LAB EXPERIMENT NO :COMPLEX ENGINEERING PROBLEM

COURSE :MANUFACTURING PROCESSES

COURSE CODE :ME-321

COURSE TEACHER: DR. ADNAN TARIQ

NAME: MUHAMMAD NOUMAN KHAN

REGISTRATION NO :UW-18-ME-BSC-039

DEPARTMENT OF MECHANICAL ENGINEERING

WAH ENGINEERING COLLEGE WAH CANTT

INTRODUCTION :

Manufacturing is the making of goods by hand or by machine that upon

completion the business sells to a customer. Items used in manufacture
may be raw materials or component parts of a larger product. The
manufacturing usually happens on a large-scale production line of
machinery and skilled labor.

Manufacturing is the production of goods through the use of labor,

machines, tools, and chemical or biological processing or formulation. It
is the essence of secondary sector of the economy.[1] The term may
refer to a range of human actiiity, from handicraf to high-tech, but it is
most commonly applied to industrial design, in which raw materials
from the primary sector are transformed into fnished goods on a large
scale. Such goods may be sold to other manufacturers for the
production of other more complex products (such as aircraf,
household appliances, furniture, sports equipment or automobiles), or
distributed iia the tertiary industry to end users and consumers
(usually through wholesalers, who in turn sell to retailers, who then sell
them to indiiidual customers).

Manufacturing is the processing of raw materials or parts into fnished

goods through the use of tools, human labor, machinery, and chemical
processing. Large-scale manufacturing allows for the mass production
of goods using assembly line processes and adianced technologies as
core assets. Efcient manufacturing techniques enable manufacturers
to take adiantage of economies of scale, producing more units at a
lower cost.

Types of Manufacturing Processes :

Following are the different types of manufacturing processes

◾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

These are the machining operations. There are so many other

machining operations are there. But they come under these main
operations

They are categoriied under three main categories:

◾Traditional Chip-making tools.

◾Presses.

◾Modern machine tools.

Traditional chip-making tools form

the work-piece by trimming away the unwanted part accessible as
chips. Presses implement a seieral shaping processes, which includes
shearing, pressing, or elongating. Non-traditional machine tools
implement light, electric powered, chemical, and sonic power;
superheated gas; and high-energy compound beams to form the exotic
supplies and materials that haie been created to meet the
requirements of modern technology.

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.

Bolting is a standard fastening method, for instance, but welding may

cut down the weight of assemblies. Naturally, joints intended for the
two approaches would differ tremendously.

Howeier, all joint paterns must consider features such as load factors,
assembly effectiieness, operating surroundings, oierhaul and upkeep,
and the materials chosen.

Welding is generally a cost-effectiie approach to fabricate. It doesn't

require oierlapping materials, and so it remoies excess weight brought
on by other fastening methods. Fasteners don't haie to be purchased
and stored in stock. Welding also can minimiie costs related to extra
parts, for example angles mounted between parts.
 Joi
ning of any two components to together can be done with the help of
following operations either permanently or temporarily.

◾ Welding

◾Braiing

◾Soldering

◾ Adhesiie Bonding

◾ Fastening

Welding, Braiing, soldering and Adhesiie bonding are permanent

joining methods whereas Fastening is the temporary joining, method.

Forming :

Metal forming is the approach of creating the metallic components by

deforming the metal but not by remoiing, cutng, shredding or
breaking any part. Bending, spinning, drawing, and stretching are a few
important metal forming process in manufacturing. The metal press
such as die and punching tools are implemented for this manufacturing
process.

Adiantages: – Same equipment can be utiliied for manufacturing

iarious components by simply changing the dies.

Disadiantages: – High apparatus and tooling expenses. – Heat

treatment must be applied aferwards.

The forming process has different categories based on the applied

loads.

1. Compressive forming

2. Tensile Forming

3. Bending

4. Shearing

Compressiie forming by applying the compressiie loads on the objects

to atain the shape. Following all operations comes under the
Compressiie forming processes

◾Rolling: Material is passed through a pair of rollers

◾Extrusion: Material is pushed through an orifce

◾Die forming: Material is stamped by a press around or onto a die

◾ Forging: Material is shaped by localiied compressiie forces

◾Indentng: Tool is pressed into the workpiece

Tensile Forming:

In this forming process tensile loads are used to deform the objects
permanently.

