Code No: RR312002

Set No. 1

III B.Tech I Semester Supplementary Examinations, February 2007 METROLOGY AND QUALITY CONTROL (Production Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ⋆⋆⋆⋆⋆ 1. (a) What do you understand by line and end measurements ? Discuss their relative characteristics ? (b) Discuss the possible effects upon accuracy of measurement due to i. temperature variation ii. elastic deformation iii. cosine errors [8+8] 2. (a) Explain how i. angle of a workpiece ii. taper plug gauge is measured with the help of angle gauges ? Discuss with sketches. (b) Calculate the angle of taper and minimum diameter of an internal taper from the following readings ? i. ii. iii. iv. Diameter Diameter Height of Height of of bigger ball = 10.25 mm of smaller ball = 6.07 mm top of bigger ball from datum = 30.13 mm top of smaller ball from datum = 10.08 mm [8+8] 3. (a) Describe the principle and working of Tracer type profilogram with the help of a neat sketch (b) The surface finish on the milled surface is not to exceed 5µm Ra with a cut-off length 2 mm, machining allowance 0.5 mm and direction of lay parallel. How will you represent it on a drawing ? (c) It is not possible to produce perfectly “smooth” surface. Justify the statement. [8+4+4] 4. (a) Mention the materials used for the manufacture of GO and NOGO gauges. Explain the disposition of tolerance on GO and NO GO gauges by taking reference to work tolerances. (b) Draw neat sketches of i. Taper plug gauge 1 of 2

Code No: RR312002 ii. Taper Ring gauge Explain how you use them

Set No. 1
[8+8]

5. (a) What are the advantages and limitations of electrical and electronic comparator ? (b) Discuss the principle and applications of a Sigma comparator. Show with a neat sketch how it works. [8+8] 6. (a) What do you understand by drunken thread ? How it is caused? Describe a method to test drunkenness of a 31 mm dia x 2 mm pitch component machined on centres. (b) Describe a method to measure the effective pitch diameter of a screw plug gauge. Also explain how the errors in pitch and angle affect the virtual effective diameters. [8+8] 7. (a) Distinguish between Type I and Type II errors in i. Control charts ii. Assignable causes and chance causes. (b) Control charts for X and R are maintained on the tensile strength in kilograms of a certain yarn. The subgroup size is 5. The values of X and R are computed R = 515. Compute for each sub group. After 25 subgroups X = 2005, the values 3 sigma limits for X and R charts and estimate the value of ‘σ’ on the assumption that the process is in statistical control. [8+8] 8. (a) Design a single sampling plan for which the ‘Consumer’s risk’ of acceptance of 2% detective product is 0.10 and the ‘Producer Risk’ of rejection of 0.6% defective product is 0.05. Determine the values of P0.50 and ‘indifferent quality’ for this sampling plan. (b) What are the advantages of adopting ISO 9000. List out summary elements of ISO 9001. Enumerate the various standards available on Total Quality Management (TQM). [8+8] ⋆⋆⋆⋆⋆

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Code No: RR312002

Set No. 2

III B.Tech I Semester Supplementary Examinations, February 2007 METROLOGY AND QUALITY CONTROL (Production Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ⋆⋆⋆⋆⋆ 1. (a) Sketch an Inside Micrometer calipers and show various parts. i. A bench micrometer was used for measuring the diameter of a plug gauge, using the setting cylinder, the following data were obtained : Nominal diameter of setting cylinder = 30.000 mm Reading on setting cylinder = 13.128 mm Reading on plug gauge = 15.134 mm What is the dia of gauge ? Also. Calculate the least count of a micrometer ? (b) Explain the spindle locking arrangement in micrometer with a neat sketch. What are the precautions to be taken in using Micrometer. [8+8] 2. (a) Sketch the different types of Sine bars and describe them. (b) Discuss the constructional features and uses of i. Vernier bevel protractor. ii. Optical bevel protractor. [8+8]

