Metrology & Quality Control
Introduction to metrology
Metrology Basics, Definition of metrology, Categories of
metrology, Scientific. metrology, Industrial metrology, Legal metrology, need of
inspection, Revision of (no questions be set) - Precision, Accuracy,
Sensitivity, Readability, Calibration, Traceability, Reproducibility, Sources
of errors, Factors affecting accuracy, Selection of instrument, Precautions
while using an instrument for getting higher precision and accuracy. Limits,
Fits Tolerances and Gauges Concept of Limits, Fits, And Tolerances, Selective Assembly,
Interchangeability, Hole and Shaft Basis System, Taylor’s Principle, Design of
Plug, Ring Gauges, IS919- 1993 (Limits, Fits & Tolerances, Gauges IS
3477-1973, concept of multi gauging and inspection. Linear Measurement, Description,
working principle, method of reading, least count for Vernier callipers, Micrometres
(Outside micrometres, Inside Micrometres), Depth gauge, Height Gauge, Feeler
Gauge, slip gauges (category, use, Selection of Slip Gauges for setting
particular dimension), Length bars. Angular Measurement, Concept, Instruments for
Angular, Measurements, Working and Use of Universal Bevel Protractor, Sine Bar,
Spirit Level, Principle of Working of Clinometers, Angle Gauges (With Numerical
on Setting of Angle Gauges). Standards and Comparators Definition and
introduction to line standard, end standard, Wavelength standard, Definition,
Requirement of good comparator, Classification, use of comparators, Working
principle of comparators, Dial indicator, Sigma comparator, Pneumatic
comparator, Electrical, Electronic, Relative advantages and disadvantages.
Threads and Gear Metrology
Screw thread Measurements, Types of thread, Errors in
threads, Pitch errors, Measurement of different elements such as major
diameter, minor diameter, effective diameter, pitch, two wire methods, Thread
gauge micrometre, Working principle of floating carriage dial micrometre. Gear
Measurement and Testing Analytical and functional inspection, rolling test, Measurement
of tooth thickness, gear tooth vernier, Errors in gears such as backlash, run
out, composite.
Testing Techniques
Measurement of surface finish, Primary and secondary
texture, Sampling length, Lay, terminology as per IS 3073- 1967, direction of
lay, Sources of lay and its significance, CLA, Ra, RMS, Rz values and their
interpretation, Symbol for designating surface finish on drawing, Various techniques
of qualitative analysis, Machine tool testing Parallelism, Straightness,
Squareness, Coaxiallity, roundness, run out, alignment testing of machine tools
as per IS standard procedure.
Quality Control
Quality: Definitions, meaning of quality of product &
services, Quality characteristics, Quality of design, Quality of conformance,
Quality of performance, Concept of reliability, Cost, Quantity assurance, Cost
of rework & repair, Quality & Inspection, Inspection stages. Total
Quality Management:
• Principles and concept of total quantity management.
• Quality Audit: Concept of audit practices, lead assessor certification.
• Six sigmas: Statistical meaning, methodology of system Improvement,
ISO 9000 Series & other standards
Concept, ISO 9000 series quality standards, QS14000, Standards
in general, Its evaluation & Implications, necessity of ISO certification,
other Quality systems.
Elementary Statistics & it’s application in quality control
Statistical Quality Control – Meaning and importance of SQC, Variable and attribute Measurement. control charts – inherent and assignable sources of variation, control charts for variables – X & R charts, control charts for attributes p, 100p np, C, U - charts (simple numerical based on charts), process capability of machine, determination of statistical limits, different possibilities, Rejection area, Statistically capable and incapable processes, Acceptance Sampling – Concept, Comparison with 100% inspection, Different types of sampling plans, with merits and demerits.
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