Developing an Integrated Curriculum in Metrology for a Mechanical Engineering Technology Program

Joseph P. FuehnePurdue University

Mechanical Engineering TechnologyColumbus, Indiana

jfuehne@purdue.edu

• Learning Outcomes- Who is PCOT in Columbus?

- Details including objectives of 3 new metrology-related classes

- Specific lab activities

- Integration into the MET curriculum

• Purdue University College of Technology– Statewide system– 10 locations throughout Indiana– Direct administrative link to West Lafayette

campus– Not a “regional” campus– Work together with host campus to deliver

program– Host campus provides instruction for general

education classes

• Purdue COT in Columbus– Four degree programs

• MET – Mechanical Engineering Technology• OLS – Organizational Leadership & Supervision• IT – Industrial Technology• CNIT – Computer & Information Technology

– Commuter Campus• Low cost alternative to “main” campus• Still awarding Purdue diplomas

• Mechanical engineering technology– BSMET at locations is equivalent to BSMET at the

main campus• Not true at regional campus although very similar

– Hands-on program– Applied Engineering– Better preparation for manufacturing-related

careers– No real metrology effort on the main campus

• This effort in Columbus leads COT’s metrology curriculum

• Metrology Rationale– Critical tool in manufacturing– Underappreciated in higher education– Most engineering or engineering technology

programs ignore metrology and closely-related GD&T

– Only a handful of higher education institutions really address metrology in curricula

• Metrology Lab Collaboration– A community effort– Cummins, Inc– Community Education Coalition– Environmentally-controlled lab– Donated equipment

• Starrett CMM• Optical measurement systems• Mass and length standards• Mass balances• Force measurement system• Super micrometer• Hand tools

• Engineering Technology vs Engineering– Metrology is a better fit in ET programs– Practical, hands-on program focused on

design and production processes – manufacturing!

– ET is ideal for integrating measurement devices, techniques, analysis and plan development

• Integrated curricula vs Skill Attainment– Integrate metrology as a tool to improve

design and production process– Curriculum committees

• Not necessarily interested in “Introduction to CMM” class

• At least, not at upper division level• Easier to gain approval for a class that addresses

overall big picture of design and production processes rather than a “skill attainment” class

• Inspection and Validation of Product Design– Fall 2012 class– Senior-level course (MET 490)– Satisfies an elective requirement in the POS– Addresses the efficiency and effectiveness of

the manufacturing process– Class completes study of GD&T started in an

earlier course– Focuses on design intent and then utilizes

metrology tools for validation

Description: Inspection and Validation of Product Design

This class has resulted from the new Metrology lab at the Purdue Columbus COT location. It builds on the outcomes of MET 102 – Production Design and Specifications – especially those related to geometric dimensioning and tolerancing (GD&T). The class initially will focus on GD&T, extend the outcomes from MET 102 and increase the depth of knowledge in this important manufacturing topic while focusing on design intent. The lab portion will utilize the two coordinate measuring machines, the two optical instruments, height gages, gage blocks, and surface finish measurement tools to inspect the design and validate the design intent.

Course Objectives:

Upon successful completion of this course, the student will be able to:

1. Review basic GD&T principles including datum reference planes, basic dimensions, virtual conditions and bonus tolerances.

2. Define, interpret, and compute tolerance zones for GD&T form, orientation, position, concentricity, symmetry, runout and profile controls.

3. Utilize coordinate measuring machines (bridge and articulated arm) to inspect and validate GD&T callouts and design intent.

4. Analyze data from measuring machines to determine critical parameters associated with each GD&T control.

5. Utilize optical measuring instruments to inspect and validate design intent.

6. Utilize a surface finish measurement machine to determine critical parameters related to surface finish and validate design intent.

7. Compare and contrast various devices and methods to determine design intent.8. Define and compute measurement uncertainty for measurement systems utilized to determine design intent.