3. (a) Why is the assessment of surface texture important ? Describe two methods to obtain a numerical value of the texture from a given graphical record. (b) How CLA index number is determined ? Explain why CLA index number alone is not sufficient to specify the surface texture required and to make the information complete, is any other thing to be specified. [8+8] 4. (a) Design the ‘Workshop’ inspection and General types of GO and NO GO plug gauges for checking the hole of +0.005 30 −0.03mm Assume each of the wear allowance and gauge allowance as 10% of work tolerance (b) Classify different gauges. Write a note on the following : i. Indicative type limit gauges ii. Taper gauges [8+8]

5. (a) With the help of neat sketches describe how a dial gauge may be used as ? i. Comparator ii. Part of limit gauge iii. A fiducial indicator 1 of 2

Code No: RR312002 iv. A test indicator

Set No. 2

(b) What is meant by pneumatic comparator ? State some uses of air gauging? State the mathematical relationship between measured length or thickness and other related parameters. [8+8] 6. (a) Define “best wire size” ? Compute the “best wire size” for 20 mm ISO thread of 3 mm pitch. (b) What are the different elements of a spur gear which require inspection ? Name the instruments used in the inspection of these elements with their expected accuracies ? [8+8] 7. (a) Describe the various situations where a P-chart is clearly applicable. Give examples wherever necessary. (b) Outline the step wise procedure in establishing X-chart in a production process. Give suitable example. [8+8] 8. (a) What do you mean by “acceptance sampling”. Define“acceptance number”. How the “operating characteristic”is affected by sample size and acceptance number. (b) In a double sampling 2% AOQL acceptance rectification plan: n1 = 32 c 1 = 0 n2 = 38 c 2 = 2 n = 1000 Determine i. the probability of acceptance of a 2% defective lot. ii. the average total inspection. ⋆⋆⋆⋆⋆ [8+8]

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Code No: RR312002

Set No. 3

III B.Tech I Semester Supplementary Examinations, February 2007 METROLOGY AND QUALITY CONTROL (Production Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ⋆⋆⋆⋆⋆ 1. (a) With the help of neat sketches, explain the working of a differential screw type micrometer ? (b) Describe the method of checking flatness and squareness with the axis of spindle end of an external micrometer. [8+8] 2. (a) Discuss briefly the Spirit level. What are the factors that determine the sensitivity and accuracy of Engineer’s Spirit level ? (b) Sketch a Bevel protractor and explain its uses (c) With the help of Slips, rollers how do you determine taper angles of a taper plug gauge ?Sketch the experimental set up and explain pushright [6+5+5] 3. (a) Describe surface profile graphically by Ten Point Height method. Sketch a typical profile of a machined surface to suitable scales and determine its Ra index number. (b) State the units in which Ra value is expressed. Determine Ra index number of a surface for which the graph was drawn to a vertical magnification of 15,000 and a horizontal magnification of 100, and the areas above and below the datum line were? Above 160 90 180 50mm2 Below 95 65 170 150mm2 [8+8] 4. (a) Mention the materials used for the manufacture of GO and NOGO gauges. Explain the disposition of tolerance on GO and NO GO gauges by taking reference to work tolerances. (b) Draw neat sketches of i. Taper plug gauge ii. Taper Ring gauge Explain how you use them

[8+8]

5. (a) Explain the Johnson ‘Mikrokator’ with a neat sketch. Mention its characteristics and uses. (b) Discuss the following : i. Constructional features of any mechanical comparator. ii. Constructional features and working of solex pneumatic comparator.[8+8] 1 of 2

