Metrology and Quality Control - Dec 2016

Mechanical Engg (Semester 5)

TOTAL MARKS: 100
TOTAL TIME: 3 HOURS (1) Question 1 is compulsory.
(2) Attempt any four from the remaining questions.
(3) Assume data wherever required.
(4) Figures to the right indicate full marks.

Solve any one question.Q1(a,b) Q2(a,b)

1(a) Differentiate between systematic errors and random errors.(5 marks)

Solve any one question.Q1(a,b) Q2(a,b)

1(a) Draw a neat sketch of Vernier caliper and How to calculate least count of Vernier caliper give one example.(4 marks) 1(b) State different types of comparators, explain sigma comparator in detail.(5 marks) 1(b) write short notes on
i) Types of standards
ii) Electrical comparator (LVDT)(6 marks) 2(a) Describe with neat sketches of auto-collimator and sine bar.(5 marks) 2(a) Write short notes on universal measuring machine(5 marks) 2(b) State different types of linear and angular measuring instruments, explain any two with example.(5 marks) 2(b) Explain angle Dekker with neat sketch.(5 marks)

Solve any one question.Q3(a,b) Q4(a,b)

3(a) State and explain Taylor's Principle of Gauge Design with example.(5 marks)

Solve any one question.Q3(a,b) Q4(a,b)

3(a) Explain Interferometry applied to flatness testing by using optical flat(5 marks) 3(b) Optical arrangement of interferometer for testing flatness of surfaces.(5 marks) 3(b) Determine the dimensions and tolerances of shaft and hole having size of 30H7f8 fit. (IT7=16i,
IT8=25i, D is in a step 18-30mm, Fundamental deviation for f=-5.5D^0.41(5 marks) 4(a) What is surface texture? State different methods to analyze surface trace.(5 marks) 4(a) Derive an expression for best wire size for measuring effective diameter Calculate Effective diameter and best wire diameter for M22×2.5 screw plug gauge by using Floating carriage Micrometer for which reading were taken as Diameter of standard cylinder 20 mm Micrometer reading over standard cylinder with two wire is=15.9334mm Micrometer reading over plug screw gauge with two wire is=15.2245mm(6 marks) 4(b) A machine operator needs a guage for checking the diameter of bores being machined to diameter 20+0.06 mm. What should be the dimensions (diameter) of the guage if unilateral system of tolerances are incorported? Assume gauge tolerance and wear allowance each 10% of work tolerance.(5 marks) 4(b) Write short notes on Gear tooth vernier caliper.(4 marks)

Solve any one question.Q5(a,b) Q6(a,b)

5(a) Explain PDCA & PDSA Cycle.(8 marks)

Solve any one question.Q5(a,b) Q6(a,b)

5(a) Explain Deming's cycle and 14 point towards quality improvement.(8 marks) 5(b) Describe different quality costs.(8 marks) 5(b) Explain seven old quality tools.(8 marks) 6(a) Write short note on: Juran's Trilogy(8 marks) 6(a) Explain the concept of quality circle and their structure and limitation.(8 marks) 6(b) Differentiate between Quality Assurance & Quality control.(8 marks) 6(b) What is cost of quality? Explain its types.(8 marks)

Solve any one question.Q7(a,b,c) Q8(a,b,c)

7(a) Ten samples of parts were taken from a production line For 100% inspection, each sample containing 300 parts. The total number of defection was 350. Compute upper and lower conrol limit.(5 marks)

Solve any one question.Q7(a,b) Q8(a,b)

7(a) Control chart for X overline is to be prepared for a certain dimension of component the sub group size is 4 after 20 sub group it is found that $$\sum \bar{X}=825.60mm$$ and ∑R=5.60 mm compute the central line and the control limits for X overline chart d2 for sub group size 4=2.059. If the specified dimension is41.0±+0.40mm and the above process is in the control and is normally distributed, can it meet the specification requirement? If not, determine the percentage of rejection.(8 marks) 7(b) Explain analysis on out control condition refering control charts.(5 marks) 7(b) Explain the following OC curve characteristics
i) Changing of lot size
ii) Changing of sample size
iii) Changing of acceptance number
iv) Changing of sample size and acceptance number.(8 marks) 7(c) Explain in detail with flow chart single sampling and double sampling plan.(8 marks) 8(a) A new process is started, and the sum of sample standard devitation for 25 subgroups of size 4 is 750. If the specifications are 700 ±80, what is process capability index? What action would you recommand take for four samples factor for centeline=c4=0.9213(6 marks) 8(a) Exlain the Multiple sampling plan with flow chart(8 marks) 8(b) Ten casting were inspected in order to locate defect in them after in spection total 37 defects were found. Compute control limit for c-Chart.(4 marks) 8(b) Define producer risk; consumer risk and AOQL and AOQ for the given data calculate sample size and AOQ for single sampling plan.
i) Probability of acceptance for 0.4% defective in a lot is 0.558.
ii) Lot size N= 10000
iii) np'=1.6 & c=1
iv) Defectives found in the sample are not to be replaced.(8 marks) 8(c) Write note on PPAP and OC curve.(8 marks) 9 Write short note on(any four)
a) Cauuse & effect diagram
b) Pareto diagram
c) Kaizen
d) TPM
e) 5 s
f) J I T(16 marks) 9 Explain the following terms(Any Three)
a) KANBAN
b) JIT
c) FMECA
d) DMAIC
e) FIVE S(18 marks)