MIAE 311
Manufacturing Processes
Lecture 1
LECTURER: MICHAEL REMBACZ, ENG.
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Manufacturing & Machining Instructor
https://www.linkedin.com/in/michael-rembacz-eng-892a1036/
Who am I?
Michael Rembacz, Eng.
Manufacturing & Machining Instructor
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https://www.instagram.com/remm.watches/?hl=en
Welcome
All course content and information will be posted on the course Moodle page.
Lectures 13 X 2.5 hours
Tutorials 13 X 1.5 hours
Labs 4 X 4 hours
Textbook:
Black, J. T and Kohser, R. A., Materials and Processes in Manufacturing,11th Edition, John Wiley,
2012.
Online content and chapters:
http://bcs.wiley.com/he-bcs/Books?action=index&itemId=0470924675&bcsId=6493
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Deliverables
Deliverable
Laboratory Safety Quiz
Timeline:
Semester Start: May 4th
Semester End: June 17th
Due dates for specific
deliverable will be indicated
in the course outline and the
course Moodle page.
Laboratory
Laboratory Exam
Percentage
See Lab Manual
20%
See Lab Manual
Midterm
15%
Formal Report
5%
Video Presentation
5%
Assignments
10%
Surprise Quizzes (minimum 5)
5%
Final Exam*
40%
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Deliverables - Laboratory
Labs will be deferred to the fall 2020 semester or later. A formal declaration will be sent from the University for this.
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Introduction
What is manufacturing? What are manufacturing processes?
Definition:
Manufacture: noun man·u·fac·ture ;
1.
Something made from raw materials by hand or by machinery
2.
The process of making wares by hand or by machinery especially when carried on
systematically with division of labor
3.
A productive industry using mechanical power and machinery
4.
The act or process of producing something
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Manufacturing Processes
How things are manufactured:
◦
◦
◦
◦
What processes entail the manufacturing of various components.
Machine selection
Tool Selection
Optimizing machine, process, tools and time.
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Manufacturability
Can it be made? How? What Process?
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Manufacturability
Now change the Tolerance!
What about simple shapes?
Dimensions in mm
Can we make this?
Can we measure this?
What process? What Tool? What cost?
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Metrology: Measurement and Inspection
Metrology: noun me·trol·o·gy - The science of measurement
Everyday use of measurement and inspection?
1.
2.
3.
Application in Engineering
1.
2.
3.
"…inspection is to ensure that what is being manufactured will conform to the specifications of the
product." DeGarmo pg 223
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Metrology: Measurement and Inspection
Measurement: Fundamental exercise of inspection; Act of measuring or being measured.
Why measure? Manufactured parts correspond to the specifications of the product.
(QA) Confirm functionality, performance, reliability, process capability, etc.
How to measure?
◦ Attributes ( Qualitative, go or not-go, Gaging, decisions)
◦ Variables (quantitative, dimensions, useful for analysis and decision)
What to measure?
◦ Size/geometry of tools
◦ Size/geometry of a part from a machine tool
Benefits
◦ Determines capability of a process.
◦ Indicates the need of maintenance.
◦ Feedback of manufacturing.
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Attributes vs Variables
Attributes
Good or bad, pass or fail, accept or reject
Typically with the use of gages, go or no-go
Ex. A shaft doesn't fit in either ring gage, it's diameter is too big, therefore no-go
Variables
Use of measuring tools to determine actual dimensions
Ex. Using a micrometer the shaft has a diameter of 1.3742"
What determines if the. Value is acceptable or not?
TOLERANCE!
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Attributes vs Variables
Attributes
Variables
•Qualitative
•Quantitative
•Fast and economical
•Slow and expensive
•Pass or fail
•Exact dimension is needed
•Mostly for standard and less severe
applications (Automobile)
•Useful for highly reliable applications
(Aircrafts)
•Useful after process development
•Needed for development
•Large production volume
•Small production volume
• Not ideal for tight tolerance differences
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Standards of measurement - Units
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Accuracy vs precision
Low
Precision
High
Accuracy refers to the ability to hit was is aimed and, Precision reefers to the repeatability of the
process.
High
Accuracy
Low
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Allowance and Tolerance
Allowance = Clearance or interference between components
Tolerance = undesirable but permissible deviation from the desired dimension.
Will these parts fit together?