9. Conduct a gage Repeatability and Reproducibility (R & R) Study to analyze and improve potential measurement system.

• Laboratory Projects– Micrometer calibration– Gage R&R study using washers– Flatness evaluation– Identification and measurement of threads– Determine coefficient of thermal expansion– Perform measurements to compute density of

washers and determine material– Operating a CMM to determine roundness– Operating a CMM to determine angles of holes

• Measurement artifacts provided by Cummins, Inc

• Measurement Systems Analysis– Spring 2013 class– Senior-level elective (490)– Non-laboratory activities

• Develop a gage R&R spreadsheet in Excel (AIAG Measurement Systems Analysis book

• Learn to describe, report and use uncertainties in measurements

– An Introduction to Error Analysis by John R. Taylor– Propagation of uncertainties– Statistical analysis of random uncertainties

• Lab Activities– CMM programming– Reverse Engineering projects

Description: Measurement Systems AnalysisMeasurement Systems are vital to the manufacturing enterprise and analyzing these systems for their effectiveness is critical to verifying those measurements. Manufacturing companies may supply parts to another enterprise or accept parts from suppliers to make their products. Confirming measurements of those parts and the systems used to make them are critical to accepting and rejecting supplier parts. This class will investigate measurement systems and how to assess them through a combination of classroom and laboratory work and includes using hand tools, video measurement systems and coordinate measurement machines to measure parts and assess their effectiveness.

Course Objectives:Upon successful completion of this course, the student will be able to:

1. Conduct measurements utilizing systems including hand tools, video measurement systems, coordinate measurement machines, surface finish machines, and mass measurement devices.

2. Conduct statistical analyses of these measurements using Excel and MiniTab to determine stability, bias, linearity, repeatability, reproducibility, range and variance.

3. Conduct Analysis of Variance (ANOVA) studies to determine the sources of variation.4. Determine measurement uncertainty including Type A and Type B uncertainties and calculating

overall measurement uncertainty.5. Demonstrate and calculate the propagation of measurement uncertainty in computations using

measurement data.6. Investigate several statistical distributions and how they relate to measurement analysis and

uncertainty.7. Perform a complete reverse engineering project, including measuring a part, creating a CAD model

and drawing of the part including proper dimensions and geometric tolerances, rapid prototyping the part, creating the part using CNC machining equipment and developing a measurement system analysis of both the prototype and the CNC-machined part that includes recommending a manufacturing and measurement system for putting the part into mass production.

• Dimensional Metrology– Fall 2013 Course– Handbook of Dimensional Metrology by Curtis and

Farago– Introduction to metrology– Introduction to error analysis and uncertainty– Laboratory activities

• Calibration of a micrometer• Wringing gage blocks• Measuring with optical and pneumatic tools• Employing sine bars and plates to measure angles• Measuring screw threads and gears

Description: Dimensional Metrology

Measurement Systems are vital to the manufacturing enterprise and analyzing these systems for their effectiveness is critical to verifying those measurements. Manufacturing companies may supply parts to another enterprise or accept parts from suppliers to make their products. Confirming measurements of those parts and the systems used to make them are critical to accepting and rejecting supplier parts. This class will investigate measurement systems and how to assess them through a combination of classroom and laboratory work and includes using hand tools video measurement systems and coordinate measurement machines to measure parts and assess their effectiveness.

Course Objectives:

Upon successful completion of this course, the student will be able to:

1. Define metrology, traceability and explain the role of metrology in national and international trade.

2. Define the terms precision, accuracy, and reliability.

3. Convert dimension units between English and metric systems.

4. Demonstrate using graduated scales within the recognized limitations.

5. Understand the relationship between scale divisions and discrimination.

6. List the primary sources of error in graduated-scale instruments.

7. Correctly measure a part using a vernier instrument.

8. Correctly measure a part using a micrometer and a super-micrometer.

9. Describe how Abbe’s law contributes to micrometer measurement.

10. Describe the mathematical basis for gage block series.

11. Demonstrate how to properly wring blocks together.

12. Combine gage blocks to any desired dimension.

13. Describe the difference between direct measurement and comparison measurement.

14. Describe how pneumatic metrology works.

15. Demonstrate measurement using a pneumatic metrology instrument.

16. Apply circle and trigonometric functions with sine bars and plates to angular measurements.

17. Describe and use optical systems for measurement.

18. Describe and demonstrate measurements of screw threads.

19. Describe and demonstrate measurements of gears.

• Summary and conclusions– Integrating metrology concepts and skills

(tools) into an MET curriculum– Not necessarily “skill attainment” courses– Fit metrology into larger vision of product

design, inspection, and validation. – Potential for developing modules of courses

into short courses or training courses