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REGISTRATION NO :UW-18-ME-BSC-039
INTRODUCTION :
◾Machining
◾Joining
◾Forming
◾Casting
◾Moulding
Machining :
Tools used for machining are immobile power-driien units used to form
or shape solid materials, specifcally metals. The forming is done by
remoiing extra materials from a work-piece. Machine tools make up
the foundation of adianced industry and are utiliied either indirectly or
directly in the manufacturing of tool parts.
In this process, there are many operations iniolied. They are listed
below.
◾ Turning
◾ Milling
◾Drilling
◾Presses.
Joining :
Eiery joining approach has particular design needs, while certain joint
needs may propose a particular joining approach. Design for assembly,
and fastener selection apply their own specifcations.
Howeier, all joint paterns must consider features such as load factors,
assembly effectiieness, operating surroundings, oierhaul and upkeep,
and the materials chosen.
◾ Welding
◾Braiing
◾Soldering
◾ Adhesiie Bonding
◾ Fastening
Forming :
1. Compressive forming
2. Tensile Forming
3. Bending
4. Shearing
Tensile Forming:
In this forming process tensile loads are used to deform the objects
permanently.
Bending:
Shearing:
Shearing loads are used to deform the objects to atain the required
shape in this forming process.
In this forming process both the Tensile and the compressiie loads are
used to deform the objects permanently..
Castng :
◾ Sand castng: Where the moulds are prepared with the Sand.
◾Die castng: Forcing the molten metal into the moulds with heaiy
pressure
Moulding :
Melting the Plastic and forcibly injected into a tightly closed mould.
Then the plastic will take the shape of the mould. Afer the injection of
plastic into the mould, the mould is open the object will be pulled out
of the Mould. Botle caps are made from the injection moulding.
◾Blow moulding:
◾Compression moulding:
Molten plastic is poured into the Mould and further it will be pressed
against the mould shape before the plastic
Molten plastic is placed inside of the moulds and the moulds are
rotated with the help of mechanical arms then the Plastic will pull
towards the mould shape faces. By this way, hallow shaped objects like
water storage tanks are made with the rotational Moulding.
Purpose :
Importance :
Gears are used for transmitng power from one part of a machine to
another. In a bicycle, for example, it's gears (with the help of a chain)
that take power from the pedals to the back wheel. Similarly, in a car,
gears transmit power from the crankshaf (the rotating axle that takes
power from the engine) to the driieshaf running under the car that
ultimately powers the wheels.In purely scientifc terms, gears are used
to transmit motion. They're really good at what they do, too, which is
probably why they'ie been used by crafsmen and other laborers for
centuries. One of the earliest recorded references to gear use was in 50
ADS, though there's more than a litle eiidence that suggests the
ancient Greeks also used them as early as the third century BC. And we
keep using gears because they work. Clocks, bicycles, automobiles and
heaiy-duty industrial machines all rely on common gears, and without
those, we wouldn't be able to liie the modern, conienient liies we do
today. There's no question that custom gears, steel shafs and other
industrial manufacturing parts play a huge role in deliiering us the
consumer goods we rely so desperately upon. But eien gears, the
objects that make manufacturing so easy, require a bit of
manufacturing themselies. Throughout the generations, human beings
haie more or less perfected the design and creation of these
production wonders through a few key methods.
Castng
Sand casting, die casting and iniestment casting are the casting
processes that are best suited for gears.Sand casting
Characteristcs:
Applicatons:
Materials:
The materials that can be sand cast are C I, cast steel, bronies, brass
and ceramics. The process is confned to large gears that are machined
later to required accuracy..Die-Casting
Characteristcs:
Applications:
Materials:
◾ Accuracy depends on the original master patern used for the mold.
Mat
erials:
Tool steel, nitriding steel, monel, beryllium copper are the materials
that can be iniestment casted for the manufacture of gears. The
process is used only if no other process is suitable since production cost
is high. Fig shows a wire twister stellite gear which mates with a rack
made by IC. Complicated shape makes it economical to produce by
iniestment casting process.
Characteristcs:
Applicatons:
Materials:
The materials for injection molding components are Nylon, cellulose
acetate, polystyrene, polyimide, phenolics
Extruding :
Extruding is used to form teeth on long rods, which are then cut into
usable lengths and machined for bores and keyways etc. Nonferrous
materials such as aluminum and copper alloys are commonly extruded
rather than steels. This result in good surface fnishes with clean edges
and pore free dense structure with higher strength
Materials:
Applicatons:
Splined hollow & solid shafs, sector gears are extruded and iarious
gears
Cold Drawing:
Applicatons:
Stamped gears are used as toy gears, hand operated machine gears for
slow speed mechanism.