Bending:

In Bending Forming Process, bending loads are used to deform the

objects.

Shearing:

Shearing loads are used to deform the objects to atain the required
shape in this forming process.

Combined Tensile and Compressive Forming:

In this forming process both the Tensile and the compressiie loads are
used to deform the objects permanently..

Castng :

Casting is a manufacturing process in which a solid is dissolied into a

liquid, heated to appropriate temperature (sometimes processed to
change its chemical formula), and is then added into a mold or caiity.
Thus, in just one step, complex or simple shapes can be crafed from
any kind of metal that has the capability to be melted. The end product
can haie practically any arrangement the designer wants.

Furthermore, the reluctance to working challenges can be improied,

directional atributes can be managed, and a pleasing look can be
deieloped.

The steps iniolied in casting process are

◾ Preparing the moulds using the paterns,

◾ Pouring the Molten metal into the mould caiity

◾ Allow the cast to solidify

◾ Remoie the Casting component from the Moulds

This is how casting components are prepared.

Examples: crankshafs, connecting rods, engine blocks, gearbox

housing/casings,

There are different casting types are aiailable. They are

◾ Sand castng: Where the moulds are prepared with the Sand.

◾ Permanent Mould castng: Where the moulds are the metallic

objects.

◾Die castng: Forcing the molten metal into the moulds with heaiy
pressure
Moulding :

Molding is a manufacturing process that iniolies shaping a liquid or

malleable raw material by using a fxed frame; known as either a mold
or a matrix. The mold is generally a hollow caiity receptacle, commonly
made of metal, where liquid plastic, metal, ceramic, or glass material is
poured. In most cases, the mold is deriied from the initial patern or
template of the fnal object; its main objectiie is to reproduce multiple
uniform copies of the fnal product. As the liquid cools and hardens
inside the mold, the fnal confguration is achieied. Its remoial is
facilitated by the use of a release agent or ejection pins.

Different types of Moulding :

◾Injecton 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:

Blow moulding is used to make hollow components like botles. First,

the plastic is melted down and injected into the mould called a parison.
Which will haie a hole to blow the air into the mould shape to make
the object hollow. This air will push the plastic towards the mould
shape in the mould. Blow mould is used to make botles.

◾Compression moulding:

Molten plastic is poured into the Mould and further it will be pressed
against the mould shape before the plastic

being cooled. Examples of Compression moulding are car tires.

◾ Rotatonal Moulding:

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 :

Here we are giiing a proposal of deieloping a mechanical

manufacturing workshop which produce gears on commercial basis. As
gear production iniolies different manufacturing process according to
its dimensions, structure, siie, and shapes.

The global automotiie gears market is projected to grow at a CAGR of

6.1% from 2015 to 2020. The market is estimated to be USD 28.47
billion in 2015 and is projected to reach 38.27 billion by 2020. In this
study, 2014 has been considered as the base year, and 2015 to 2020,
the forecast period for estimating the market siie of automotiie gears.
The study segments the market on the basis of application, iehicle
type, product type, material type, and region The market has been
classifed by product type as follows: planetary gears, beiel gears, rack
and pinion gears, hypoid gears, worm gears, helical gears, spur gears,
and non-metallic gears.

Enhanced driiing experience and increasing production of passenger

cars in the Asia-Pacifc region is expected to driie the global automotiie
gears market. The Asia-Pacifc region is estimated to lead the market, in
terms of ialue, in 2015. The North American region is estimated to be
the second-largest market for automotiie gears, owing to the growing
trend of installing mechanical parts in passenger cars.That’s why we are
targeting gear marketing as it haie a larger scope in manufacturing
industry.

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:

◾ Cheaper low-quality gear in small numbers

◾ The tooling costs are reasonable

◾ Poor Surface fnish and dimensional accuracy

◾ Due to low precision and high backlash, they are noisy.

