MECHANICAL ENGINEERING DEPARTMENT

SESI AKADEMIK 2: 2022/2023

CODE & COURSE : BJF40013 – MANUFACTURING PROCESS & MACHINE TOOLS

PROGRAMME : BACHELOR OF MANUFACTURING ENGINEERING TECHNOLOGY

(AUTOMOTIVE DESIGN) WITH HONOURS

ASSESSMENT : CASE STUDY 2

NAME : MUHAMMAD IQMAL DANIEAL BIN MOHAMAD ZAHARI
MATRIX NUMBER : 15BMA22F3005

Prepared by: Verified by:

………………………………………………………………… ………………………………………………………………….

Course Coordinator/Lecturer Programme Leader/Head of Department

Date: Date:

• Tandatangan perlu disertakan dengan cop rasmi

 CONTENT
1.0 INTRODUCTION
1.1 Background
1.2 Scope
1.3 Purpose
2.0 PROCESS
2.1 Background Process
2.2 Equipment Used for Manufacturing Process
3.0 MANUFACTURING PROCESS SELECTION
3.1 Laser beam machining process selected
3.2 Bumper machining process by Laser Beam Machining
3.3 Bumper advanced machining process
4.0 DRAWING
4.1 Drawing Detail
5.0 ADVANTAGES OF USING SAND CASTING
5.1 Versatility
5.2 Functionality
5.3 Maintainability
5.4 Precision
6.0 CONCLUSION
7.0 REFERENCES

1.0 INTRODUCTION
1.1 Background

The crash management system of an automobile must include bumpers. They reduce
the severity of a crash because they are passive safety features. They are placed at the
front end to prevent physical harm and absorb stress from light impacts. In earlier car
designs, bumpers were just rigid metal bars (Insurance Institute for Highway Safety
and Safety, 2015). Today's typical bumper construction is comprised of a plastic
cover covering a strengthened bar made of metal alloy, notably steel and aluminium
alloy. Later, bumper covers made of thermoplastic elastomers were introduced
(Drobny, 2014) [1].

1.2 Scope

The primary focus of this work's inquiry was the manufacturing process for bumpers,
which provides further details on the bumper's manufacture, including the tools and
methods used.

1.3 Purpose

This document aims to outline the procedures involved in producing bumper. At the
same time, I'm curious to find out what the ideal material is for bumper construction.
In addition, I'll go into detail on how bumper are built and put together.

2.0 PROCESS
2.1 Background process

At originally, bumpers were essentially brittle metal bars. [2] The first automobile
bumper was created by George Albert Lyon. The first bumper was fitted on a car in
1897 by the Czech automaker Nesselsdorfer Wagenbau-Fabriksgesellschaft. These
bumpers' design was unreliable because they served just a decorative purpose. Earlier
automobile owners had the front spring hanger bolts changed out for ones that could
accommodate a metal bar. [3] G.D. Fisher obtained a patent for a bumper bracket that
made it easier to attach the item. [3] In 1901, the first bumper intended to deflect
blows debuted. Frederick Simms received a patent for this creation in 1905, and it was
constructed of rubber. [4] Materials with a high strength-to-weight ratio are needed
for the expanding number of advanced applications being developed, such as
aerospace, automobiles, electronics, and medical devices. Researchers from all over
the world are creating advanced materials with superior properties to satisfy the
expanding demand. In addition to having a high strength-to-weight ratio, materials
like nickel, titanium, and their alloys, as well as ceramics, are known for their
increased level of corrosion resistance, capacity prolongation at higher temperatures,
and superior mechanical strength in comparison to other engineering materials [5].
These materials are more complex and difficult to conventionally machine because
they have greater properties like a higher density and melting point, are ductile, and
are harder and stronger. Even while it may be machined using traditional methods, the
increased cutting pressures and severe tool wear make shaping these materials to the
required specifications quite expensive. In order to replace traditional machining
techniques, numerous unconventional machining processes (UMPs) were created.
Laser beam machining (LBM), which is one of the UMPs, is frequently used to
machine certain challenging materials. LBM is regarded as appropriate for cutting
hard materials. LBM is distinguished by its independence from the work material's
hardness attribute. Due to its benefits, including higher light intensity with low power
requirements, good focusing property within short pulse duration, uniform heat
distribution, eco-friendly nature which results in accuracy in machining, narrow heat
affected zone, increased productivity, and lower manufacturing cost [6], LBM is
gaining attention among researchers and industry people. The principles of lasers and
their various varieties, the process of laser machining, its benefits, uses, and
restrictions are all covered in detail in the following sections.