Code No: RR312002

Set No. 3

6. (a) Compare two-wire and three-wire methods of measuring the effective diameter of a screw. (b) Explain how the various elements of internal threads are measured using a pitch measuring machine. [8+8] 7. (a) Name the control charts for variables and attributes. How these are set up ? (b) The data below shows the number of defectives over period of 20 days in a fixed sample size of 200 Determine, whether the data exhibit statistical control ? Evaluate the preliminary and revised control limits for the process. Day No. of defectives 1 10 2 15 3 10 4 12 5 11 6 9 7 22 8 4 9 12 10 24 Fraction Day No. of Defectives 0.050 11 21 0.075 12 15 0.050 13 8 0.060 14 14 0.055 15 4 0.045 16 10 0.110 17 11 0.020 18 11 0.060 19 26 0.120 20 13 Fraction defective 0.105 0.075 0.040 0.070 0.020 0.050 0.055 0.055 0.130 0.065 [8+8] 8. (a) What is meant by Quality assurance ? List out the functions of Quality assurance. Name the types of Quality characteristics and explain them. (b) Describe the various sampling techniques. Write briefly note on Quality circles. [8+8] ⋆⋆⋆⋆⋆

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Code No: RR312002

Set No. 4

III B.Tech I Semester Supplementary Examinations, February 2007 METROLOGY AND QUALITY CONTROL (Production Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ⋆⋆⋆⋆⋆ 1. (a) Four length bars of basic length 100 mm are to be calibrated using a calibrated length bar of 400 mm whose actual length is 399.9992 mm. It was also found that lengths of bars B, C and D in comparison to A are + 0.0002 mm, +0.0004 mm and 0.0001 mm respectively and the length of all four bars put together in comparison to standard calibrated bar is + 0.0003mm longer. Determine the actual dimensions of all the four end bars. (b) How do you compare an end gauge with a line standard by displacement method. [8+8] 2. (a) Explain how a Sine Bar may be employed to determine the Taper angles of a given component. What are the limitations of Sine Bars. (b) “An angle of 1020 8’ 42” is to be measured with the help of standard 13 pieces set of angle gauges and a square block. Sketch the combination [8+8] 3. (a) Show by means of simple diagram how the following are indicated on an engineering drawing i. Surface roughness not to exceed 16µm ii. Surface roughness to lie between 8 and 16µm iii. Direction of lay Explain what is meant by lay of a machined surface. How it can be classified. (b) Given the following information, determine the arithmetical mean deviation (Ra ) for a given surface Sampling length 120 mm Area above centre line 533mm2 Areas below centre line 447mm2 Optical magnification × 50 Mechanical magnification × 100 [8+8] 4. (a) Mention the materials used for the manufacture of GO and NOGO gauges. Explain the disposition of tolerance on GO and NO GO gauges by taking reference to work tolerances. (b) Draw neat sketches of i. Taper plug gauge ii. Taper Ring gauge Explain how you use them 1 of 2

[8+8]

Code No: RR312002

Set No. 4

5. (a) What do you understand by the term “damping” of an instrument ? (b) How is damping effect achieved in the Sigma Mechanical comparator. Explain with sketch. (c) Briefly explain the working of mechanical optical comparator. [4+6+6]

6. (a) What do you understand by the term “the best wire” in connection with screw thread measurement ? Derive an expression for the size of the best wire ? What are its advantages and applications ? (b) With neat sketches, describe the working of a Rolling gear Tester. How it can be used to check various parameters of a gear. [8+8] 7. (a) How the process charts check the working of machines and put-down the number of rejected parts ? In what way these charts are made ? How the lack of control is indicated on control charts. (b) What is the difference between C chart and np chart Draw a c chart and comment on it. Inspection of 20 compressors is given below : Compressor No. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 No. of defects 2, 5, 7, 3, 5, 4, 1, 6, 3, 2 Compressor No. 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 Number of defects : 4, 4, 3, 7, 12, 2, 3, 1, 4, 2 [8+8] 8. (a) Define the following : i. ii. iii. iv. Quality Quality Quality Quality Policy Management Plan and Audit System

(b) What are the various standards for Quality Management ? Discuss the objectives of ISO 9000. Briefly explain the function of each relevant standard? [8+8] ⋆⋆⋆⋆⋆

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