Max Shaft Ø = 0.5 + 0.0025
= 0.5025
Min Hole Ø = 0.506 – 0.0025
= 0.5035
0.5035 – 0.5025 > 0 Therefore Clearance
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Allowance and Tolerance
σ𝑛𝑖=1 𝑋𝑖
𝑋ത =
𝑓𝑜𝑟 𝑛 𝑖𝑡𝑒𝑚𝑠
𝑛
𝜇 + 3𝜎 = 𝑈𝑁𝑇𝐿
𝜇 − 3𝜎 = 𝐿𝑁𝑇𝐿
Upper / lower natural tolerance limit
𝜎=
σ𝑛𝑖=1 𝑋𝑖 − 𝑋ത
𝑛
2
Statistical analysis requires a sample size to initiate!
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Allowance and Tolerance
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Types of Tolerance
Limits
GD&T
𝑴𝑨𝑿
𝑴𝑰𝑵
Unilateral
+𝑻𝑶𝑳 𝑼𝑷𝑷𝑬𝑹
−𝑻𝑶𝑳 𝑳𝑶𝑾𝑬𝑹
Doesn’t have to be + / -
𝑵𝑶𝑴𝑰𝑵𝑨𝑳
Bilateral
𝑵𝑶𝑴𝑰𝑵𝑨𝑳 ± 𝑻𝑶𝑳
Can be + /+ or - /-
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Types of Tolerance
Geometrically - GD&T – MECH 313
• MMC – Parts are made with the
largest amount of material
possible
• LMC - Parts are made with the
least amount of material possible
• RFS – Regardless of feature size
• Datums- Concept/Feature
common for design,
manufacturing and inspection
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Types of Allowance – Fits – ANSI
ANSI – American National Standards Institute
Class 1. Loose fit: large allowance. Accuracy is not essential.
Class 2. Free fit: Liberal allowance. For running fits where speeds are above 600 rpm and pressures are 600 psi ( 4.1 MPa)
or above
Class 3. Medium Fit: Medium allowance. For running fits below 600 rpm and pressure below 600 psi ( 4.1 MPa) and for
sliding fits.
Class 4. Snug Fit: Zero allowance. No movement under load is intended, and no shaking is wanted. This is the tightest fit
that can be assembled by hand
Class 5. Wringing fit: zero to negative allowance. Assemblies are selective and not interchangeable.
Class 6. Tight fit: slight negative allowance. An interface fit for parts that must not come apart in service and are not to be
disassembled or are to be disassembled only seldom. Light pressure is required for assembly. Not to be used to with stand
other than very light loads.
Class 7. Medium force fit: an interference fit requiring considerable pressure to assemble; ordinarily assembled by heating
the external member or cooling the internal member to provide expansion or shrinkage. Used for fastening wheels, crank
disks, and the like to shafting. The tightest fit that should be used on cast iron external members.
Class8. Heavy force and Shrink fits: considerable negative allowance. Used for permanent shrink on steel members.
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Types of Tolerance – Fits – ISO (Metric)
ISO System of Limits and Fits – International Organization for Standardization
MECH 313
3 Types:
1. Clearance Fits
2. Transition Fits
3. Interference Fits
NOMINAL HX/gY
Ex. 45 H8/g7
Introduction of the IT Grade system – See machinery’s Handbook
Shaft or Hole basis system
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Gage Blocks
https://en.wikipedia.org/wiki/Gauge_block
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Gage Blocks
Gage blocks wrung together
https://www.youtube.com/watch?v=2lOOl3VxOtE
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Factors in selecting inspection equipment
1. Gage Capability
Rule of 10 – Selected measuring equipment should be 10 times more precise than the tolerance
being measured.
14 cm ± 1 cm - Measuring tool must be able to read to the nearest millimeter.
1.500” ± 0.005” – Measuring tool must be able to read to the nearest 0.0005”
2. Linearity – Calibration accuracy over its working range.
3. Repeat Accuracy – How repeatable the device is
4. Stability – How well does the device retain its calibration over time.
5. Magnification - Amplification of the output portion of the device, bigger dials as the
dimension gets smaller.
