Professional Documents
Culture Documents
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Frequency of Inspection
Is based on the classification of products characteristics
Critical - bodily harm or loss of the mission (100% inspection) Major - loss of function (sampling inspection) Minor - does not affect fit, form, or function (sampling inspection)
Inspection Requirements
A mechanical drawing is required for inspection on an assembly line
Drawing used must have latest revision Must be on display for easy access
Airframe and instrument checks are initially checked visually with a detailed checklist so that nothing is missed
May include mechanical drawings, electrical schematics, illustrated breakdown and assembly drawings for complex assemblies
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Engineering Drawings
Do not try to memorize a drawing Keep only the latest revision of drawing on file To avoid damage, handle drawings carefully and store them properly If there is a question about the drawing, clear it up with supervisor before proceeding Always follow drawing to the letter Never mark on drawing unless you are authorized to do so. If you are authorized, sign and date your markings Make sure you read and understand all notes on a drawing before you begin work
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Local Notes
Apply to one or more particular characteristics Used with a leader line pointing to characteristic Used with triangle flag with number (note at bottom of drawing)
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Note: The Title Block on an Engineering Drawing is located in the lower right hand corner
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Object Line
.200
Hidden Line
Center Line
Dimension Line
Section Lines
A-A
Break Lines
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3. To avoid unnecessary detail. 4. To show direction of a unilateral profile tolerance zone in geometric tolerancing
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Rear
Left
Front
Bottom
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Orthographic view
Isometric view
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.8000
1.5000
For a hole:
Hole diameter varies between .456 and .464 At Maximum Material Condition (MMC), the hole measures .456 At Least Material Condition (LMC), the hole measures .464
For a shaft:
Shaft diameter varies between .456 and .464 At Maximum Material Condition (MMC), the shaft measures .464. At Least Material Condition (LMC), the shaft measures .456.
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The M in the feature control frame means that the tolerance applies only when the hole diameter measures .495 (MMC).
As the hole diameter increases towards its upper limit, additional (bonus) tolerance is allowed. The bonus tolerance is equal to the increase in hole diameter from the Maximum Material Condition (MMC).
.8000
Position tolerance at LMC = .010 + .008 = .018
1.5000
The M in the feature control frame means that the tolerance applies only when the shaft diameter measures .464 (MMC).
As the shaft diameter decreases towards its lower limit, additional (bonus) tolerance is allowed. The bonus tolerance is equal to the increase in hole diameter from the Maximum Material Condition (MMC).
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Flatness - All the points on a surface are in one plane, the tolerance specified by a zone formed by two parallel planes.
Roundness or Circularity - All the points on a surface are in a circle. The tolerance is specified by a zone bounded by two concentric circles.
Cylindricity - All the points of a surface of revolution are equidistant from a common axis. A cylindricity tolerance specifies a tolerance zone bounded by two concentric cylinders within which the surface must lie.
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Parallelism - The condition of a surface or axis equidistant at all points from a datum plane or axis. Parallelism tolerance specifies one of the following: a zone defined by two planes or lines parallel to a datum plane or axis, or a cylindrical tolerance zone whose axis is parallel to a datum axis. www.spacetec.org
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Measurement/Measuring Tools
Transfer Tools - tools that cannot be read directly
Made to contact part, locked into place, measured with another tool
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Measurement/Measuring Tools
Reference and Measured surface Referenced surface - a fixed surface Measured surface - a movable surface Proper measurement requires fixing the reference surface and measuring with the movable surface Proper Tool for measurement Rule of thumb (10 to 1 rule) - select a measuring tool that is ten times more accurate than the tolerance to be measured (ex: to measure a tolerance of .010, pick a tool accurate to .001 Unnecessary accuracy increases time and cost of measurement Use tool properly Develop a feel for constant and proper pressure Pick proper tool for job Storage
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Measurement Errors
Observational Misreading the gage Parallax error Manipulative Holding the gage incorrectly Not locating datum's properly Mounting the part on the wrong datum's Not aligning the gage properly Bias Rounding off incorrectly Gage inaccuracy
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Measurement Errors
Gage errors Precision loss (e.g., a sluggish or sticking indicator) Accuracy loss (e.g., incorrect gage block stack, bent micrometer frame) Out-of-calibration error Part error Within-the-piece variation (e.g., taper, roundness, etc.) Dirty parts Poor surface finish Flaws
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Surface Plates
