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\section{ME 3263}\label{me-3263}
\subsection{Lab \#1 - Measurements of machining precision and
accuracy}\label{lab-1---measurements-of-machining-precision-and-accuracy}
\subsubsection{How can you measure
something?}\label{how-can-you-measure-something}
All measurements have traceable standards. There are seven base units in
SI - meter (length), second (time), Mole (amount of substance), Ampere
(electric current), Kelvin (temperature), Candela (Luminous intensity),
and kilogram (mass)
\href{https://www.nist.gov/pml/weights-and-measures/metric-si/si-units}{1}.
Any measurement you make should have some method to check against a
reference. In this lab, we will use calipers that measure dimensions
i.e. meter*10\(^{-3}\) (length). Calipers can always be verified to work
with gage blocks.
\subsubsection{Sources of measurement
variations}\label{sources-of-measurement-variations}
No measurement is exact. No surface is compeletely flat. Every
measurement you make has two types of uncertainties, \emph{systematic}
and \emph{random}. \emph{Systematic} uncertainties come from faults in
your assumptions or equipment. Here are some examples for caliper
measurements:
\begin{itemize}
\item
Your calipers were dropped on the floor and bent, now all of your
measurements will be too long or too short.
\item
The bar stock was not machined with square edges so each measurement
along the sides increases or decreases
\item
You align the calipers with the bar stock, instead of measuring
point-to-point. Now your measurements are only the maximum length from
edge-to-edge
\end{itemize}
\emph{Random} uncertainties are associated with unpredictable (or
unforeseen at the time) experimental conditions. These can also be due
to simplifications of your model. Here are some examples for caliper
measurements:
\begin{itemize}
\item
You assume the surface is flat, but it is in fact rough
\item
The temperature in the room changes the dimensions through thermal
expansion
\item
Your calipers are not aligned parallel to the edges of the bar stock
\end{itemize}
In theory, all uncertainies could be accounted for by factoring in all
physics in a problem e.g. Temperature-dependence, Coriolis effect,
electrical disturbances in your readings. In practice, the diminishing
return on investment prevents this practice. For something like
measuring bar stock, it is more than sufficient to report the average
and standard deviation with good calipers.
\subsubsection{Procedure - Measuring tolerances and comparing groups and
samples}\label{procedure---measuring-tolerances-and-comparing-groups-and-samples}
You are given four groups, A-D, of 5 samples, 1-5. You will use 4-inch
calipers to measure the lengths of the four groups of samples. Make sure
each lab member takes measurements. Measure the length of each sample
four times, fill in Table 1.
\textbf{Table 1. Lengths of machined bar stock. Sets A-D, samples 1-5,
length measurements 1-4. Calculate the average and standard deviation
and note the lab member.}
\begin{longtable}[]{@{}lllllllll@{}}
\toprule
Set & Sample & Length 1 & Length 2 & Length 3 & Length 4 & Average &
Stand. Dev. & User\tabularnewline
\midrule
\endhead
A & 1 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
A & 2 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
A & 3 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
A & 4 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
A & 5 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
B & 1 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
B & 2 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
B & 3 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
B & 4 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
B & 5 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
C & 1 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
C & 2 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
C & 3 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
C & 4 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
C & 5 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
D & 1 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
D & 2 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
D & 3 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
D & 4 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
D & 5 & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_ & \_\_\_\_\_\_ & \_\_\_\_\_\_
& \_\_\_\_\_\_\tabularnewline
\bottomrule
\end{longtable}
Sample groups A-D were machined with two different methods, a saw and a
computer numerical control (CNC) mill. There is a roughness associated
with the process and a randomness associated with the mounting and
cutting of the four groups of samples. The roughness affects the
variation of the multiple measurements on one sample i.e. Length 1, 2,
3, and 4. The mounting and cutting process introduces variations between
A1, A2, etc.
Next, you will determine the probability that two groups of
samples-\/-e.g. group A and group B-\/-have the same average length.