6. Resolution - Sensitivity; smallest input value that can be detected or measured
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Rulers
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Combination Squares
Take pic ofhow to use combo square
Center head
Square head
Bevel protractor
https://www.youtube.com/watch?v=jAGBJQP2dl8
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Combination Squares
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Combination Squares
Center head
Bevel Protractor
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https://www.youtube.com/watch?v=o8Bd8G21Vv8
Squares
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Calipers – Vernier, Dial, Digital
Precision: Ability to read as small as 0.001” (Some digital claim to read to 0.0005”)
https://www.youtube.com/watch?v=F9bThpevHfA
https://www.youtube.com/watch?v=rdFwZaRgO8s
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Calipers – Three possible measurements
External
Depth
Internal
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Height Gage
Vernier Scale
https://www.youtube.com/watch?v=Xp9U_0YUF9U
Digital
Using the scribe to mark a part at a
specific height
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Micrometer
Precision: Ability to read as small as 0.0001”
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Micrometer
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Inside Micrometer
http://www.chicagobrand.com/help/inside_micrometer.html
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Bore Gage Micrometer
http://www.longislandindicator.com/p174.html
http://store.gaging.com/Bore_Measurement
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Depth Micrometer
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Calipers
http://www.lighttoolsupply.com/catalog/Product/MitutoyoSpring-Dividers-and-Calipers-Series-950?productID=345088
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EDML APP
http://users.encs.concordia.ca/~m_rembac/EDML%20APP/
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Angular measurement – Bevel Protractor
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https://www.youtube.com/watch?v=PO-Ab7YfBzY&t=455s
Angular measurement – Sine Bar
𝑒𝑥𝑎𝑚𝑝𝑙𝑒:
1" 𝑔𝑎𝑔𝑒 𝑏𝑙𝑜𝑐𝑘
sine bar is 5” long
1
sin 𝛼 =
5
⇒
𝛼=
sin−1
1
= 11.5369 𝑑𝑒𝑔𝑟𝑒𝑒𝑠
5
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Gages – Gage Blocks
Round gages used for hole diameter, tool calibration or measuring non-parallel faces
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Gages – Plug
GO = 1.1250”
NO GO = 1.1260”
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Gages –Ring
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Gages - Radius
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Gages – Thread Pitch
Thread gages allow the user to match the pitch (metric) or threads per inch (imperial) and visually determine if acceptable.
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Gages – Thread Pitch
16 TPI Gage used to show how although the teeth
line up with threads, there is a void between.
32 TPI, thread gage is a perfect match.
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Gages – Deviation Type – Dial Indicators
https://www.youtube.com/watch?v=00dl0DxRYvM
5:10
0.05” gage block added as reference.
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Optical measurement - Microscope
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Optical measurement - Optical comparator
1. Projection of light over
object
2. Measurement using
micrometer scales
3. Ability to magnify the
feature being measured.
4. Interchangeable lenses
allow magnification from
5X, 10X, 31.25X, 50X,
62.5X, 90X, 100X and
125X
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Optical measurement - Optical comparator
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Optical measurement - Lasers
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https://www.youtube.com/watch?v=8I5P-r4ogm4
Optical Flats
An optical flat is an opticalgrade piece of glass lapped
and polished to be
extremely flat on one or both
sides, usually within a few
tens of nanometres
(billionths of a meter).
They are used with
a monochromatic light to
determine
the flatness (surface
accuracy) of other surfaces,
whether optical, metallic,
ceramic, or otherwise,
by interference.
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Optical measurement
Photographic
Pixel recognition
Using pixel variation or patterns to identify features.
Fast, no contact, accuracy depends on image quality. Modern cameras are very capable!!!
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Optical measurement
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CMM
https://www.youtube.com/watch?v=844UiRBVxlY
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CMM - Faro
https://youtu.be/vu3lw4-ULKk
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CMM – How it Measures?
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CMM – 3D Scanners
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NDT – Non-Destructive Testing
Destructive
Non-Destructive
Quantitative results
Qualitative results
Do not require interpretation
Skilled interpretation of results
Restricted for costly
measurements
High cost equipment
Low material cost
Low cost equipment
Consistent results
More subjective results
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Surface Roughness
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Surface Roughness
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NDT – Non-Destructive Testing
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NDT – Non-Destructive Testing
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NDT – Non-Destructive Testing
Liquid penetrant Inspection
https://www.youtube.com/watch?v=xEK-c1pkTUI
http://www.karldeutsch.de/KD_GENERAL_KnowledgeBase_PT_EN_M1.html
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NDT – Non-Destructive Testing
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NDT – Non-Destructive Testing
68
NDT – Non-Destructive Testing
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NDT – Non-Destructive Testing
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NDT – Non-Destructive Testing
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NDT – Non-Destructive Testing
Leak Testing – Spray with soapy water – are there bubbles?
