machining and casting report

7/29/2019 machining and casting report

1/14

Abrasive jet machining

Ultrasonic machining

Water jet machining

Magnetic abrasive finishing

Electro chemical machining

Electro Discharge machining

Laser beam machining

Plasma beam machining

Turning

Milling

Drilling

Planing

Shaping

Broaching

Gear cutting

Boring

Polishing

Buffing

Lapping

Grinding

Honing

Superfinishing

MECHANICAL ENGINEERING DEPARTMENT

MBB 4012

FINAL YEAR PROJECT 1

EXTENDED PROPOSAL

NAME : AHMAD FAIZ BIN MD YUNUS

ID : 12511

PROPOSED TITLE : COMPARATIVE STUDY ON MANUFACTURING

PROCESSES OF A SWIRLER

SUPERVISORS : AP. DR. IR. MOHD AMIN BIN ABDUL MAJID


2/14

Abstract

The project is involved the comparative on machining and castingprocess for manufacturing the swirler. Both of the processes could

be used in manufacturing the swirler with different kind of approach.The selection process done among the wide variety type ofmachining and casting process which available today. In order todecide the most appropriate manufacturing process, the criticalanalysis should be carried out by focusing on material selection,process planning including machines, tooling and fixturesrequirement. The process is analyses by computer simulationsoftware and support by data from industrial. The process times andcost production of the swirler is expected to below thanconventional manufacturing process

TABLE OF CONTENTS


3/14

CHAPTER 1: INTRODUCTION

1.1 Objective

1. To analyze the differences between the two manufacturing processes of

casting and machining for manufacturing the swirler.

2. To assess the appropriate manufacturing process for the swirler in term of

flexibility, reliability, low cost production and less consuming of time.

3. To develop a process planning in order to estimate the process time and cost

production.

1.2 Scope of Study

The scopes of the study for the project are:

1. To compare the casting and machining process for manufacturing the swirler.

2. To select the proper material and determined process planning including

machines, tooling and fixtures requirement for manufacturing the swirler.

3. To estimate the process times and cost requirement to manufacture the swirler.

1.3 Problem Statement

A manufacturing process of the swirler can be carried out by both of the processes

that been compared which is machining and casting. Basically, both of processes are

obviously have different outcome especially in term of cost production and time

requirement. Therefore, the study will cover on each type of machining and casting

available. However, deciding the right manufacturing process need a critical analysis

task but has very little detailed data included due to secrecy policy in each

manufacturer company. The available information tends to be sales orientated and

again, the data is not sufficiently detailed to indicate the most suitable process in

manufacturing process. A study and research need to be conducted in order to increase

the productivity and efficiency for manufacturing process of swirler. Analyze will befocusing to find a way to reduce cost and time but still maintain the quality of product

in same time

CHAPTER 2: LITERATURE REVIEW

2.1 Type of Machining and Casting Processes

Type of Machining Processes

Machining is the process subtracting excess material in the form of

chips from a workpiece through a certain type of cutting tool to


4/14

achieve the desired geometric dimensions. The machining processcan classified into three major type as illustrate in figure 2.

Figure 2:Classification of Machining Processes [2]

Type of Casting Processes

Casting process can be defined as a manufacturing process involves

pouring of liquid metal into a mould cavity and then allowing it to

solidify. The final shape of the metal was determined by the shape

of the mould cavity. The solidified metal is also refers as a casting.

The casting processes can be broadly classified by the type of mould used as illustrate

in figure 8. The expandable mould is non reusable mould and

usually destroyed to remove out the solidified cast. In contrast, the

permanent can be reuse to make other casting.


5/14

Figure 8: Classifications of Casting Processes

2.2 Parameter of selection Machining and Casting

Processes

Machinability

In order to accomplish the manufacturing process effectively, efficiently and

economically, there are parameters need to follow in manufacturing process. For

machining process, the selection of process depends on machinability of theworkpiece. The term machinability is used for rating workpiece material respect to

type of cutting tool material, geometry, and type of machining operation. In the other

words, machinability can be defined as [ ]:

The ability of the work material to be machined,

How easily and fast a material can be machined, and

Material response to machining.

A good machinability material will be had criteria as per below:

a. Low power consumption


6/14

The forces required to cut the workpiece related to the rate of power

consumption by machine tool. A good machinability material needs only little

electrical power consumption for removal part.

b. Shorter process time

The machining process is done smoothly and easily.

c. Good surface finishing

Type of material which is not suitable for the particular machining process

tends to form build up edge (BUE) which give the poor surface finishing.

d. Long tool life.The tool does not wear too much due to machining processand allowing the tool life last longer.

Figure: Parameter of machinabilityCastability

The term castability is used to refer of ease of producing castingwithout a defect at minimum cost and lead-time. The castability canachieve by doing the process at high compatibility between theprocess and material properties. The major factor s that influencedcastability explained in detail as follow:

a) Material selectionAccording to Prof. Dr. Ahmet Aran, the properties of materialthat influenced the castability are:

i. Low melting point: The material has low melting point is betterdue to casting temperature has to higher than meltingtemperature. If melting temperature is too high, the moldmaterial has to be more refractory and probablyexpensive.The temperature also must be controlled accordingto casting technique and the complexity of the casting.

ii. Good Fluidity: An ability of metals and alloys to flow throughthe gating system filling the cavity of the casting mold andconforming its shape.

iii. Low specific heat: Less energy requirement to reach melting

temperature and fast solidification process.