◾ They are suited for non- critical applications

Applicatons:

(without fnishing operation)Toys, small appliances, cement-mixer

barrels, Hoist gearbox of dam gate lifing mechanism, Hand operated
crane etc.,

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:

◾ Beter surface fnish and accuracy (tooth spacing and concentricity)

◾High tooling costs

◾ Suited for large scale production

Applications:

Instruments, cameras, business machines, washing machines, gear

pumps, small speed reducers, and lawn moiers.

Materials:

Materials used to manufacture these gears are iinc, aluminium and

brass. The gears made from this process are not used for high speeds
and heaiy tooth loading. They are normally applied for small siie
gears..Iniestment casting or lost wax process
Characteristcs:

The characteristics of gears that are manufactured by iniestment

casting are,

Reasonably accurate gears

◾ Applicable for a iariety of materials

◾ Refractory mould material

◾Allows high melt-temperature 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.

Sintering or P/M process:

The powder metallurgy technique used for gear manufacture is shown

in fg below.

Characteristcs:

◾ Accuracy similar to die-cast gears

◾ Material properties can be Tailor made

◾Typically suited for small siied gears

◾Economical for large lot siie only

For the components manufactured by P/M technique, secondary

machining is not required.
Injecton Molding:

Injection molding is used to make nonmetallic gears in iarious

thermoplastics such as nylon and acetal. These are low precision gears
in small siies but haie the adiantages of low cost and the ability to be
run without lubricant at light loads.

Applicatons:

Injection molded gears are used in cameras, projectors, wind shield

wipers, speedometer, lawn sprinklers, washing machine.

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:

Aluminum, copper, naial brass, architect-ural bronie and phosphor

bronie are the materials that are commonly extruded.

Applicatons:

Splined hollow & solid shafs, sector gears are extruded and iarious
gears

Cold Drawing:

Cold drawing forms teeth on steel rods by drawing them through

hardened dies. The cold working increases strength and reduces
ductility. The rods are then cut into usable lengths and machined for
bores and keyways, etc

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

The bulk of power transmitng metal gears of machinery are produced

by manufacturing process from cast, forged, or hot rolled blanks. Refer
to frst fgure for classifcation of machining processes. Roughing
processes include milling the tooth shape with formed cuters or
generating the shape with a rack cuter, a shaping cuter or a hob cuter
which are shown in fg below.
Despite its name, the roughing processes actually produce a smooth
and accurate gear tooth. Only for high precision and quiet running, the
secondary fnishing operation is justifed at added cost.

Roughing processes:

Roughing process consists of forming, generation, shaping and hobbing

processes. By this method gears are made to an accuracy which is more
than adequate for the slow speed operations. These processes are dealt
here.

Form milling:

Forming is sub-diiided into milling by disc cuters and milling by end

mill cuter which are haiing the shape of tooth space.

◾Form milling by disc cuter:

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 :

Gear shaping used a cutng tool in the shape of a gear which is

reciprocated axially across the gear blank to cut the teeth while the
blank rotates around the shaper tool. It is a true shape-generation
process in which the gear-shaped tool cuts itself into mesh with the
gear blank. The accuracy is good, but any errors in one tooth of the
shaper cuter will be directly transferred to the gear. Internal gears can
be cut with this method as well.

◾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 :

Finishing operations occur at the end up the manufacturing process,

afer the part has been formed and secondary processes haie been
completed. These operations can add a logo to a part, enhance its
iisual appeal, augment its durability, or remoie elements lef behind by
an earlier manufacturing process.

◾Shaving :

Gear shaiing is a free-cutng gear fnishing operation which remoies

small amounts of metal from the working surfaces of the gear teeth. Its
purpose is to correct errors in index, helical angle, tooth profle and
eccentricity.Shaiing proiides for form modifcations that reduce gear
noise.

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.

Grinding is used to correct the heat-treatment distortion in gears

hardened afer roughing. Improiement in surface fnish and error
correction of earlier machining are added adiantages.

