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है”ह”ह

IS 7778-2 (2003): Small Tools Sampling InspectionProcedures, Part 2: Reamers [PGD 32: Cutting tools]

IS 7778 (Part 2): 2003

m 2M

(Wi’1 pi%wl)

Indian Standard

SMALL TOOLS SAMPLING INSPECTIONPROCEDURES

PART 2 REAMERS

(First Revision )

ICS 25.100.30

0 BIS 2003

BUREAU OF INDIAN STANDARDSMANAK BHAVAN, 9 BAHADLJR SHAH ZAFAR MARG

NEW DELHI 110002

.Ja/Tuu/:)2003 Price Group 2

D-i11s,Reamers and Threading Tools Sectional Committee, BP 10

—

FOREWORD

This Indian Standard (Part 2) (First Revision) was adopted by the Bureau of Indian Standards, after the draftf;nalized by the Drills, Reamers and Threading Tools Sectional Committee had been approved by the Basic andProduction Engineering Division Council.

This standard was first published in 1975. In the light of experience gained over the years, in this revision

following changes have been incorporated:

a) Definition of various terminologies used in the standard have been aligned with the practice followedat 1S0 level,

b) Scale of sampling and criteria of conformity have been modified,

c) Classification of non-conformities for various type of cutting tools have been updated, and

d) To cater the specific need of the different industries and to make this standard user friendly, thisstandard has been splitted in 11 Parts for easy adoption/acceptance and guide updation.

This standard has been prepared based on prevalent practice and experience available in the Indian Industries.While formulating this standard considerable assistance has been derived from IS 2500 (Part 1) :2000 ‘Samplinginspection procedures: Part 1 Attribute sampling plans indexed by acceptable quality level (AQL) for lot-by-lotinspection (third revision)’. IS 7778 ‘Small tools sampling inspection procedures’ is now being published inI I Parts. Other parts of the standard are given below:

Part 1

Part 3

Part 4

Part 5

Part 6

Part 7

Part 8

Part 9

Part 10

Part I 1

Twist drills, countersinks and counterbores

Sleeves, sockets and adaptors

Screwing taps, dies and knurling tools

Milling cutters

Milling arbors and accessories

Gear cutting tools and broaches

Saws

Single point (HSS and carbide tipped) tools

Carbide tips and indexable inserts

Hard metal burrs

....

.

IS 7778 (Part 2) :2003

Indian Standard

SMALL TOOLS SAMPLING INSPECTIONPROCEDURES

PART 2 REAMERS

(First Revision )1SCOPE

This standard (Part 2) (First Revision) specifiessarnpllng plans and procedures for reamers submittedfor inspection in lots.

2 REFERENCES

The following standards contain provisions whichthrough reference in this text, constitute provision ofthis standard. At the time of publication, the editionsindicated were valid. All standards are subject torevision and parties to agreements based on thisstandard are encouraged to investigate the possibilityof applying the most recent editions of the standardsindicated below:

IsNo, Title

2500 (Part 1) : Sampling inspection procedures:2000 Part 1 Attribute sampling plans

indexed by a acceptable quality level(AQL) for lot-by-lot inspection (thirdrevision)

4905:1968 Methods for random sampling

3 TERMINOLOGY AND DEFINITIONS

For the purpose of this standard the followingdefinitions shall apply. For terms not defined belowand for other clarifications, reference may be made to1S 2500 (Part 1).

3.1 Defect — A departure of a quality characteristicthat results in a product, process or service notsatisfying its intended normal usage requirements.

3.2 Non-Conformity — A departure of a qua]ity

characteristic that results in a product, process orservice not meeting a specified requirement. Non-conformities will generally be established by theirdegree of seriousness, such as:

Class A — Those non-conformities of a typeconsidered to be of the highestconcern for the product or service.In acceptance sampling, such typesof non-conformity will be assignedvery small AQL values.

Class B — Those non-conformities of a typeconsidered to have the next lower

degree of concern. Therefore thesecan be assigned a larger AQL valuethan those in Class A and smallerthan in Class C, if a third class exists.

3.3 Non-Conforming Unit — A unit of product orservice containing at least one non-conformity. Non-conforming units will generally be classified by theirdegree of seriousness such as:

Class A — A unit which contains one or morenon-conformities of Class A and mayalso contain non-conformities ofClass B and/or Class C.

Class B — A unit which contains one or morenon-conformities of Class B and mayalso contain non-conformities ofClass C, but contains no non-conformity of Class A.

