Advanced Manufacturing Techniques

Activity -8
Co-ordinate measuring machining

ASSIGNMENT-08( WEEK10) 2024-25

1) Describe the principle, construction and working of Co-ordinate measuring machining with sketch.
OR
Illustrate the Working of Co-Ordinate Measuring Machines (CMM). -------10 APRIL/MAY 2024
OR
Explain the working of Co-Ordinate Measuring Machine (CMM).------------------10 July-2024 makeup
2) List the advantages, dis-advantages and application of CMM.
3) NDT methods are used for inspecting manufacturing parts.Why is Non Destractive Testing (NDT)
important? What test is available? What criterions are considered in selection of these (NDT?)
methods?
4) Discuss and demonstrate different Non Destractive Testing (NDT) methods,
A. -Radiography testing
B. -Ultrasonic testing
C. -Magnetic particle testing
D. -Penetrate testing
E. -Visual testing
F. -Electromagnetic testing.
5) Compare Destructive and Non -Destructive testing and List the different NDT methods.
OR
Discuss the differences between Destructive and non-destructive testing methods? List the
different NDT methods. ------------------------------------------------10 APRIL/MAY 2024
6) The components which are manufactured by Additive Manufacturing (AM) technology known to have
various internal defects, such as porosity, internal cracks thermal stresses etc., which can significantly
affect the mechanical properties and safety of final parts. Therefore inspection methods are very much
important. List different inspection methods adopted in AM. Explain ultrasonic testing and write their
advantages. Feb/March 2023
7) AM-produced parts are being used many applications. These parts are tested using Non- Destructive
testing methods. Suggest the best Non-Destructive testing method used in this case. Present arguments to
support your selection. Feb/March 2023
8) Safety and reliability are of prime importance for the AM-produced parts, which are used in aviation
and power industries. The parts are tested using Non-destructive testing methods. Discuss the different
NDT methods and suggest the best NonDestructive testing and support your selection. June/July-2023
8) Explain Electromagnetic testing type of Non-destructive testing method. Mention any three advantages
and any two disadvantages. ------------------------------------------------------------10 APRIL/MAY
2024
9) List the different inspection methods adopted in AM. Discuss benefits and need of NDT----10
July-2024 makeup
10) Explain Die Penetrant Non-Destructive testing with neat sketch-------------------10 July-2024 makeup
6) The components which are manufactured by Additive Manufacturing (AM) technology known to
have various internal defects, such as porosity, internal cracks thermal stresses etc., which can
significantly affect the mechanical properties and safety of final parts. Therefore inspection
methods are very much important. List different inspection methods adopted in AM. Explain
ultrasonic testing and write their advantages. Feb/March 2023
Scheme:- List – 1/2x6=3 Marks, Explanation-3 Marks, Advantages 0.5x8=4M
Ans: Different inspection methods are
1. Magnetic particle testing
2. Radiographic Testing
3. Magnetic particle testing
4. Ultrasonic testing
5. Electromagnetic Testing
6. Tube Inspection With Remote Field Testing (RFT)
7. Remote Visual Inspection (RVI)
8. Liquid penetrant testing
Ultrasonic testing
Ultrasonic testing remains the most popular nondestructive testing method after visual testing. In this
method, a high-frequency sound wave generated by a transmitter travels through the object under test.
The frequency of this wave is usually between 1 and 10 MHz. The wave distorts when encountering a
change in the density of the material. This change in the transmitted wave is captured by a receiver. The
equipment then measures and analyses the received wave to understand the nature and depth of the defect.
The equipment can also calculate the thickness of the specimen by dividing the wave speed in the
material by the time taken for travel. There are many types of ultrasonic testing available each with its
own nuances and field of application. These are pulse-echo testing, immersion testing, guided wave
testing and phased array ultrasonic testing to name a few. We can identify defects such as cracks,
abrasions, thinning, pitting and corrosion using ultrasonic inspection. Advantages of ultrasonic testing:
1. Quick
1. 2.Clean
2. Reliable
3. Portable
4. Safe and easy to use
5. Highly accurate and sensitive
6. Ability to gauge dense materials
7. Detection of surface and subsurface defects
8. Identifications of minor defects not visible to the naked eye
7) AM-produced parts are being used many applications. These parts are tested using Non-
Destructive testing methods. Suggest the best Non-Destructive testing method used in this case.
Present arguments to support your selection. Feb/March 2023
Scheme: Suggestion-5 Marks , Argument-5
Ans:
Initial manufacturing process and repair also use NDT. Two of the most significant NDT methods used in
aerospace are Magnetic Particle Inspection (MT) and Penetrant testing (PT).
Penetrant Testing – penetrant inspection, or penetrant testing (PT) , is another method of NDT used in
the aerospace industry.
One of the oldest approaches to detect surface flaws like cracks, porosity, gouges, and seams, inspectors
add the dye to target areas on a surface.
By capillary action, the dye finds its way into openings, coating the flawed areas. After the excess dye is
removed, an additive called the “developer” is introduced, and it draws the remaining dye out.
After a final cleaning step, the dye that penetrated through the developer exposes the critical cracks and
porosity in the part when viewed under a black light.
While PT can be used in nearly any NDT application, compatibility of test materials must be considered
for the specific industry.
With the inherent severity of chemical incompatibility in the aerospace industry, manufacturers developed
classes of penetrants best suited for that industry.
The most common penetrant systems in aerospace are Type I (fluorescent), Methods A, B, and D (water
washable, post emulsified – lipophilic, and post emulsified – hydrophilic, respectively).
Benefits of Penetrant testing
1. i)The method has high sensitivity to small surface discontinuities.
2. ii) The method has few material limitations, i.e. metallic and non-metallic, magnetic and
nonmagnetic, and conductive and non conductive materials may be inspected.
3. iii) Large areas and large volumes of parts/materials can be inspected rapidly and at low cost.
4. iv) Parts with complex geometric shapes are routinely inspected.
5. v) Aerosol spray cans make penetrant materials very portable.
6. vi) Penetrant materials and associated equipment are relatively inexpensive.
The balance in the design of aerospace components comes with aiming to lighten the component mass
while withstanding the high structural loads on the materials. This high load-to-material strength ratio
makes the components susceptible to thermal and pressure cycle fatigue, as well as vibration, due to the
wide ranges of operating conditions.
Additionally, corrosion from humidity in the ground air that condenses on the plane attacks the material
as well. Over 80% of inspections are performed visually by trained inspectors. Inspectors use NDT for
much of the remaining 20% they cannot access visually.
8) Two vernier calipers are used to measure a 10.000 mm gage block. Five measurements are taken
with each caliper. June/July-2023
Scheme:- Calculation of Error for Caliper A and Caliper B (2+2=4 marks)
Calculation of Mean and Standard Deviation for Caliper A (2 marks)
Calculation of Mean and Standard Deviation for Caliper B (2 marks)
Comparison and Analysis for better accuracy caliper (1 mark)
Comparison and Analysis for better precision caliper (1 Mark)
For caliper A, the five measurements were 10.01 mm, 10.00 mm, 10.02 mm, 10.02 mm, and 10.01
mm.
For caliper B, the five measurements were 10.01 mm, 9.98 mm, 9.98 mm, 10.01 mm, and 9.99 mm.
Determine: (i) The mean and standard deviation of the error for each of the calipers
(ii) Which caliper has the better accuracy?
(iii) Which caliper has the better precision.

