History
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Y
Configuration of CNC Machine
XZ
Tool
Gantry type
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3- Axis CNC Milling Machine
X - Y - Z
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5 – Axis CNC Milling Machine
X - Y – Z – B - C
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Precision Machine Tools
Desirable Characteristics
• Accurate running Spindle• Perpendicularity of Spindle with Table• Straightness of slides (axes) • Parallelism between axes• Location accuracy of axes• Angularity errors between Axes
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3 Axis CNC Machine Tool
Axes : X, Y, Z
Geometric errors per axis
Location error : 1Straightness errors : 2Angular errors : 3
Total no of errors for machine : 18
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Geometric Errors for Y axis
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Geometric Errors for 3 axis CNC
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Straightness Error of Z axis - EXZ
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Testing Straightness - Linear axis
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Location Errors – Y axis
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Straightness Errors – Y axis
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Tool Path with Geometric Errors
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Part Inspection
• Dimensional Tolerance
• Geometric Tolerance• Form• Orientation• Location• Position
• Surface Finish
• Topography
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Part with Dimensional Tolerances
+0.480 +0.1
39.839.5
+0.220 0
20 g
6
-0.0
0720
-0
.020
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Part with Geometric Tolerances
A B
80.25
0.02 C
0.002 A - B0.1 A
C
- 0.0070.070
2.020
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Basics of Metrology
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Precision and Accuracy