3.4 Percent Non-Conforming — The percent non-conforming of any given quantity of units of productsis 100 times the number of non-conforming unitsdivided by the total number of units of products, thatis:

Percent non-conforming

_ Number of non-conforming units ~ ~O.—Total number of units

3.5 Acceptable Quality Level (AQL) — When acontinuous series of lots is considered, the quality levelwhich for the purpose of sampling inspection is a limitof a satisfactory process average.

3.6 Sampling Plan — A specific plan which indicatesthe number of units of products from each lot whichare to be inspected (sample size or series of samplesizes) and the associated criteria for determining theacceptability of the lot (acceptance and rejectionnumbers).

3.7 Lot — A collection of units of product from whicha sample shall be drawn and inspected to determineconformance with the acceptability criteria, and whichmay differ from a collection of units designated as alot for other purposes (for example, production,shipment, etc).

—

1

IS7778(Part 2):2003

3.8Sample — A sample consists of one or more unitsof product drawn from a lot, the units of the samplebeing selected at random without regard to theirquality. The number of units of product in the sampleis the sample size.

4 SCALE OF SAMPLING

4.1 All small tools shall be selected at random from alot as per IS 4905to ensure randomness of selection.

4.2 Small tools shall be selected and examined foreach lot separately for ascertaining its conformity tothe requirements of the relevant specification.

The number of small tools to be selected from a lotshall depend on the sizes of the lot and type ofsampling plans and shall be in accordance withTables 1, 2 and 3.

5 DETERMINATION OF ACCEPTABILITY

5.1 To determine acceptability of a lot under percentnon-conforming inspection, the single sampling planshall be used in accordance with 5.1.1 for hardnesstest and performance test and the double sampling planshall be used in accordance with 5.1.2 for dimensionaland visual characteristics.

5.1.1 Single Sampling Plan

The number of sample units inspected shall be equalto the sample size given by the plan. If the number ofnon-conforming units found in the sample is equal toor less than the acceptance number, the lots shall beconsidered acceptable. If the number of non-

conforming units is equal to or greater thanrejection number, the lot shall be consideredacceptable.

5.1.2 Double Sampling Plan

thenot

The number of sample units first inspected shall beequal to the first sample size given by the plan. If thenumber of non-conforming units found in the firstsample is equal to or less than the first acceptancenumber, the lot shall be considered acceptable. If thenumber of non-conforming units found in the firstsample is equal to or greater than the first rejectionnumber, the lot shall be considered not acceptable.

If the number of non-conforming units found in thefirst sample is between the first acceptance andrejection numbers, a second sample of the size givenby the plan shall be inspected. The number of non-conforming units found in the first and second samplesshall be accumulated. If the cumulative number of non-conforming units is equal to or less than the secondacceptance number, the lot shall be consideredacceptable. If the cumulative number of non-conforming units is equal to or greater than the secondrejection number the lot shall be considered notacceptable.

6 CLASSIFICATION OF NON-CONFORMITY

Non-conformities of various inspection parameters forreamers and carbide tipped reamers covered undervarious Indian Standards have been classified as ClassA and Class B and are tabulated in Tables 4 and 5.

Table 1 Scale of Sampling and Criteria for Conformity for Lot Quality for Visual and DimensionalCharacteristics (Double Sampling Plan for Normal Inspection — Inspection Level 111)

(Clause 4.2)

SI Lot Size Sample Sample Size CumulativeNo. Sample Size

Non-Conformity

Class A Class BAQL 1.5 AQL 4.0

Ac Re Ac Re

(1) (2) (3) (4) (5) (6) (7) (8) (9)

i) up to 150 First 20 20 0 2 1 4

Second 20 40 1 2 4 5

ii) 151 to280 First 32 32 0 3 2 5

Second 32 64 3 4 6 7

iii) 281 to 500 First 50 50 1 4 3 7

Second 50 100 4 5 8 9

iv) 501 to I 200 First 80 80 2 5 5 9

Second 80 160 6 7 12 13

v) 1201 to3200 First 125 125 3 7 7 11

Second 125 250 8 9 18 19

.—

2

..-

Table 2 Scale of Sampling and Criteria forConformity for Lot Quality for Hardness Test

(Single Sampling Plan for NormalInspections — Inspection Level I)

(Clause 4.2)

sl Lot Size Sample Size AQL 1.5No.