Solution :
To determine the mean and standard deviation of the error for each caliper, we need to calculate the
differences between each measurement and the true value (10.000 mm). Let's perform the calculations for
both callipers: Calliper A:
Error = Measurement - True Value
Measurement 1: 10.01 mm - 10.000 mm = 0.01 mm
Measurement 2: 10.00 mm - 10.000 mm = 0.00 mm
Measurement 3: 10.02 mm - 10.000 mm = 0.02 mm
Measurement 4: 10.02 mm - 10.000 mm = 0.02 mm
Measurement 5: 10.01 mm - 10.000 mm = 0.01 mm
(a) Mean of the Error for Calliper A:
Mean = (Error1 + Error2 + Error3 + Error4 + Error5) / 5
Mean = (0.01 mm + 0.00 mm + 0.02 mm + 0.02 mm + 0.01 mm) / 5
Mean = 0.06 mm / 5
Mean = 0.012 mm
To calculate the standard deviation, we need to find the differences between each error and the mean,
square them, sum the squared differences, divide by (n-1), and take the square root:
Squared Differences:
(0.01 mm - 0.012 mm)^2 = 0.000004 mm^2
(0.00 mm - 0.012 mm)^2 = 0.000144 mm^2
(0.02 mm - 0.012 mm)^2 = 0.000064 mm^2
(0.02 mm - 0.012 mm)^2 = 0.000064 mm^2
 (0.01 mm - 0.012 mm)^2 = 0.000004 mm^2

Sum of Squared Differences = 0.000280 mm^2

Standard Deviation (σ) for Caliper A:
σ = √(Sum of Squared Differences / (n - 1))
σ = √(0.000280 mm^2 / (5 - 1))
σ = √(0.000280 mm^2 / 4)
σ = √0.000070 mm^2
σ = 0.008 mm
Caliper B:
Error = Measurement - True Value

