INSPECTION AND WEEK # 01

QUALITY CONTROL
COURSE CONTENTS
S/R TOPIC
01 Inspection Techniques
02 Inspection Gauges
03 Limit Gauges
04 Quality
05 Responsibility of Quality
06 Fundamentals of Statistics Frequency Distribution
07 Measures of Central Tendency and Dispersion
08 Concepts of Population and Sample
COURSE CONTENTS
S/R TOPIC
09 Normal Curve
10 Introduction to Control Charts-Control Charts
Techniques
11 Specifications
12 Process Capabilities
13 Sampling
14 Introduction to ISO 9000
WHAT IS INSPECTION ?
Inspection is a process to examine a part or a process for shortcomings.

In engineering activities inspection involves the measurements, tests,

and gauges applied to certain characteristics in regard to an object or
activity.

The results are usually compared to specified requirements and

standards for determining whether the item or activity is in line with
these targets
 WHAT IS INSPECTION ?
Inspection is Watchdog of
manufacturing process.

Cost of inspection is
Significantly High.

Inspection Process is mostly

manual.
 WHAT IS INSPECTION ?

Objective: Constraints:
 Assess Conformity with Design
Specifications.  Product Volume
 Improve Product Quality and  Product Cost
Reliability.  Product Functional Performance
CHALLENGES
Miniaturization

High Precision and Accuracy

High Productivity and Reliability

Shortest Time to market

Quick Turn-around
MODES OF INSPECTION

Accuracy Testing of Machine Tools

Process Quality Control

Part/Product Inspection
ACCURACY TESTING OF
MACHINE TOOLS
Involes control of The closeness of a
machine accuracy measurement to its
true value
Objective
• To Test kinematic and Geometric accuracy of Machine Tool.

• Alignment, Location, Orientation errors between Spindle,

Slides, Tool/ work Holders.

• Certification, Maintenance tasks, History

ACCURACY TESTING OF
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
ACCURACY TESTING OF
MACHINE TOOLS
Inspection of All 3 Axis for 3-Axis CNC
Milling Machine
 PROCESS QUALITY
INSPECTION
It involves in-process tests
performed for conformance with
established protocols, analytical
methods and specifications.

It also checks the process

parameters whether they are within
the limit as specified in the process
specification.

These are identified in Product

Control Plan.
PROCESS
QUALITY
INSPECTI
ON
VISUAL INSPECTION
Visual inspection provides a means of detecting and examining a
variety of surface flaws, such as corrosion, contamination, surface
finish, and surface discontinuities on joints.

Most widely used method for detecting and examining surface cracks.

Involves a wide variety of equipment, ranging from examination with

the naked eye to the use of interference microscopes for measuring the
depth of scratches in the finish of finely polished or lapped surfaces
 COORDINATE MEASURING
MACHINE
CMMs are used to inspect the dimensions of a
finished product.
Consists of the machine, probes and moving
arms for providing measurement input, a
computer for making rapid calculations and
comparisons based on the measurement input,
and the computer software that controls the
entire system

Largely used to collect inspection data on

which to make the decision to accept or reject
parts.
 MACHINE VISION
It acquires an image, analyze it, and then makes an appropriate
decision which is used in inspection and quality control applications.
Machine vision can provide accurate and inexpensive inspection of
workpieces, thus dramatically increasing product quality.

It enables machine vision to be used for a variety of functions, including:

identification of shapes, measurement of distances and ranges, gaging of
sizes and dimensions, determining orientation of parts, quantifying
motion, and detecting surface shading.
 MACHINE VISION

(A) Measuring Fit and Gap of Fender.

(B) Reading Box Labels
(C) Reading Part Numbers on Silicon
Wafers.
(D) Vision System for Arc Welding
 HARDNESS TESTING
It is a nondestructive method that can be used to
predict the strength of metals
All heat treated steels are subjected to hardness
testing to verify that the heat treatment produced
the correct hardness and thus strength.
The most common types of hardness tests are
indentation methods.
Common Types are Brinell Hardness, Rockwell
Hardness, Vickers Hardness Tests.
Rockwell test is testing steels that have been
hardened and tempered
 CHEMICAL ANALYSIS
The overall chemical composition of metals and alloys is most
commonly determined by x-ray fluorescence (XRF) and optical
emission spectroscopy (OES).