Ac Re

(1) (2) (3) (4) (5)

i) up to 280 8 0 1ii) 281 to 1200 32 1 2iii) 1201 to3 200 50 2 3

IS 7778 (Part 2) :2003

Table 3 Scale of Sampling and Criteria forConformity for Lot Quality for Performance Test

(Single Sampling Plan for ReducedInspection — Inspection Level S-3)

(Clause 4.2)

sl Lot Size Sample AQL 4.0No. Size

I Ac Re

(1) (2) (3) (4) (5)

O up to 150 I 2

Io

I1

ii) 151t03200 5 0 2

Table 4 Classification of Non-Conformity in Reamers

(C/ause 6)

SI 1s No. Type of Tool Class A Class B

No. Non-Conformity Non-Conformity

(3) I (4) I (5)

i) 5444 Parallel hand reamers with parallel Hardness, Reamer diameter and Cutting edge length, Overall length,shanks Shank diameter Shank length, Square width, Back

taper, Bevel lead and Taper lead

ii) 5445 Long fluted machine reamers with Hardness, Reamer diameter and Cutting edge length, Overall length,morse taper shank Morse taper shank Bevel lead and Back taper

iii) 5446 Machine chucking reamers with Hardness, Reamer diameter and Cutting edge length, Shank length,parallel shank Shank diameter Overall length, Bevel lead and Back

taper

iv) 5447 Machine chucking reamers with morse Hardness, Reamer diameter and Cutting edge length, Overall length,taper shank Morse taper shank Bevel lead and Back taper

v) 5881 Taper pin hand reamers Hardness, Taper angle, Shank Cutting edge length, Overall length,diameter dzand d3diameter Shank length, Square length and

Square width

vi) 5882 Socket reamers with parallel shank Hardness, Taper angle, Gauge Cutting edge length, Overall length,diameter and Shank diameter Square length and Square width

vii) 5907 Socket reamers with morse taper shank Hardness, Taper angle, Gauge Cutting edge length and Overalldiameter and Morse taper shank length

lfiii) 5918 Taper pin machine reamers with taper Hardness, Taper angle, d2 and d3 Cutting edge length and Overallshank diameters and Morse taper shank length

ix) 5919 Machine bridge reamers Hardness, d diameter, Morse Cutting edge length, Overall length,taper shank and Back taper d, diameter and Taper lead

~) 5926 Shell reamers Hardness, Reamer diameter, Taper Cutting edge length, Overall length,bore, Bevel lead and Back taper Driving slot width and Driving slot

depth

xi) 10851 Taper pin machine reamers with Hardness, Taper angle, Shank Cutting edge length, Overall lengthparallel shank diameter, dzand dj diameters and Shank length

xii) I 1002 Machine jig reamers with morse taper Hardness, Reamer diameter, Cutting edge length, Overall lengthshank Guide diameter, Morse taper and Bevel angle

shank and Back taper I

3

1S 7778 (Part 2) :2003

-i---

SI Is No.No.

+

(1) (2)—

i) 10884

Iii) ~ 10885

iii) 1I934

I

T-iv) I 1935

I

vi I 1937

Table 5 Classification of Non-Conformity

(Clause 6)

in Carbide Tipped Reamers

Type of Tool Class ANon-Cooformity

—

(3) (4)—

:arbide tipped chucking reamers with Hardness on shank, Reamer diameter,pwal Iel shank Shank diameter, Bevel lead and Back

taper

Carbide tipped chucking reamers with Hardness on shank, Reamer diameter,morse taper shank with short cutting Morse taper shank, Bevel lead and Backedge taper

Carbide tipped shell reamers

Carbide tipped chucking reamers withmorse taper shank with long cuttingedge

Hardness on body, Reamer diameter,Taper bore, Bevel lead and Back taper

Hardness on shank, Reamer diameter,Morse taper shank, Bevel lead and Backtaper

Carbide tipped long fluted machinereamers with morse taper shank

Hardness on shank and body, Reamerdiameter, Morse taper shank, Bevel leadand Back taner

Carbide tipped machine jig reamerswith morse taper shank

Hardness on shank and body, Reamerdiameter, Guide diameter, Morse tapershank, Bevel lead and Back taper

Class B

Non-Conformity

(5)

Cutting edge length, Shanklength and Overall length

Cutting edge length, Overalllength and Neck diameter

—

Cutting edge length, Overalllength, Cross slot width andCross slot depth

Cutting edge length andOverall length

Cutting edge length andOverall length

Cutting edge length, Guidelength and Overall length

.—

4

Bureau of Indian Standards

BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promoteharmonious development of the activities of standardization, marking and quality certification of,goodsand attending to connected matters in the country.

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Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewedperiodically; a standard along with amendments is reaffirmed when such review indicates that no changes areneeded; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standardsshould ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of‘BIS Catalogue’ and ‘Standards: Monthly Additions’.

This Indian Standard has been developed from Doc : No. BP 10 (0325).

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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