Measurement 1: 10.01 mm - 10.000 mm = 0.01 mm

Measurement 2: 9.98 mm - 10.000 mm = -0.02 mm
Measurement 3: 9.98 mm - 10.000 mm = -0.02 mm
Measurement 4: 10.01 mm - 10.000 mm = 0.01 mm
Measurement 5: 9.99 mm - 10.000 mm = -0.01 mm (a)
Mean of the Error for Caliper B:
Mean = (Error1 + Error2 + Error3 + Error4 + Error5) / 5
Mean = (0.01 mm - 0.02 mm - 0.02 mm + 0.01 mm - 0.01 mm) / 5
Mean = -0.03 mm / 5 Mean = -0.006 mm
Squared Differences:
(0.01 mm - (-0.006 mm))^2 = 0.000529 mm^2
(-0.02 mm - (-0.006 mm))^2 = 0.000256 mm^2
(-0.02 mm - (-0.006 mm))^2 = 0.000256 mm^2
(0.01 mm - (-0.006 mm))^2 = 0.000529 mm^2
(-0.01 mm - (-0.006 mm))^2 = 0.000025 mm^2
Sum of Squared Differences = 0.001595 mm^2
Standard Deviation (σ) for Caliper B:
σ = √(Sum of Squared Differences / (n - 1))
σ = √(0.001595 mm^2 / (5 - 1))
σ = √(0.001595 mm^2 / 4)
σ = √0.000399 mm^2
σ = 0.020 mm
(b) Better Accuracy: To determine which caliper has better accuracy, we compare the means of the
errors. A caliper with a mean error closer to zero indicates better accuracy. In this case, Caliper A has a
mean error of 0.012 mm, while Caliper B has a mean error of -0.006 mm. Therefore, Caliper B has better
accuracy since its mean error is closer to zero.
(c) Better Precision: To determine which caliper has better precision, we compare the standard
deviations. A smaller standard deviation indicates better precision. In this case, Caliper A has a standard
deviation of 0.008 mm, while Caliper B has a standard deviation of 0.020 mm. Therefore, Caliper A has
better precision since it has a smaller standard deviation.
In summary: (a) Mean and Standard Deviation of Error:
Caliper A: Mean = 0.012 mm, Standard Deviation = 0.008 mm
Caliper B: Mean = -0.006 mm, Standard Deviation = 0.020 mm
(b) Better Accuracy: Caliper B (mean error closer to zero) (c) Better Precision: Caliper A (smaller
standard deviation)

9) Safety and reliability are of prime importance for the AM-produced parts, which are used in
aviation and power industries. The parts are tested using Non-destructive testing methods. Discuss
the different NDT methods and suggest the best NonDestructive testing and support your selection.
June/July-2023
Scheme: Discussion of NDT Methods (5 marks): Selection of the Best NDT Method (5 marks)
Answer:
Safety and reliability are indeed crucial for AM-produced parts used in aviation and power industries.
Non-destructive testing (NDT) methods play a significant role in ensuring the quality of these parts
without causing any damage. Let's discuss the different NDT methods and determine the best one,
supported by a selection rationale.

Liquid Penetrant Testing:

Principle: This method uses liquid penetrant materials to detect surface discontinuities.
Application: It is widely used in aircraft maintenance to detect surface defects or structural
damage in various materials.
Advantages: Fast, simple to use, inexpensive, and easily portable. Can detect small surface
discontinuities. Suitable for use on aircraft or in workshops.
Limitations: Requires proper cleaning before and after the test.
Magnetic Particle Testing:
Principle: This method utilizes magnetic fields and ferromagnetic particles to detect surface and
near- surface defects in ferromagnetic materials.
Application: Effective for inspecting components such as engines, landing gear, shafts, and bolts.
Advantages: Simple in principle, easily portable, and fast. Suitable for detecting surface and
subsurface defects in ferromagnetic materials.
 Limitations: Only applicable to ferromagnetic materials. Requires a demagnetization procedure.
Positional limitations due to the directional nature of the magnetic field.
Eddy Current Testing:
Principle: This method uses electromagnetic induction to detect surface and near-surface defects
in conductive materials.
Application: Commonly used for inspecting materials such as aluminum alloys and stainless
steel.
Advantages: Can detect small defects near the surface. Provides rapid inspection results.
Limitations: Limited to conductive materials. Depth of penetration is limited.
Ultrasonic Testing:
Principle: High-frequency sound waves are used to detect internal defects, measure material
thickness, and assess material properties.
Application: Suitable for inspecting various materials, including metals and composites.
Advantages: High sensitivity, ability to detect both surface and subsurface defects, and
capability to measure material thickness.
Limitations: Requires skilled operators. Complex equipment.
After considering the above NDT methods, the best non-destructive testing method for AM-produced
parts in aviation and power industries would be Ultrasonic Testing. This selection is based on the
following justifications:
1. Sensitivity: Ultrasonic testing provides high sensitivity, capable of detecting both surface and
subsurface defects, ensuring thorough inspection of AM-produced parts.
2. Versatility: It is suitable for inspecting a wide range of materials used in aviation and power
industries, including metals and composites.
3. Reliability: Ultrasonic testing is known for its accuracy and reliability in detecting defects,
making it highly suitable for ensuring the safety and reliability of AM-produced parts.
4. Material Thickness Measurement: Ultrasonic testing can also measure material thickness,
which is crucial in assessing the integrity and quality of AM-produced parts. Considering these
factors, Ultrasonic Testing emerges as the best NDT method for AM-produced parts in aviation
and power industries, ensuring the highest level of safety and reliability during testing and
inspection processes.