This process is called the Student t-test {[}2{]}. The variable,
\(t=\frac{|M_A-M_B|}{\sqrt{ab}}\)
\(a=\frac{N_A+N_B}{N_A N_B}\)
\(b=\frac{(N_A-1)S_A^2+(N_B-1)S_B^2}{N_A+N_B-2}\)
is a function of the two group means, \(M_A\) and \(M_B\), two group
deviations, \(S_A\) and \(S_B\), and number of samples per group,
\(N_A\) and \(N_B\). Calculate \(t\) for groups A and B by filling in
Table 2.
\textbf{Table 2: Determining t for groups A and B}
\begin{longtable}[]{@{}lllll@{}}
\toprule
Sample & A Length & \((L-M_A)^2\) & B Length &
\((L-M_A)^2\)\tabularnewline
\midrule
\endhead
1 &\tabularnewline
2 &\tabularnewline
3 &\tabularnewline
4 &\tabularnewline
5 &\tabularnewline
\textbf{sum} &\tabularnewline
\(M\) and \(S^2\) & \(sum/N_A\) & \(sum/(N_A-1)\) & \(sum/N_B\) &
\(sum/(N_B-1)\)\tabularnewline
\bottomrule
\end{longtable}
\subsection{Example calculations in
Python}\label{example-calculations-in-python}
Compare two groups of samples:
\begin{longtable}[]{@{}llllll@{}}
\toprule
group & sample 1 & sample 2 & sample 3 & sample 4 & sample
5\tabularnewline
\midrule
\endhead
A & 104.14 mm & 101.61 mm & 99.06 mm & 102.87 mm & 106.68
mm\tabularnewline
B & 104.12 mm & 101.63 mm & 97.79 mm & 101.58 mm & 104.17
mm\tabularnewline
\bottomrule
\end{longtable}
\begin{Verbatim}[commandchars=\\\{\}]
{\color{incolor}In [{\color{incolor}11}]:} \PY{n}{A}\PY{o}{=}\PY{n}{np}\PY{o}{.}\PY{n}{array}\PY{p}{(}\PY{p}{[}\PY{l+m+mf}{104.14}\PY{p}{,} \PY{l+m+mf}{101.61} \PY{p}{,} \PY{l+m+mf}{99.06}\PY{p}{,} \PY{l+m+mf}{102.87}\PY{p}{,} \PY{l+m+mf}{106.68}\PY{p}{]}\PY{p}{)}
\PY{n}{B}\PY{o}{=}\PY{n}{np}\PY{o}{.}\PY{n}{array}\PY{p}{(}\PY{p}{[}\PY{l+m+mf}{104.12}\PY{p}{,} \PY{l+m+mf}{101.63} \PY{p}{,} \PY{l+m+mf}{97.79}\PY{p}{,} \PY{l+m+mf}{101.58} \PY{p}{,} \PY{l+m+mf}{104.17}\PY{p}{]}\PY{p}{)}
\PY{n}{meanA}\PY{o}{=}\PY{n}{np}\PY{o}{.}\PY{n}{sum}\PY{p}{(}\PY{n}{A}\PY{p}{)}\PY{o}{/}\PY{n+nb}{len}\PY{p}{(}\PY{n}{A}\PY{p}{)}
\PY{n}{meanB}\PY{o}{=}\PY{n}{np}\PY{o}{.}\PY{n}{sum}\PY{p}{(}\PY{n}{B}\PY{p}{)}\PY{o}{/}\PY{n+nb}{len}\PY{p}{(}\PY{n}{B}\PY{p}{)}
\PY{n}{s2A}\PY{o}{=}\PY{n}{np}\PY{o}{.}\PY{n}{sum}\PY{p}{(}\PY{p}{(}\PY{n}{A}\PY{o}{\PYZhy{}}\PY{n}{meanA}\PY{p}{)}\PY{o}{*}\PY{o}{*}\PY{l+m+mi}{2}\PY{p}{)}\PY{o}{/}\PY{p}{(}\PY{n+nb}{len}\PY{p}{(}\PY{n}{A}\PY{p}{)}\PY{o}{\PYZhy{}}\PY{l+m+mi}{1}\PY{p}{)}