For close die forging the feed stock has to be iery near to the net shape
and this is obtained by performing. This is explained by fow diagrams
both in sinter forging and precision hot forging.
MACHINING
Roughing processes:
Form milling:
The disc cuter shape conforms to the gear tooth space. Each gear
needs a separate cuter. Howeier, with 8 to 10 standard cuters, gears
from 12 to 120 teeth can be cut with fair accuracy. Tooth is cut one by
one by plunging the rotating cuter into the blank as shown
◾Form milling by end mill cuter:
The end mill cuter shape conforms to tooth spacing. Each tooth is cut
at a time and then indexed for next tooth space for cutng. A set of 10
cuters will do for 12 to 120 teeth gears. It is suited for a small iolume
production of low precision gears. The form milling by end mill cuter is
shown.Form milling by end mill cuter
◾Rack generaton:
In rack cuter the tooth shape is trapeioid and can be made easily. The
hardened and sharpened rack is reciprocated along the axis of the gear
blank and fed into it while gear blank is being rotated so as to generate
the iniolute tooth on the gear blank.The rack and gear blank must be
periodically repositioned to complete the circumference.This
introduces errors in the tooth geometry making this method less
accurate than shaping and hobbing. The process is limited to small
gears since the length of the rack has to be equal to circumference of
the gear at pitch diameter.
◾Gear shaping :
◾Hobbing :
Hob teeth are shaped to match the tooth space and are interrupted
with grooies to proiide cutng surfaces. It rotates about an axis normal
to that of the gear blank, cutng into the rotating blank to generate the
teeth. It is the most accurate of the roughing processes since no
repositioning of tool or blank is required and each tooth is cut by
multiple hob-teeth, aieraging out any tool errors. Excellent surface
fnish is achieied by this method and it is widely used for production of
gears.
Finishing Processes :
◾Shaving :
Grinding :
Grinding is an abrasiie machining process that uses a grinding wheel as
the cutng tool. A wide iariety of machines are used for grinding:
Hand-cranked knife-sharpening stones (grindstones) Handheld power
tools such as angle grinders and die grinders.
◾Burnishing :
◾Lapping :
◾Honing :
Cost Analysis :
All these ialues will be taken from internet due to Coiid-19 lockdown
these ialues may not be accurate as we do not haie the real market
ialue, but we would try to optimiie it to as much degree as we can
containing the accuracy of the results too.
Cold Extrusion
Cost of electricity :
Energy Consumption :
Total Cost :
Hobbing:
Cost of electricity:
Drilling machine cost would be same for all process i.e 68.75Pkr
Total cost :
Milling Process:
Cost Analysis:
Cost of workpiece :
= 48.8 Pkr
Drilling machine cost would be same for all process i.e 68.75Pkr
Total Cost:
Powdered Metalurgy:
Cost analysis:
Cost of 100 Pieces = Cost for pre heat + (Cost for 25 pieces ) × 4
Energy Consumption = 3.3 kW× 0.5 min × 1 hour/60 min = 0.0275 kWh
Cost of material:
Powdered steel:
Cost of one work piece = 500 gram × 148.7 Pkr/ Kg × 1kg/1000 grams =
74.35 Pkr
Conclusion:
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materials/
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machining- process/blog.html
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conientional-machining-and-non-traditional-machining-ntm/
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htps://www.millerbroach.com/what-is-broaching/
htps://en.wikipedia.org/wiki/Broaching((metalworking)
htps://en.wikipedia.org/wiki/Hobbing
htps://www.quora.com/What-are-important-properties-of-material-
for-gear-application
htps://www.ctemag.com/news/articles/fundamentals-industrial-
sawing
htps://www.machinesells.com/new-machine/new-machine-for-sell-
871498699
htps://www.licncmachine.com/cnc-iertical-milling-machine/xk7136-
cnc-milling-machine-159.html
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china.com/product/AoeJdxhCsaYn/China-18-Variable-Speed-Drill-Press-
ZQJ525W-.html
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htps://dir.indiamart.com/impcat/mold-castings.html