CHAPTER-1 INSPECTION

1.1 Inspection:- It is the process of measuring the qualities of a product or service in

terms of established standards.

1.2 Physical Quantity:- Any quantity which can be measured is called physical
quantity. There are two types:
1. Fundamental or basic quantities:- The mutually independent quantities are called
fundamental or basic quantities. Some of are mass, length, time, temperature etc.
2. Derived quantities:- The quantities which can be expressed in terms of fundamental
quantities are called derived quantities. Some of are velocity, linear momentum etc.

1.3 System of units:- Four systems of units recognized universally:

1. C.G.S. System:- In this system, the units of length, mass and time are centimetre,
gram and second respectively.
2. F.P.S. System:- In this system, the units of length, mass and time are foot, pound and
second respectively.
3. M.K.S. System:- In this system, the units of length, mass and time are metre,
kilogram and second respectively.
4. S.I. System:- In this system, the units of length, mass and time are metre(m),
kilogram(kg) and second(s) respectively.

1.4 Measurement:- It is the process of comparing an unknown quantity with a known

fixed unit quantity of the similar nature.

1.4.1 Standards of Measurement:-

1) Primary Standards:- The highest standard of either a base unit or a derived unit
is called a primary standard.
2) Secondary Standards:- These are the reference calibrated standards designed
and calibrated from the primary standards.
3) Tertiary Standards:- These are properly maintained in laboratories and
workshops as reference for comparison of the working standards.
4) Working Standards:- These are the normal standards used by the technicians
and workers who are actually carrying out the operational measurements.
1.5 Interchangeability:- the ability to select components for assembly at random and fit
them together within proper tolerances.

1.6 Objectives of inspection:-

1. Inspection separates defective components from non-defective ones and thus ensures
the adequate quality of products.
2. By doing so, it prevents the defective or sub-quality products from reaching the
assembly stage and, hence, the customer.
3. Inspection prevents further work being done on semi-finished products already
detected as spoiled.
4. It helps the companies in enhancing their reputation by maintaining quality standards.

1.7 Types of Inspection:-

Depending upon the method of production and location of the work, generally, the inspection
may be of the following kinds:

A. Based upon the Method of Inspection:

1. Remedial inspection
2. First-off inspection
3. In-process inspection
4. Operation inspection
5. Sampling inspection
6. Final inspection
7. Preventive inspection
B. Based upon Location:

1. Centralized or crib inspection

2. Decentralized or floor inspection

1.8 Study Of Factors Influencing The Quantity Of Manufacture:

1. Raw Material: The quality of finished products basically depends upon the
incoming raw material.
2. Skilled Manpower: Skilled manpower is needed to produce a quality work.
3. Machinery and Equipment: Modern machinery are required for best
quality of manufactured product.
4. Process: The process adopted should be right and according to the requirement.
5. Design: The quality is affected by the design of product.
6. Purpose: Quality varies according to the requirement.
CHAPTER- 2 MEASUREMENT AND GAUGING

2.1 Steel Rule:- It is made of tempered steel. It measures on the basic technique of
comparing an unknown length to the previously calibrated.

fig.2.1

2.2 Divider:- It is used for transferring dimensions, marking out curves and circles and
for doing general layout work. It may be firm-joint or spring type.

fig.2.2

2.3 Calipers :- Calipers is that measuring instrument is used for comparing linear
measurement against known dimension.

1) Outside caliper:- It is used for measurement measuring outside dimensions and

thickness.

fig.2.3.1
 2) Inside caliper:- It is used for measuring inside dimensions.

fig.2.3.2

3) Odd leg or hermaphrodite caliper:- It is usedfor making line parallel the edge
of the work and for locating centre of cylindrical work.

fig.2.3.3

4) Transfer caliper:- It is used for measure recessed areas from which the legs of the
caliper can not be removed directly, But are collapsed after the dimension is
measured.

fig.2.3.4

2.4 Vernier Caliper:- It is a precision instrument which is used for measuring external
as well as internal diameter of the shafts, thickness of parts etc. to an accuracy of 0.02 mm.
 fig.2.4

Least count:- It is the difference between the value of main scale division and the vernier
scale division.
Least count = Value of one small division on main scale – value of one small division on the
vernier scale.

2.4.1 Vernier height Gauge:- It is mainly used in the inspection of parts and layout
work. It may be used to measure and mark vertical distances above a reference surface.

fig.2.4.1
2.4.2 Vernier depth Gauge:- It is used to measure the depth of holes, recesses and
distances from a plane surface to a projection.
 fig.2.4.2

2.5 Micrometer:- These are precision measuring instruments. There are designed on the
principle of “screw and nut”.

1) Outside micrometer:- It is mainly used to measure the outside diameter of a job or

length of a small part. It can measure the dimension to an accuracy of 0.01mm.

fig.2.5.1

2) Inside micrometer:-It is used to measure the internal dimensions to an accuracy of

0.01mm. It works on the same principle as that of outside micrometer.

fig.2.5.2
3) Screw thread micrometer:- It is used to measure the pitch diameter of the screw
threads .It can measure with the accuracy of 0.01mm.

fig.2.5.3

4) Depth gauge micrometer:- It is used to measure the depth of holes, slots and
recessed areas to an accuracy of 0.01mm.

fig.2.5.4

5) Differential micrometer:- This type of micrometer is used to increase the accuracy

of the micrometer.

fig.2.5.5
6) Dial indicator:- It is used to true and align machine tools, fixtures and work and to
the test and inspect the size and trueness of finished work to an accuracy of 0.01mm.

fig.2.5.6

7) Surface plate:-It is use to test the flatness of work itself. It is also used for marking
outwork. Surface plate is of solid design and made of grey cast iron. They are available
in various sizes of 1.5 X 5m, 1.5 X 3m, 2 X 2m and 2 X 4m.

fig.2.5.7

8) Straight Edge:- It is used to test the straightness or flatness of plane surfaces. It is

generally in rectangular in shape.

fig.2.5.8

9) Try Square:- It is used mainly to test squareness of two adjacent surfaces.

fig.2.5.9

10) Protractor:- It is used to measure the angle between two faces of a component.
 a. Vernier Bevel Protrator:-

fig.2.5.10.a

b. Optical Bevel Protractor:-

fig.2.5.10.b

11) Sine Bar:- A sine bar is a simple device used either for accurate measurement of
angles or for locating work to a given angle. It is generally used in conjunction with slip
gauges.
The following points in its construction ate important:
1. The rollers should be of equal diameter.
2. The distance between the roller centres must be absolutely correct.
3. The centre line of the roller centres must be exactly parallel with the top and bottom
edges of the bar.

fig.2.5.11
12) Tool Room Microscope:- A tool room microscope is a versatile instrument which
measures by optical means with no pressure involved.

fig.2.5.12

13) Profile Projector:- It is also known as magic lantern. It is used to protect a magnified
image of a small transparent object like a photographic film or a slide on a screen. It
produces a real, inverted and magnified image of the object on the screen of an
arrangement of lenses.

fig.2.5.13

14) Gauges:- these are generally used to check the particular dimension of a work piece
within its tolerance.

15) Plug gauges:- These are used to check holes of different shapes and sizes. Plug gauges
are available to check straight cylindrical holes, tapered, threaded and splined holes.

fig.2.5.15
16) Screw Pitch Gauges:- These are used to check the pitch of screws.

fig.2.5.16