\PY{n}{s2B}\PY{o}{=}\PY{n}{np}\PY{o}{.}\PY{n}{sum}\PY{p}{(}\PY{p}{(}\PY{n}{B}\PY{o}{\PYZhy{}}\PY{n}{meanB}\PY{p}{)}\PY{o}{*}\PY{o}{*}\PY{l+m+mi}{2}\PY{p}{)}\PY{o}{/}\PY{p}{(}\PY{n+nb}{len}\PY{p}{(}\PY{n}{B}\PY{p}{)}\PY{o}{\PYZhy{}}\PY{l+m+mi}{1}\PY{p}{)}
\PY{n}{a}\PY{o}{=}\PY{p}{(}\PY{n+nb}{len}\PY{p}{(}\PY{n}{A}\PY{p}{)}\PY{o}{+}\PY{n+nb}{len}\PY{p}{(}\PY{n}{B}\PY{p}{)}\PY{p}{)}\PY{o}{/}\PY{p}{(}\PY{n+nb}{len}\PY{p}{(}\PY{n}{A}\PY{p}{)}\PY{o}{*}\PY{n+nb}{len}\PY{p}{(}\PY{n}{B}\PY{p}{)}\PY{o}{*}\PY{l+m+mf}{1.0}\PY{p}{)}
\PY{n}{b}\PY{o}{=}\PY{p}{(}\PY{p}{(}\PY{n+nb}{len}\PY{p}{(}\PY{n}{A}\PY{p}{)}\PY{o}{\PYZhy{}}\PY{l+m+mi}{1}\PY{p}{)}\PY{o}{*}\PY{n}{s2A}\PY{o}{+}\PY{p}{(}\PY{n+nb}{len}\PY{p}{(}\PY{n}{B}\PY{p}{)}\PY{o}{\PYZhy{}}\PY{l+m+mi}{1}\PY{p}{)}\PY{o}{*}\PY{n}{s2B}\PY{p}{)}\PY{o}{/}\PY{p}{(}\PY{n+nb}{len}\PY{p}{(}\PY{n}{A}\PY{p}{)}\PY{o}{+}\PY{n+nb}{len}\PY{p}{(}\PY{n}{B}\PY{p}{)}\PY{o}{\PYZhy{}}\PY{l+m+mi}{2}\PY{p}{)}
\PY{c+c1}{\PYZsh{}tstat=(meanA\PYZhy{}meanB)/np.sqrt(s2A/len(A)+s2B/len(B))}
\PY{n}{tstat}\PY{o}{=}\PY{p}{(}\PY{n}{meanA}\PY{o}{\PYZhy{}}\PY{n}{meanB}\PY{p}{)}\PY{o}{/}\PY{n}{np}\PY{o}{.}\PY{n}{sqrt}\PY{p}{(}\PY{n}{a}\PY{o}{*}\PY{n}{b}\PY{p}{)}
\PY{n+nb}{print}\PY{p}{(}\PY{l+s+s1}{\PYZsq{}}\PY{l+s+s1}{example groups A and B have t=}\PY{l+s+si}{\PYZpc{}1.2f}\PY{l+s+s1}{\PYZsq{}}\PY{o}{\PYZpc{}}\PY{k}{tstat})
\end{Verbatim}
\begin{Verbatim}[commandchars=\\\{\}]
example groups A and B have t=0.59
\end{Verbatim}
\begin{Verbatim}[commandchars=\\\{\}]
{\color{incolor}In [{\color{incolor}12}]:} \PY{n}{df}\PY{o}{=}\PY{n+nb}{len}\PY{p}{(}\PY{n}{A}\PY{p}{)}\PY{o}{+}\PY{n+nb}{len}\PY{p}{(}\PY{n}{B}\PY{p}{)}\PY{o}{\PYZhy{}}\PY{l+m+mi}{2}
\PY{c+c1}{\PYZsh{} Print out the table for df degrees of freedom (N1+N2\PYZhy{}2)}
\PY{n+nb}{print}\PY{p}{(}\PY{l+s+s1}{\PYZsq{}}\PY{l+s+s1}{df=}\PY{l+s+si}{\PYZpc{}i}\PY{l+s+s1}{\PYZsq{}}\PY{o}{\PYZpc{}}\PY{k}{df} )
\PY{n+nb}{print}\PY{p}{(}\PY{l+s+s1}{\PYZsq{}}\PY{l+s+s1}{| p=0.05 | p=0.025 | p=0.01 | p=0.005 |}\PY{l+s+s1}{\PYZsq{}}\PY{p}{)}
