MIAE 311

Tutorial 1
Course Outline

2
Project Presentation
Each student must prepare and present a formal report on a selected
topic as a part of one of the six main topics.
The presentations are scheduled as
follows: 3

No. Title of the main topic Date of presentation

1 Aerospace Industry Related Processes Week of October 21st
2 Automotive Industry Related Processes Week of October 28th
3 Computers and Computer Peripheral Industry Week of November 4th

4 Engines and Power Generating Industry Week of November 11th

5 Materials and Manufacturing Week of November 18th
6 Food and Healthcare Industry Week of November 25th
All students must have their topics
assigned by the Deadline.
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Q1. Why is it important to interface the
manufacturing engineering requirements
with the design phase as early as possible?

•The least expensive time to make a change to the design is before the part is
made. Putting the manufacturing engineering requirements into the design phase
helps ensure that the part can be economically fabricated.

Chapter 10
Q2. What is difference
between tolerance
and allowance?

•The allowance determines the desired fit 6

between mating parts.

•Tolerance takes into account the deviations

from a desired dimension.

Chapter 10
Q3. What is difference
between accuracy and
precision?

•To determine the aim of the process one 7

needs the measures of accuracy. To
determine the variability in a process one
needs measures of precision.
•Accuracy is measured by distribution means
and precision is measured by variances or
standard deviations.

Chapter 10
Q4. Explain how could you
determine whether your ordinary
bathroom scale is linear and has
good repeat accuracy assuming the
scale is analog?
8

•To determine the repeat accuracy, just step on the scale and step off many times and
take reading. Determining the linearity requires that you have a set of standard weights
which you can load on and load off say 10, 50, 90, 130 etc. pounds and plot linear loads
verses readings

Chapter 10
Q5. What are some
unattractive features of
destructive methods?

•When destructive testing is employed,

statistical methods must be used to
determine the probability. If certain test
specimens are good, the entire production
will be good. There always remains some
degree of uncertainty about the quality of the
remaining products because they have never
been individually evaluated.

Chapter 11
Q6. What is proof test
and what assurances
does it provide?

10

•In a proof test, a product is subjected to

loads of determined magnitude, generally
equal to or greater than the designed
capacity. If the part remains intact, then there
is a reason to believe that it will perform
adequately in the absence of abuse of loads
in excess of its rated level.

Chapter 11
Q7. What are some factors that
should be considered when
selecting a nondestructive testing
method?
11

•In selecting a non-destructive method one should consider the advantages and
limitations of various techniques. Some can be performed on only certain types of
materials.

•Each is limited in the type, size, and orientation of the flaws that can be detected.
Availability of the equipment, the cost of operation, the need for skilled operators, and the
availability of a permanent record are other considerations.

Chapter 11
Q8. What is
the primary
limitation of a
visual 12

inspection?
• Visual inspection is limited to
accessible surfaces of a
product so no information is
provided relating to the
interior structure.

Chapter 11
 Q9. What is the
primary materials-
related limitation of
magnetic particle 13

inspection?
• Materials must be ferromagnetic in
order to be examined by the
magnetic particle technique.
Nonferrous metals, ceramics and
polymers cannot be inspected

Chapter 11
Q10. Why don’t standard tables exist
detailing the natural variability at a
given process, such as rolling,
extruding, or turning? 14

• Two identical machine tools doing exactly the same process will have different
amounts of process variability. The individual machines will have different
variability when the work material is changed and when also the operator is
changed. Thus, it is necessary to gather data on the specific machine tool during
the process itself.

Chapter 12
Q11. How does the Taguchi approach
differ from the typical experimental
approach?
• In a typical experimental approach one variable at a time is examined and all the
other variables are kept constant. In the Taguchi approach, all significant variables are 15

mixed and varied in the same experiment. The latter approach permits one to find the
important interactions between dependent variables as well as to evaluate the
significance of each variable.

Chapter 12
Q12. What are common reasons for
sampling inspection rather than
100% inspection?
• For 100% inspection: 16
a) Not possible when the test is destructive.
b) Test is expensive compared to the cost of the item when items are produced in great
volumes

Chapter 12
Q13. For each of the inspection
• A major limitation to each of the following is:
methods listed, cite one major
limitation to its use.
Depends upon the skill of an inspector and is
Visual inspection
limited to surface flaws.

Liquid penetrant Can only detect flaws that are open to the surface.
inspection
Orientation of the flaw and field affects sensitivity,
Magnetic particle limited to ferromagnetic materials, detects only 18
inspection surface and near-surface flaws.

Difficult to use with complex shape parts, trained

Ultrasonic inspection
technicians are required, and the area of inspection
is small.

Chapter 11
Q13. For each of the inspection
• A major limitation to each of the following is:
methods listed, cite one major
limitation to its use.
Costly, must observe radiation precautions, defects
Radiography
must be larger than a minimum size, must
generally process film to get results.