Types Flat surface Cast Iron Granite Damaged areas produce no raised material Lower in price Retain flatness longer Will not rust Care Do not abuse No unnecessary objects Not a storage area (keep only what you are using at the time on the surface plate) Clean surface plate before and after use Keep covered when not in use (do not set objects on plate when not in use)
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Surface Plates
Accessories Angle plates (knee) V-Blocks Matched V-Blocks Matched V-Blocks can be use to contact multiple datum diameters Stack gage blocks Planer gages Fixed parallels Rectangular in shape Available in various sizes Extends reference surface where necessary
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Electrical/Pressure Measurements
Pneumatic systems utilize relief valves and burst disc to relieve pressures at predetermined rates. Hydraulic fluid systems use selector valves to direct flow of fluid to varies components and systems. Fluids readily transmit pressure but are incompressible. The component in a hydraulic systems that is used to direct the flow of the fluid is the selector valve. (Metering Valve/Proportioning Valve) All fluids readily transmit pressure
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Electrical/Pressure Measurements
In a fix container when the pressure increases, the temperature increases
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Nondestructive Testing
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Definition of NDT
The use of noninvasive techniques to determine the integrity of a material, component or structure or quantitatively measure some characteristic of an object.
i.e. Inspect or measure without doing harm.
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Methods of NDT
Visual
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Visual Inspection
Most basic and common inspection method. Tools include fiberscopes, borescopes, magnifying glasses and mirrors. Portable video inspection unit with zoom allows inspection of large tanks and vessels, railroad tank cars, sewer lines. Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors, pipelines.
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Radiography
The radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that we see as visible light. The radiation can come from an X-ray generator or a radioactive source.
High Electrical Potential Electrons +
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Film Radiography
The part is placed between the radiation source and a piece of film. The part will stop some of the radiation. Thicker and more dense area will stop more of the radiation. The film darkness (density) will vary with the amount of radiation X-ray film reaching the film through the test object. = less exposure = more exposure
Top view of developed film
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Radiographic Images
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Eddy current testing is particularly well suited for detecting surface cracks but can also be used to make electrical conductivity and coating thickness measurements. Here a small surface probe is scanned over the part surface in an attempt to detect a crack.
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Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect sound.
initial pulse
crack echo
crack plate
0 2 4 6 8 10
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Ultrasonic Imaging
High resolution images can be produced by plotting signal strength or time-of-flight using a computercontrolled scanning system.
Gray scale image produced using the Gray scale image produced using sound reflected from the back surface the sound reflected from the front of the coin (inspected from heads side) surface of the coin www.spacetec.org
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Probe
Signals produced by various amounts of corrosion thinning.
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Cameras on long articulating arms are used to inspect underground storage tanks for damage.
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Aircraft Inspection
Nondestructive testing is used extensively during the manufacturing of aircraft. NDT is also used to find cracks and corrosion damage during operation of the aircraft. A fatigue crack that started at the site of a lightning strike is shown below.
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Rail Inspection
Special cars are used to inspect thousands of miles of rail to find cracks that could lead to a derailment.
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Bridge Inspection
The US has 578,000 highway bridges. Corrosion, cracking and other damage can all affect a bridges performance. The collapse of the Silver Bridge in 1967 resulted in loss of 47 lives. Bridges get a visual inspection about every 2 years. Some bridges are fitted with acoustic emission sensors that listen for sounds of cracks growing.
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Pipeline Inspection
NDT is used to inspect pipelines to prevent leaks that could damage the environment. Visual inspection, radiography and electromagnetic testing are some of the NDT methods used.
Remote visual inspection using a robotic crawler.
Magnetic flux leakage inspection. This device, known as a pig, is placed in the pipeline and collects data on the condition of the pipe as it is pushed along by whatever is being transported.
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Special Measurements
Boeing employees in Philadelphia were given the privilege of evaluating the Liberty Bell for damage using NDT techniques. Eddy current methods were used to measure the electrical conductivity of the Bell's bronze casing at various points to evaluate its uniformity.
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