\PY{n+nb}{print}\PY{p}{(}\PY{l+s+s1}{\PYZsq{}}\PY{l+s+s1}{| \PYZhy{}\PYZhy{}\PYZhy{} | \PYZhy{}\PYZhy{}\PYZhy{} | \PYZhy{}\PYZhy{}\PYZhy{} | \PYZhy{}\PYZhy{}\PYZhy{} |}\PY{l+s+s1}{\PYZsq{}}\PY{p}{)}
\PY{n+nb}{print}\PY{p}{(}\PY{l+s+s2}{\PYZdq{}}\PY{l+s+s2}{| }\PY{l+s+si}{\PYZpc{}1.2f}\PY{l+s+s2}{ | }\PY{l+s+si}{\PYZpc{}1.2f}\PY{l+s+s2}{ | }\PY{l+s+si}{\PYZpc{}1.2f}\PY{l+s+s2}{ | }\PY{l+s+si}{\PYZpc{}1.2f}\PY{l+s+s2}{ |}\PY{l+s+s2}{\PYZdq{}}\PY{o}{\PYZpc{}}\PY{p}{(}\PY{n}{t}\PY{o}{.}\PY{n}{interval}\PY{p}{(}\PY{l+m+mf}{0.95}\PY{p}{,} \PY{n}{df}\PY{p}{)}\PY{p}{[}\PY{l+m+mi}{1}\PY{p}{]}\PY{p}{,}\PYZbs{}
\PY{n}{t}\PY{o}{.}\PY{n}{interval}\PY{p}{(}\PY{l+m+mf}{0.975}\PY{p}{,} \PY{n}{df}\PY{p}{)}\PY{p}{[}\PY{l+m+mi}{1}\PY{p}{]}\PY{p}{,}\PYZbs{}
\PY{n}{t}\PY{o}{.}\PY{n}{interval}\PY{p}{(}\PY{l+m+mf}{0.99}\PY{p}{,} \PY{n}{df}\PY{p}{)}\PY{p}{[}\PY{l+m+mi}{1}\PY{p}{]}\PY{p}{,}\PYZbs{}
\PY{n}{t}\PY{o}{.}\PY{n}{interval}\PY{p}{(}\PY{l+m+mf}{0.995}\PY{p}{,} \PY{n}{df}\PY{p}{)}\PY{p}{[}\PY{l+m+mi}{1}\PY{p}{]}\PY{p}{)}\PY{p}{)}
\end{Verbatim}
\begin{Verbatim}[commandchars=\\\{\}]
df=8
| p=0.05 | p=0.025 | p=0.01 | p=0.005 |
| --- | --- | --- | --- |
| 2.31 | 2.75 | 3.36 | 3.83 |
\end{Verbatim}
\begin{Verbatim}[commandchars=\\\{\}]
{\color{incolor}In [{\color{incolor}13}]:} \PY{n}{plt}\PY{o}{.}\PY{n}{hist}\PY{p}{(}\PY{n}{A}\PY{p}{,}\PY{n}{np}\PY{o}{.}\PY{n}{linspace}\PY{p}{(}\PY{l+m+mi}{97}\PY{p}{,}\PY{l+m+mi}{105}\PY{p}{,}\PY{l+m+mi}{5}\PY{p}{)}\PY{p}{,}\PY{n}{histtype}\PY{o}{=}\PY{l+s+s1}{\PYZsq{}}\PY{l+s+s1}{step}\PY{l+s+s1}{\PYZsq{}}\PY{p}{,}\PY{n}{label}\PY{o}{=}\PY{l+s+s1}{\PYZsq{}}\PY{l+s+s1}{A}\PY{l+s+s1}{\PYZsq{}}\PY{p}{)}
\PY{n}{plt}\PY{o}{.}\PY{n}{hist}\PY{p}{(}\PY{n}{B}\PY{p}{,}\PY{n}{np}\PY{o}{.}\PY{n}{linspace}\PY{p}{(}\PY{l+m+mi}{97}\PY{p}{,}\PY{l+m+mi}{105}\PY{p}{,}\PY{l+m+mi}{5}\PY{p}{)}\PY{p}{,}\PY{n}{histtype}\PY{o}{=}\PY{l+s+s1}{\PYZsq{}}\PY{l+s+s1}{step}\PY{l+s+s1}{\PYZsq{}}\PY{p}{,}\PY{n}{label}\PY{o}{=}\PY{l+s+s1}{\PYZsq{}}\PY{l+s+s1}{B}\PY{l+s+s1}{\PYZsq{}}\PY{p}{)}
\PY{n}{plt}\PY{o}{.}\PY{n}{xlabel}\PY{p}{(}\PY{l+s+s1}{\PYZsq{}}\PY{l+s+s1}{length (mm)}\PY{l+s+s1}{\PYZsq{}}\PY{p}{)}
\PY{n}{plt}\PY{o}{.}\PY{n}{ylabel}\PY{p}{(}\PY{l+s+s1}{\PYZsq{}}\PY{l+s+s1}{counts}\PY{l+s+s1}{\PYZsq{}}\PY{p}{)}
\PY{n}{plt}\PY{o}{.}\PY{n}{legend}\PY{p}{(}\PY{p}{)}
\end{Verbatim}