Eddy-current testing Reference standards are needed for comparison

and trained operators are required, materials must 19

be conductive, depth is limited.

Acoustic emission Only growing flaws can be detected, experience is

monitoring required, and there is no indication of the size or
shape of the defect.

Chapter 11
Q14. Which of the major nondestructive inspection
methods might you want to consider if you want to detect
surface flaws and internal flaws in products made from
each of the following materials?
a. Ceramics b. Polymers c. Fiber-reinforced composites
with (i) polymer matrix and (ii) metal matrix (consider 20
various fiber materials)
• Consideration of various inspection techniques means will they work, in contrast to
selecting the best measurement scheme.

• Techniques for the detection of surface flaws and internal flaws can be separated
based on the penetration of the probe into the material. This will depend on the kind
of probe used and the transparency of the material to it.
 The most obvious properties of ceramics that will affect choice of
measurement technique are low electrical conductivity and absence of
a) Ceramics: ferromagnetism. Some ceramics are transparent to light but overall,
most structural ceramics are not optically transparent.

Polymers are also poor electrical conductors, nonmagnetic and have

b) Polymers: low density. Different polymers are transparent and opaque.
21

c) Fiber-reinforced
composites with Fiber composite regions that might be of interest are the fibers, the
(i) polymer matrix matrix and the fiber-matrix interface. The usefulness of the means of
and (ii) metal inspection will depend on the region of interest.
matrix (consider
various fiber
materials):
 Surface Flaws
The general purpose of
nondestructive Composites
inspection methods Ceramic Polymers Polymer Metal
(e.g., not leak testing) Matrix Matrix
described in the 22
Visual Yes Yes Yes Yes
chapter can be
screened using the Liquid
Yes Yes Yes Yes
general Go – No. Go Penetrant
concept used in Magnetic
Chapter 9 for materials No No No Probably
Particles
screening.
The general purpose of nondestructive inspection methods (e.g., not leak testing) described in the chapter can be screened using
the general Go – No. Go concept used in Chapter 9 for materials screening.

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24
Q15. The pulse-echo ultrasonic technique can be used to
determine the thickness of a part or structure. By
accurately measuring the time it takes for a short
ultrasonic pulse to travel through the thickness of a
material, reflect from the back or inside surface, and
return to the transducer, the distance can be calculated 25
by:
where d = thickness of the test piece, V = velocity of
sound in the material being tested t = measured round
trip time.

What are some alternative means of measuring thickness?

Briefly discuss their relative pros and cons. Consider such
features as geometric and material constraints, and the
Answer- When both sides of the part are accessible easy-to-use, accurate, inexpensive
mechanical measuring instruments can be used – rules, rules and calipers, vernier and
micrometer calipers and even dial indicators, depth gages and height gages can be used.
Large enough flat surface areas have to be accessible.

Optical instruments such as microscopes, optical comparators and vision systems can be
used if edge-on views are practical.

Even though designed for more complicated measuring tasks, coordinate measuring
machines can be used to measure part thickness if the two sides are accessible.
26

In general, when both sides of the part are accessible to mechanical or optical instruments
and the part shape is compatible with the size of the probe (the micrometer anvil size for
example) many, simple measurement techniques are available.
When only one side of the part is accessible suitable thickness measurement instruments
are more limited.

The pulse-echo technique described in the problem is a possibility as is the resonance

testing method described on page 231. The theoretical “ability to measure from only one
side” is usually not the actual case.
Answer- The part will probably be resting on a surface and so thickness measurements
using various physical phenomena can be envisioned, although they may be impractical
due to cost, safety or other concerns.

Electrical resistance between the support surface and an electrode on the accessible part
surface can be used to measure thickness. A heat source applied to the part surface and
temperature measurements at the part surface and support surface along with thermal
conductivity data could be used to measure thickness. Similarly, measuring the heat flux
needed to maintain a constant temperature difference could be used to deduce thickness. 27
Q16- If , V for a particular metal is 5000 m/sec and a part
made of that material is 3 mm thick, what is the transit
time for the pulse to cross the material and reflect back to
the source/receptor? (Note: The transit time is a
consideration in evaluating equipment capabilities and
may well influence cost!)
Answer- The expression given in the problem above can be used as 28

t
Q17- Determine the standard deviation and process mean
for the data given for golf ball diameters. A golf ball has a
dimpled surface to improve flight accuracy and distance.
Its diameter is specified as 1.68 inches minimum by the
Professional Golf Association. Measurements were made
with a 1-to-2-inch micrometer. Golf balls are made by a
29
process with a natural total tolerance of 6σ'
approximately equal to 0.01 inches with an average size
of 1.68 inch.

The data given for the golf balls (See chart below) was for
good used golf balls found on the golf course near one of
the author's home. They were separated by Titleist (TI),
Pro Staff (PS), Topflight (TF), Pinnacle (PI), and Dunlop
30
Answer- Standard deviation and process mean for the
data given for golf ball.

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