Lecture 3
Measuring and Gauging parts
• Metrology "the science of measurement, embracing both
experimental and theoretical determinations at any level of
uncertainty in any field of science and technology“
• The measuring devices are used for production and quality control
• Simple measuring device is steel rule and Vernier Caliper.
• E.g. calipers, micrometers, height gages, coordinate measuring
machine
Different inspection or measuring methods
Applications
• Air: Gaging holes and shaft
• Optical light energy: Interferometry : Checking float ness; Microscope
• Optical electron energy: Precision measurement SEM
• Electronics: Electronics signals are used to record and measurement
• Mechanical: Dial indicators, Calipers
Factors in selecting Inspection equipment
• Gauge Capacity: The measurement device (or working gage) should
be 10 times more precise than the tolerance to be measured.
• Linearity:
• Repeat Accuracy
• Stability
• Magnification
• Resolution/Sensitivity: Smallest unit of scale or dimensional input
that can be detected by the device
Combination Set
Vernier calliper
ANGLE-MEASURING INSTRUMENTS
Bevel Protactor
Setup to measure an angle on a part using
a sine bar
GAGES FOR ATTRIBUTESMEASURING
• Attribute-type instruments called gages
• Types: Fixed type or Deviation type gages
FIXED-TYPE GAGES
• Fixed-type gages are designed to gage only one dimension and to
indicate whether it is larger or smaller than the previously established
standard.
• They only indicate the items are suitable or unsuitable as per
dimension.
• Materials: Harden steel
Go and Non go gauge
Plug gage.
• It is also known as go and no-go gauge
Fig. Step-type plug gage with go and no-go elements on the same end
Design principle: it is better to reject a good part than declare a bad part to be within
specifications.
• Ring gages are used to check shafts or other external round members
Go and no-go (on right) ring gages for checking a shaft.
Snap gages are the most common type of fixed gage for measuring external
dimensions.
Fig. Adjustable go-not go limit snap gages
• Form gages are available for use in checking the profile of various
objects.
Fig: Thread pitch gages
Design for recycling/ Design for environment
Introduction
• Design for Environment indicate the phenomena of taking care of
environment during the design of the product.
• Environmental impact in production: Energy consumption,
Consumption of natural resources, Liquid, Gaseous emission, solid
waste generation.
• The environmental effect on
• Energy
• Material
Two life cycle of the product
• The product life cycle initiated from the extraction of resources from
the mines for the manufacturing of the raw material.
• Natural Biological life cycle: Growth and decay of the organic material
• Product industrial life cycle
Environmental impact of the product
• Global warming:
• Resource depletion:
• Water pollution:
• Air pollution:
• Land degradation:
• Biodiversity:
• Ozone depletion:
Historical development of the Design For
Environment
• The concept has been developed during the 1970 s. The same concept
is also known as Green design, Eco design, Sustainable design.
• Few of the important persons /Designer contributed in the field of
Design for Environments are:
• Fiksel discussed how DFE integrates life cycle thinking into new
product and process development. As the DFE process matured,
• Brezet and van Hemel (1997) provided a practical guide called
Ecodesign.
Factors to be consider in the Design for
Environment:
• Material Chemistry
• Disassembly
• Recyclability
Case study
Three chairs in Herman Miller’s line of office seating products. Shown (from left to right) are the
Aeron (1994), Mirra (2004), and Setu (2009).
• Environmentally friendly materials: The Setu multipurpose chair
consists of environmentally safe and nontoxic materials such as 41
percent (by weight) aluminum, 41 percent polypropylene, and 18
percent steel.
• Recycled content: The Setu is made of 44 percent recycled materials
(by weight, comprising 23 percent postconsumer and 21percent
postindustrial recycled content).
• Recyclability: The Setu is 92 percent recyclable (by weight) at the end
of its useful life. Steel and aluminum components are 100 percent
recyclable.
• Clean energy: Setu is manufactured on a production line that utilizes
100 percent green power.
• Emissions: No harmful air or water emissions are released during
Setu’s production.
• Returnable and recyclable packaging: Outgoing packaging materials
include corrugated cardboard and a polyethylene plastic bag, both
materials capable of repeated recycling.
The Design for Environment process
1. Set the DFE Agenda: Drivers, Goals, and Team (Product
planning)
2. Identify Potential Environmental Impacts (Concept
development)
3. Select DFE Guidelines (Concept development)
4. Apply DFE Guidelines to Initial Design(s) (System-Level
Design)
5. Assess Environmental Impacts (Detail Design)
6. Reflect on DFE Process and Results
Set the DFE Agenda: Drivers, Goals, and Team
(Product planning)
• Drivers for DFE:
• Internal Factors: Product quality, Public image, Cost reduction, Innovation,
Operational safety, Employee motivation, Ethical responsibility, Consumer
behavior etc.
• External Factors: Environmental legislation, Market demand, Competition,
Trade organizations, Suppliers, Social pressures.
• Set DFE goals:
Few of the important goals by industries regarding the environment
• Zero landfill
• Zero process water use
• Zero hazardous waste generation
• Zero harmful gas generation
• Use of green electricity
• Sell the environmental friendly product.
Step II: Identify Potential Environmental Impacts
Step III : Select DFE Guidelines
• The Guidelines helps the product development team and industry to
prevent environmental damage.
e.g. of few guidelines
Step 4: Apply the DFE Guidelines to the Initial
Product Design
Step 5: Assess the Environmental Impacts
• During product design the following factors could be considered
1. Material chemistry:
2. Recycled content:
3. Disassembly:
4. Recyclability:
Step 6: Refine the Product Design to Reduce
or Eliminate the Environmental Impacts
Step 7: Reflect on the DFE Process and Results
