Daniels set

Question 1

What is a Product Tolerance

Answer 1

Design limits set and defined on an engineering drawing

Question 2

What is a Process Tolerance

Answer 2

Design Limits achievable via machining process

Question 3

What are the advantages and disadvantages of Digital Readouts

Answer 3

+ Easy to read

+ Computer Linkable

+ High accuracy/resolution

• needs clean temp controled environment
• needs recalibration

Question 4

What is the range, resolution and accuracy of the Linear Transducer

Answer 4

Range: 0-25mm

Resolution: 0.0001mm (1/10 micron)

Accuracy: ±0.0015mm

Question 5

What is the range, resolution and accuracy of the Digital HT Gauge

Answer 5

RANGE: 0-700 mm

RESOLUTION: 0.001 mm [ONE MICRON]

ACCURACY: +/- 0.005 mm FULL RANGE

Question 6

What is the range, resolution and accuracy of the Digital Caliper

Answer 6

RANGE: 0-150 mm

RESOLUTION: 0.01 mm [TEN MICRONS]

ACCURACY: +/- 0.03 mm FULL RANGE

Question 7

What is the range, resolution and accuracy of the MC Tool Transducer

Answer 7

RANGE: - VARIOUS UP TO SEVERAL METRES

RESOLUTION: 0.005 mm [FIVE MICRONS]

ACCURACY: +/- 0.010 mm PER METRE

Question 8

What is the Equation for Standard Deviation of a small sample?

EG n=10

Answer 8

Question 9

What is the Equation for Standard Deviation of a large sample?

EG N=100

Answer 9

Question 10

What are the factors affecting Surface Roughness

Answer 10

Tool Geometry + coating

Speed/feed/depth of cut

Material composition

Type of swarf formation

Coolant

Condition of tool

Question 11

What is the Center Line Average (CLA)

Answer 11

The distance from an imaginary mean line drawn across the surface - taking into account peaks and troughs

Question 12

What is the CLA equation?

Answer 12

CLA = 2ABC/f (mm/rev)

Question 13

Where is Surface finish important

Answer 13

Engineering components – Actuators

Aircraft Landing gear

Hydraulic cylinders

Fit and Tolerance

Contact bearings

Sheet metal

Question 14

Relative production time vs surface finish graph

Answer 14

Question 15

Roundness

Answer 15

Every Point on circumference has same radius

Question 16

Talyrond

Answer 16

Scans profile of cylindrical piece, trace provides ideal circle and compares it to actual roundness

Question 17

Cylindricity

Answer 17

The Cylindricity symbol is used to describe how close an object conforms to a true cylinder.

Cylindricity essentially forms a perfect cylindrical boundary around the object that the entire 3-Dimensional part must lie in.

Question 18

Machine Capability

Answer 18

Discrete Operation that should be capable of achieving +- 4 sigma

Question 19

Process Capability

Answer 19

Combination of Variables that should achieve +-3sigma

Question 20

What are the costs of quality?

Answer 20

Returned goods/recalls/warranty

Reworking/repair/retesting

Inspection costs

Prevention of further issues

Loss of potential earnings - (time spent fixing)

Question 21

What is the 6 Sigma Equation?

Answer 21

Question 22

Define what is meant by the surface quality of engineering components.

And describe 2 ways in which finish can be specified on eng drawings

Answer 22

Surface quality refers to the surface finish or texture that is produced on components, it is important because the nature of the finish can enhance performance and appearance.

Question 23

Define Selective Assembly

Explain where used in ball bearing manufacturing

Answer 23

Selective assembly is used to reduce manufacturing costs & allow wider process tolerance.

this involves 100degC inspection and the grading of parts

selective assembly is also used to optimise the fit between parts

Question 24

Define SPC

Answer 24

an organised procedure for sampling the output & detecting problems of “out of control” in a process, hence leading to correction of faults & improvement in quality