2.2 Equipment used in Laser Beam Machining

A non-traditional machining technique called "laser beam machining" uses laser light
to carry out the operation. The work piece is hit by the laser light at its highest
temperature, which causes it to melt. To remove material from a metallic surface,
thermal energy was used during the procedure. Laser beam machining tools are
available in a range of forms, such as:

i. Power Supply
For lasers, a high voltage is necessary. The system is given power in order to expel
the electron. The electron enters an excited state, which is a state of readiness for
work, when the power is applied [7].

ii. Flash Lamps

For a very brief period of time, white, coherent light is produced by flash lamps [7].

iii. Capacitor

The general purpose of a capacitor is to store and release electrical energy. It is used
during the flashing procedure here [7].

iv. Reflecting Mirror

A reflecting mirror is employed to focus light toward the workpiece. Internal and
external are the two categories [7].

v. Lenses

Here, lenses are offered for visual purposes. It enlarges the image so that operating on
the designated work piece mark will be simple [7].

vi. Work-piece

The work piece resembles the item on which the procedure will be performed. As an
illustration, if the body required any laser work, we would be the machine's work
piece. Similarly, if an object needed a hole or a drill hole during manufacturing, the
laser machine would perform the necessary work
[7].

3.0 MANUFACTURING PROCESS SELECTION

3.1 Laser beam machining process selected

Light Amplification by Simulated Emission of Radiation, or LASER, is essentially

what it stands for. In other terms, a laser is an electromagnetic radiation beam that is
monochromatic, coherent, and cohesive, with wavelengths spanning from ultraviolet
to infrared. For more than a decade, lasers have been used for cutting, trimming, and
drilling holes. More than five decades, and throughout that time it has developed into
a widely used method of material removal with efficient manufacturing process
solutions. The first CO2 laser was developed in 1963 by Kumar Patel, and by 1967
pressurized oxygen passing through a nozzle was used as an assist gas to cut through
a 1 mm sheet of steel (Hilton 2007).

The history of the laser began in 1960 at Hughes Research Laboratories when T.H.
Maiman successfully achieved simulated optical emission (Hilton 2007). Since that
time, laser cutting systems have evolved and improved to become a dependable
technology that is widely used in industry for cutting metals effectively, with high
levels of precision, and with high quality cuts. From macro to micro machining scale,
laser beam cutting (LBC) is the most common application of laser machining
techniques. The procedure works by focusing a overpowered laser beam on a small
area on the surface of the substance to be sliced (Hilton 2007; Wandera 2010). The
material takes in the energy and transforms it into heat, which melts or porpoises the
material. Molten metal is removed from the cut zone by an assist gas that is released
through a nozzle that is coaxial with the laser beam [8].

3.2 Bumper advanced machining process by Laser Beam Machining:

Figure 1: Schematic of laser system

(http://www.ieomsociety.org/detroit2020/papers/637.pdf)

3.3 Bumper advanced machining process

 Figure 2: (https://www.youtube.com/watch?v=_S2jqNBVyow)
The work-piece is picked up by a robot and placed into a bumper holder[9].

Figure 3:( https://www.youtube.com/watch?v=_S2jqNBVyow)

Piecework are located close to the laser machine by a robot before entering it.

Figure 4: (https://www.youtube.com/watch?v=_S2jqNBVyow)
The work piece that needs to be cut is put on the aluminium work table, which can
withstand laser light. The table can be adjusted to your needs while the laser head is
traversing over the work piece.
 Figure 5: (https://www.youtube.com/watch?v=_S2jqNBVyow)
A robot will pick up the work piece and place it on a resting table once the process is
complete.