7/14

iv. Low latent heat of fusion: Less energy required to changematerial state to another state.

v. Low viscosity and Low surface tension: The metal cast fillbetter the mould cavity.

vi. Shrinkage: For measurement shrinkage allowance for the

pattern.vii. Low chemical affinity: No reaction between materials with

environment.viii. High thermal diffusivity: Rather than conductivity,

thermal diffusivity determined the rate of disturbance to heattravel in material.

ix. Resistance to crack formation: Material should have highductility.

b) Geometry Designing

Product geometry will be determined the complexity ofprocess, tool used and cost effective.

c) Surface qualityAccording Dmitri Kopeliovich, surface quality determined by: The surface quality of the mold walls, The mold coating material properties, Gassing of the mold or coating materials, Chemical reaction between the mold material and the

alloy, Casting pressure.

Figure: The major factors influenced castability material


8/14

2.3 Process Equipment for Machining and Casting

Processes

Machining Process Equipment

A. Drilling machineDrilling machine used for producing circular hole in the workpiece byusing rotating cutter called drill. The machine can performed someoperation as illustrate in the figure below:

Figure: Operation can be performed by drilling machine.

B. Milling machine.

Milling is the process removal material by feeding a workpiece passthrough a rotating multiple tooth cutter. Milling machined canproduced slots of various shapes, making flat surfaces, grooving,slitting, and parting.

C. Grinding machine


9/14

The grinding usually applied when material is too hard to bemachined or the workpiece need high accuracy parameter and smalltolerances value. On that reasons, the major advantages of grindingprocess is has high dimensional accuracy, good surface finish, goodform and applicable to both hardened and unhardened material. In

grinding, an abrasive tool is forced to rub against the workpiece inorder to remove a very small amount of material.

D. Lathe machine

Lathe machine been used for reducing the outside diameter ofcylindrical workpiece. It performed the process called turning, inwhich the workpiece is rotated and a single-point cutting tool isbrought against it. The machine also capable performed of drilling,boring, thread cutting, and other operations.

Casting Process Equipment

In casting process, the raw materials are considered as formlesssubstance as liquid and being poured into mould to become solidbody. In this technique, the mould is acting as manufacturingequipment whereas the raw materials been used called sinteringwhich come in powder or granular form.For this project, the expandable mould will been used rather thanpermanent mould due to only need for one unit production andlower cost needed. A general picture of the casting techniquesavailable for production is given in Figure

Figure: Casting production techniques


10/14

2.4 Process Tool for Machining and Casting Processes

Machining Process Tool

The process tool for machining are depend on process been done.Stated below are the processes involved in manufacturing of swirlerto represent the cutting tool needed:

a) For cylindrical part

Face MillingIn face milling, the cutter is mounted on a spindle having anaxis of rotation perpendicular to the workpiece surface. Themilled surface results from the action of cutting edgeslocated on the periphery and face of the cutter.

End Milling

The cutter in end milling generally rotates on an axis verticalto the workpiece. It can be tilted to machine taperedsurfaces. Cutting teeth are located on both the end face ofthe cutter and the periphery of the cutter body.

Surface contouring

This kind of operation is performed by computer controlledmilling machines in which a ball-end mill is fed back and forthacross the workpiece along a curvilinear path at closeintervals to produce complex three-dimensional surfaces.

Turning process

Turning is the removal process of the outer diameter forcylindrical in part shape by a single point cutting tool using


11/14

lathe machine. In this project, the type of turning operationswill be done are:

Taper turning: the cutting tool allocated in certain inclinedangle to get tape shape.

Cutting-off: used for parting or cutting off a section of theworkpiece.

Straight turning: Used for reducing the diameter of a part to adesired dimension. The resulting machined surface iscylindrical

a) For hole partDrilling

Drilling is the process of using a multi-point tool to penetratethe surface of a workpiece and make a round hole. The typeof drilling process involved as followed:

Spot drill: This process used to make a mark for hole part.

Center drill: A short & stubby drill to produce holes so thatwork piece can be mounted between lathe center.

Twist Drills: To remove the maximum volume of metals in aminimum period of time. It does not produce a precision hole:however, this can be achieved by a reaming operation.

BoringBoring is the process of enlarging a hole that has alreadybeen drilled. A boring tool can be inserted into the drilling machine and

bore any size hole into which the tool holder will fit. A boring bar with a tool

bit installed is used for boring on the larger drilling machines. To bore

accurately, the setup must be rigid, machine must be steady, and power feed

must be used.

Reaming

Reaming process can be performed by drilling machine. Theprocess will ensure the hole of workpiece has bettertolerance of its diameter and to improve surface finish.


12/14

CHAPTER 3: METHODOLOGY

Process flow chart


13/14

REFERENCES


14/14

1. Reference: Groover M.P., (1996),Fundamentals of Modern

Manufacturing, Materials, Processes and Systems,

International Editions, Prentice Hall.

2. Casting machine. Retrieved Feb 22,2013, from The KVT :http://www.kvt.sjf.stuba.sk/WEB/02_chapter.pdf

3. M F Ashby, Material Selection in Mechanical Design,

Butterworth-Heinemann, 1999.

4. M. F. Ashby, Materials Selection in Mechanical Design, 2nd

Edition, Elsevier, new Delhi, 2005

5. Todd, H. Robert; Allen, K. Dell; Alting, Leo (1994),

Manufacturing Processes Reference Guide (1st ed.), Industrial

Press Inc., p. 198-199, ISBN 0-8311-3049-0.
http://www.kvt.sjf.stuba.sk/WEB/02_chapter.pdfhttp://www.kvt.sjf.stuba.sk/WEB/02_chapter.pdfhttp://www.kvt.sjf.stuba.sk/WEB/02_chapter.pdfhttp://en.wikipedia.org/wiki/Special:BookSources/0831130490http://www.kvt.sjf.stuba.sk/WEB/02_chapter.pdfhttp://en.wikipedia.org/wiki/Special:BookSources/0831130490

machining and casting report

Documents