Strain Sensing
•Advance Optical – Photo Video at high Resolution
•Thermal Testing
•Resistivity methods
•Xray Computed Topography (CT scan)
•Acoustic holography (Ultrasonic Sound)
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Example 1
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Example 1
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Example 2
Draw on board
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Quality Engineering – Chapter 36
Quality Engineering or Quality Assurance
Analysis / Verification of the process after a certain sample size
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Quality Engineering – Chapter 36
The basic principle of quality control – quality improvement without cost increase
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Process Capability
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Process Capability
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How to define LSL and USL?
USL = Upper Specification Limit = Nominal + Tolerance
LSL = Lower Specification Limit = Nominal - Tolerance
Acceptable min and max taking into account tolerance that will yield the same result, fit or function.
Ex:
Need a hole in a part to attach it to a base flange as per the figure. We are using a ¼”-20 fastener. What
diameter of hole should be have and what are the min and max acceptable values?
Draw on board
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Process Capability Index
Ability of the process to yield consistently the aimed output. Ability to meet specifications.
𝐶𝑝 = 𝑃𝑟𝑜𝑐𝑒𝑠𝑠 𝐶𝑎𝑝𝑎𝑏𝑖𝑙𝑖𝑡𝑦
USL = Upper Specification Limit = Nominal + Tolerance
LSL = Lower Specification Limit = Nominal - Tolerance
σ = Standard Deviation
𝐶
𝑝=
𝑇𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒 𝑆𝑝𝑟𝑒𝑎𝑑 𝑈𝑆𝐿 −𝐿𝑆𝐿
=
6𝜎
6𝜎
We want 𝑪𝒑 ≥ 𝟏. 𝟑𝟑 to be considered good.
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Process Capability Ratio
𝐶𝑝 does not take into account if the process is shifted off center (location of process mean)
If off center use 𝐶𝑝𝑘
𝐶𝑝𝑘 = 𝑃𝑟𝑜𝑐𝑒𝑠𝑠 𝐶𝑎𝑝𝑎𝑏𝑖𝑙𝑖𝑡𝑦 Ratio
𝐶𝑝𝑘 = min 𝐶𝑝𝑢 , 𝐶𝑝𝑙
USL = Upper Specification Limit
LSL = Lower Specification Limit
𝐶
𝑝𝑢=
σ = Standard Deviation
𝐶𝑝𝑢 = 𝑈𝑝𝑝𝑒𝑟 𝑙𝑖𝑚𝑖𝑡
𝐶𝑝𝑙 = 𝐿𝑜𝑤𝑒𝑟 𝑙𝑖𝑚𝑖𝑡
𝐶𝑝𝑙
𝑈𝑆𝐿 − 𝜇
3𝜎
𝜇 − 𝐿𝑆𝐿
=
3𝜎
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Process Capability - Cp vs Cpk
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How many samples to inspect?
Cost
• Factors to Consider
• Destructive
• Non-Destructive
• Attributes
• Variables
• Type of testing
• Time to complete testing
This represents inspection cost
# of Samples inspected
What about cost of dealing with parts out of spec?
84
Process Capability – Correction measures
What to do when the process is not capable or out of control:
1. Shift the job to another machine with great process capability.
2. Review the tolerance spread if it can be widened to accept the process being
completed.
3. Sorting of the product (accept vs reject)
4. Determine if the precision (repeatability) can be improved by:
a) Switching cutting tools, work holding devices or materials.
b) Overhaul existing process and/or developing preventative maintenance.
c) Finding and eliminating root cause of variability
d) Design experiments and Taguchi methods to reduce variability.
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Six Sigma - Motorola
USL - LSL
Percent Accuracy
Ratio

68.26%
 2
95.46%
 3
99.73%
7 / 10000
 6
99.9999%
3.4 parts per million
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Taguchi
The Taguchi approach uses a truncated
experimental design (called an orthogonal array)
to determine which process inputs have the
greatest effect on the process variability
(precision) and which have the least.
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