\begin{Verbatim}[commandchars=\\\{\}]
{\color{outcolor}Out[{\color{outcolor}13}]:} <matplotlib.legend.Legend at 0x7f5d002c1be0>
\end{Verbatim}
\begin{center}
\adjustimage{max size={0.9\linewidth}{0.9\paperheight}}{output_8_1.png}
\end{center}
{ \hspace*{\fill} \\}
\subsubsection{Your Report}\label{your-report}
\begin{enumerate}
\def\labelenumi{\arabic{enumi}.}
\tightlist
\item
Introduction
\end{enumerate}
\begin{enumerate}
\def\labelenumi{\alph{enumi}.}
\item
Describe sources of uncertainty in machining and measuring parts
\item
How do we measure parts and roughness?
\item
How can we use statistics to evaluate machining tolerances?
\item
What is the cost of tighter tolerances?
\end{enumerate}
\begin{enumerate}
\def\labelenumi{\arabic{enumi}.}
\setcounter{enumi}{1}
\tightlist
\item
Methods
\end{enumerate}
\begin{enumerate}
\def\labelenumi{\alph{enumi}.}
\item
Describe parts used
\item
Describe tools used
\item
How did you take the measurements?
\end{enumerate}
\begin{enumerate}
\def\labelenumi{\arabic{enumi}.}
\setcounter{enumi}{2}
\tightlist
\item
Results and Discussion
\end{enumerate}
\begin{enumerate}
\def\labelenumi{\alph{enumi}.}
\item
What are the average part dimensions?
\item
What tolerance can you assign to the machining methods?
\item
How similar are the four sets of parts: A, B, C, and D?
\item
How can you use the t-distribution to describe and compare the parts?
\end{enumerate}
\begin{enumerate}
\def\labelenumi{\arabic{enumi}.}
\setcounter{enumi}{3}
\tightlist
\item
Conclusion
\end{enumerate}
\begin{enumerate}
\def\labelenumi{\alph{enumi}.}
\item
How do the two methods of machining compare?
\item
What are the benefits to each method?
\item
Is there any way to reduce the number of measurements when determining
tolerances?
\end{enumerate}
\subsubsection{References}\label{references}
\begin{enumerate}
\def\labelenumi{\arabic{enumi}.}
\item
\url{https://www.nist.gov/pml/weights-and-measures/metric-si/si-units}
\item
\href{https://courses.washington.edu/phys431/uncertainty_notes.pdf}{Uncertainty
Notes}
\item
\href{https://www.ruf.rice.edu/~bioslabs/tools/stats/ttest.html}{Student
t-test}
\end{enumerate}
% Add a bibliography block to the postdoc
\end{document}