Scribd
Upload
10 views

Assignment 1

The document discusses optimal inspection levels in quality control. The optimal level corresponds to the minimum total cost, which is the sum of the cost of inspection and the cost of passing defective products. Non-contact inspection methods like radiography do not require physical contact. Different types of inspections can be classified by timing, location, number of samples inspected, and application. The document also provides solutions to questions about material properties testing such as tensile strength, hardness, fatigue endurance limits, and ductility.

Uploaded by

Thoufeeq Salim
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
10 views

Assignment 1

The document discusses optimal inspection levels in quality control. The optimal level corresponds to the minimum total cost, which is the sum of the cost of inspection and the cost of passing defective products. Non-contact inspection methods like radiography do not require physical contact. Different types of inspections can be classified by timing, location, number of samples inspected, and application. The document also provides solutions to questions about material properties testing such as tensile strength, hardness, fatigue endurance limits, and ductility.

Uploaded by

Thoufeeq Salim
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 5

INSPECTION AND QUALITY CONTROL IN MANUFACTURING

Solution for Assignment-01

1. At what point is the inspection level considered optimal in quality control?

(a) Sum of cost of inspection and cost of passing defectives is minimum


(b) Cost of passing defectives is minimum
(c) Sum of cost of inspection and cost of passing defectives is maximum
(d) Cost of inspection is maximum
Sol. Total inspection cost is the sum of the fixed cost and the variable cost, in which the
variable cost is related to the quantity inspected per day. The fixed cost includes the setup
cost and salaried workers of the inspection area. For calculating the optimal amount of
inspection, the variable cost is taken into consideration. The optimum level of inspection
corresponds to the total cost which is the sum of cost of inspection and the cost of passing
defectives.

2. Which inspection method among the following is of the non-contact type?

(a) Vernier Caliper


(b) Radiography
(c) Coordinate Measuring Machine
(d) Go/No-go Gauge

Sol. In non-contact inspection, no physical contact is made. Examples include:


Radiography inspection, visual inspection, scanning laser system, etc.

3. Match the following:

List-I List-II
A. Inspection of raw and intermediate 1. Timing
products, In-service damage
inspection

B. Floor, Centralized and Combined 2. Place


Inspection

C. Sampling and 100% Inspection 3. Application


D. Off-line and On-line inspection 4. Number of samples inspected

a) A-1; B-2; C-4; D-3


b) A-4; B-3; C-1; D-2
c) A-1; B-4; C-2; D-3
d) A-3; B-2; C-4; D-1

Sol. There are different parameters, on the basis of which the inspection procedure can be
classified:

i. Based on timing: Off-line and On-line inspection


ii. Based on place: Floor, Centralized and Combined Inspection
iii. Based on usefulness of the part after inspection: Destructive and non-destructive
inspection
iv. Based on contact: Contact, and non-contact inspection
v. Based on number of samples inspected: Sampling and 100% inspection
vi. Based on application: Inspection of raw and intermediate products, inspection
following secondary processing, and in-service damage inspection

4. A tensile test specimen has a gauge length of 64 mm and cross-sectional area of 412
mm2. During testing, the specimen yields under a load of 750 kN with the
corresponding gauge length of 78.35 mm. The maximum load of 845 kN is reached at
gauge length of 89.2 mm. Determine the ultimate tensile strength of the specimen

(a) 2012 MPa


(b) 1865 MPa
(c) 2051 MPa
(d) 2294 MPa

Sol. Ultimate strength,

𝐹 845 × 103
𝜎𝑦 = = = 2050.9 𝑀𝑃𝑎
𝐴 412
5. What are the initial minor loads for the Rockwell hardness test and the Rockwell
superficial hardness test, respectively?

(a) 3 kg and 10 kg
(b) 10 kg and 3 kg
(c) 1 kg and 7 kg
(d) 7 kg and 1 kg

Sol. The initial minor load (preliminary test force) is 10 kg for the Rockwell hardness test
and 3 kg for the Rockwell superficial hardness test.

6. How the specimen is positioned in Izod impact test?

(a) Cantilever beam


(b) Simply supported beam
(c) Fixed beam
(d) Overhang beam

Sol. In Izod test, the specimen is placed as 'cantilever beam'.

7. The resistance to fatigue of a material is measured by:


(a) Elastic limit
(b) Ultimate tensile strength
(c) Endurance limit
(d) Young’s modulus

Sol. When a material is subjected to fatigue load, then there exists a certain level of stress,
below which the material does not fail, no matter how many stress cycles is loaded.
This is called as endurance limit of the material.

8. Which of the following methods is not suitable for determining the fiber volume
fraction in a composite material?
(a) Optical microscopy method
(b) Acid digestion method
(c) Fiber pull-out method
(d) Resin burning-off method
Sol. The four main methods to determine fiber volume fraction present in a composite
are:

i. Acid Digestion Method.

ii. Optical Microscopy method.

iii. Resin Burning-off Method.

iv. Gravimetric Relation Method.

Fiber pull-out test method is used for mechanical characterization of fiber/matrix


interface.

9. Among the following statements, please identify the one that is incorrect regarding
fracture toughness tests.
(a) In LEFM the critical value of stress intensity factor (K) is referred to as the
fracture toughness.
(b) The fracture toughness for the materials of elastic-plastic region is referred to as
Jc, which is a measurement of the energy required to grow a thin crack.
(c) Fracture toughness is the fracture resistance of a material in the presence of
cracks.
(d) None of these.

Sol. Fracture toughness is defined as fracture resistance of a material in the


presence of cracks. In LEFM (Linear Elastic Fracture Mechanics) the critical value of
stress intensity factor (K) is referred to as the fracture toughness. The corresponding
fracture toughness value for the materials of elastic-plastic region is referred to as Jc
(J-integral or critical energy release rate), which is a measurement of the energy
required to grow a thin crack.

10. A cylindrical tensile test specimen with an initial diameter of 12.8 mm and a gauge
length of 64.80 mm undergoes tension until it fractures. At the point of fracture, the
diameter is 8.13 mm, and the fractured gauge length is 72.56 mm. Determine the
ductility, expressed as a percentage of elongation.
(a) 11.97%
(b) 18.42%
(c) 14.46%
(d) 22.12%
Sol. Ductility,

(𝑙𝑓 − 𝑙0 ) 72.56 − 64.80


%𝐸𝐿 = × 100 = × 100 = 11.97%
𝑙0 64.80

You might also like