Works well for most elements, they are not useful for dissolved gases
and some nonmetallic elements that can be present in metals as
alloying or impurity elements.
 METALLOGRAPHY
Metallography is the scientific discipline of examining and determining the constitution
and the underlying structure of the constituents in metals and alloys

The objective of metallography is to accurately reveal material structure at the surface of

a sample and/or from a cross-section specimen

Determination of extent and location of wear

Estimation of plastic deformation associated with various mechanical processes
Determination of the extent and form of corrosive attack
 METALLOGRAPHY
A. Equiaxed ferrite grain size
in plain carbon steel
B. Ion carburized gear tooth
showing case depth
C. Microstructure of
galvanized coating on
steel, thickness and
quality.
D. Multi-pass weld quality in
SS-304 Plate.
 NON DESTRUCTIVE TESTING
Nondestructive testing
(NDT) and inspection
techniques are commonly
used to detect and
evaluate flaws
(irregularities or
discontinuities) or leaks in
engineering systems.

Liquid penetrant and

magnetic particle testing
are most common.
 LIQUID PENETRANT
INSPECTION
Liquid penetrant inspection is a nondestructive method used to
find discontinuities that are open to the surface of solid,
essentially nonporous materials.
Indications of flaws can be found regardless of the size,
configuration, internal structure, and chemical composition of the
workpiece being inspected.
Liquid penetrants can seep various types of minute surface
openings) by capillary action
The equipment is very simple, and the inspection can be
performed at many stages in the production of the part, as well as
after the part is placed in service.
The major limitation of liquid penetrant inspection is that it can
detect only imperfections that are open to the surface
 EDDY CURRENT INSPECTION
Eddy current inspection is based on the principles of
electromagnetic induction.
The part to be inspected is placed within or adjacent to an
electric coil in which an alternating current is flowing.
Eddy current inspection is used:
• To measure and identify conditions and properties related
to electrical conductivity, magnetic permeability, and
physical dimensions (primary factors affecting eddy current
response)
• To detect seams, laps, cracks, voids, and inclusions
• To sort dissimilar metals and detect differences in their
composition
RADIOGRAPHIC INSPECTION
Radiography is based on differential absorption of penetrating radiation−either
electromagnetic radiation of very short wavelength or particulate radiation−by the
part or test piece (object) being inspected

Three basic elements of radiography include a radiation source, the test piece or
object being evaluated, and a sensing material.

Because of differences in density and variations in thickness of the part, or

differences in absorption characteristics caused by variations in composition, different
portions of a test piece absorb different amounts of penetrating radiation.
RADIOGRAPHIC INSPECTION

Radiography is used to detect

features of a component or
assembly that exhibit
differences in thickness or
physical density compared with
surrounding material.
ULTRASONIC INSPECTION
Ultrasonic inspection is a nondestructive method in which beams of high
frequency acoustic energy are introduced into a material to detect Surface
and subsurface flaws, to measure the thickness of the material, and to
measure the distance to a flaw.

An ultrasonic beam travels through a material until it strikes an interface

or discontinuity such.as a flaw.

Energy reflected from various interfaces and flaws can be used to define
the presence and locations of flaws, the thickness of the material, and the
depth of a flaw beneath a surface.
ULTRASONIC INSPECTION
Interfaces and flaws interrupt the beam and
reflect a portion of the incident acoustic energy.
The amount of energy reflected is a function of
(a) the nature and orientation of the interface or
flaw; and,

(b) the acoustic impedance of such a reflector.

Most ultrasonic inspections are performed using

a frequency between 1 and 25 MHz.
REMOTELY OPERATED
VEHICLES
LASER SCANNERS
THERMOGRAPHY
MOTION AMPLIFICATION
THE END