Figure 6: (https://www.youtube.com/watch?v=_S2jqNBVyow)
A car bumper that has been finished via laser beam machining.

4.0 DRAWING

The Catia V5 programme was used to make the illustration. Drawing is primarily
done with this application at Politeknik Sultan Azlan Shah.
 Figure 9: Drawing of bumper

5.0 ADVANTAGES OF USING LASER BEAM MACHINING

5.1 Versatility
Laser Beam Machining can be applied to any material, regardless of conductivity,
hardness, or brittleness. Any heat-treated or magnetised metal can be cut or welded
using Laser Beam Machining with little change in the metal's properties at the heat-
affected area [10].

5.2 Functionality

Even in small, difficult-to-access areas of the workpiece, Laser Beam Machining can
be used for cutting, welding, drilling, etching, and engraving [10].

5.3 Maintainability

Since the workpiece and tools are not physically in contact, the machine experiences
almost no wear and tear [10].

5.4 Precision

Regarding the position, size, and shapes that need to be cut, Laser Beam Machining
ensures great cutting accuracy. With microscopic sizes, Laser Beam Machining can
manufacture and carve extremely complicated structures [10]

6.0 CONCLUSION

One of the most popular unconventional machining techniques that produces

complicated and exact geometries with very little tolerance is laser beam machining.
The drilling, cutting, and bending with lasers are the key points of emphasis. The
implementation of this LBM required specialized knowledge, and operational costs
are high. Improvements in the LBM, its supporting processes, and optimization
methodologies over time have given rise to certain new study areas in the LBM. New
study areas in LBM have been created thanks to advancements in modelling
approaches, which also enhance the process' effectiveness [11]

7.0 REFERENCES

[1] O. Osokoya, “An evaluation of polymer composites for car bumper beam,”
International Journal of Automotive Composites, vol. 3, no. 1, p. 44, 2017.
[2] "The 1910 Harroun Bumper". Cycle and Automobile Trade Journal, Volume 14.
1909. p. 142. Retrieved 21 June 2016.

[3] "Bumper Development". Automobile Trade Journal. 29 (6): 301. 1 December

1924. Retrieved 20 July 2018.

[4] Hodges, David (1994). The Guinness Book of Car Facts and Feats. England:
Guinness Publishing. p. 256. ISBN 0851127681.

[5] Nagimova A, Perveen A. A review on laser machining of hard to cut materials.

Materials Today: Proceedings. 2019; 18:2440-2447.

[6] Kuar A, Doloi B, Bhattacharyya B. Modelling and analysis of pulsed Nd: YAG
laser machining characteristics during micro-drilling of zirconia (ZrO2). International
Journal of Machine Tools and Manufacture. 2006;46(12-13):1301-1310.

[7] A. K. Dey, “Laser beam machining: Definition, working process, principle,

advantages, disadvantages, application [notes with PDF],” Learn Mechanical, 27-Feb-
2021. [Online]. Available: https://learnmechanical.com/laser-beam-machining/.
[Accessed: 19-Nov-2022].

[8] C. Anghel and K. Gupta, “A review on laser beam cutting - IEOM society,” A
Review on Laser Beam Cutting, Aug-2020. [Online]. Available:
http://www.ieomsociety.org/detroit2020/papers/637.pdf. [Accessed: 19-Nov-2022].

[9] Laser Cutting. YouTube, 2019.

[10] Admin, “Laser Beam Machining,” MechanicWiz.Com, 11-Jun-2021. [Online].

Available: https://www.mechanicwiz.com/laser-beam-machining/. [Accessed: 20-
Nov-2022].

[11] S. Umredkar and V. Bhoyar, “Advance Manufacturing Processes Review Part V:

Laser Beam Machining (LBM),” Advance Manufacturing Processes Review Part V:
Laser Beam Machining (LBM), 12-Dec-2019. [Online]. Available:
https://www.irjet.net/archives/V6/i12/IRJETV6I12374.pdf.
[Accessed: 27-May-2023].