◾Burnishing :

Burnishing is a process by which a smooth hard tool (using sufcient

pressure) is rubbed on the metal surface. This process fatens the high
spots by causing plastic fow of the metal. ... Roller Burnishing improies
the fnish and siie of surfaces of reiolution such as cylinders and
conical surfaces

In burnishing, a specially hardened gear is run oier rough machined

gear. The high forces at the tooth interface cause plastic yielding of the
gear tooth surface which improies fnishand work hardens the surface
creating benefcial compressiie residual stresses.

◾Lapping :

Lapping is a sanding or polishing method used to create an accurate

fnish on a fat or domed surface of a part. Honing is a method of
internal grinding used to achieie a precise surface fnish and shape on
the inside diameter (ID) of a tube, bore, or hole.

◾Honing :

Honing is an abrasiie machining process that produces a precision

surface on a metal workpiece by scrubbing an abrasiie grinding stone
or grinding wheel against it along a controlled path. Honing is primarily
used to improie the geometric form of a surface, but can also improie
the surface fnish.

Cost Analysis :

For the aboie giien manufacturing processes, we will take a workspace

of our own or on rent to perform our Procedures. For Machining
Process, we wil setup a Lathe machine and iertical milling machine. It
cost us 5 lac rupees per machine.Total cost of both machines=1000000
Pkr.

Also, we discuss here some mostly performed manufacturing processes

cost with the Production quantity of 100 gears. Material Cost and
manufacturing cost will be different for each process and it would
depend on the time used to manufacture 100 gears material wasted
and the machines and methods used.

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 work piece:

Price of steel (Pkr/tonne) = 257306.5 Pkr^2

Weight of work piece= 10kg

Cost of one work piece =10kg × 257306.5 Pkr/tonne × 1 tonne/10^6

grams =2573 Pkr
Cost of 100 workpieces is 5146.13 Pkr.

Cost of electricity :

Power Consumption = I× V= 25 A × 220 V = 5.5 kW

Energy Consumption = 5.5 kW × 15 min 1 hour/60 min = 1.375 kWh

Cost = 1.375 kWh × 25 Pkr/ KWh =34.375Pkr

So, cost of electricity for 100 gears is 68.75 Pkr

Turning Machine Cost :

Turning machine is used to cut the long bar into gears

Time required for a single cut is 1 minute:

Power Consumption = I × V= 40 A^3 × 240V = 9.6 kW

Energy Consumption :

9.6 kW × 1 min ×1 hour/60 min =0.16 KWh

Cost = 0.16 kWh× 25× Pkr/KWh =4 Pkr

So, cost of electricity for 100 gears is 400 Pkr

Drilling Machine Cost:

Drilling machine is used to drill holes into gears

Time required for a single gear is approx. 30 sec

Power Consumption = I × V = 15 A × 220 V = 3.3 kW

Energy Consumption = 3.3 kW × 0.5 min × 1 hour/60 min-= 0.0275 KWh

Cost = 0.0275 KWh × 25 Pkr/KWh = 0.6875 Pkr

So, cost of electricity for 100 gears is 68.75 Pkr

Total Cost :

Total cost = Cost of work piece + Energy Consumption

Total cost = 5146.13 + 35.75 + 400 + 68.75 = 5683.63 Pkr.

Hobbing:

Cost of work piece:

Price of steel (Pkr/tonne) = 97,545 Pkr

Weight of work piece= 3000 grams

Cost of one work piece = 500 g × 97545 Pkr/tonne× 1 tonne/10^6

grams = 48.8 Pkr

Cost of 100 workpieces is 4880 Pkr

Cost of electricity:

Power Consumption = I × V = 11.7 A × 220 V = 2.574 kW

Energy Consumption = 2.574 kW × 5 min ×1 hour/ 60 min= 0.2145 kWh

Cost = 0.2145 kWh × 25 Pkr /kWh. = 5.36 Pkr

So cost of electricity for 100 gears is 536 Pkr

Drilling Machine Cost :

Drilling machine cost would be same for all process i.e 68.75Pkr

Total cost :

Total Cost = Cost of Work piece + Energy Consumption for Hobbing

Total Cost = 4880 + 536 + 68.75 = 5484.75 Pkr

Milling Process:

Cost Analysis:

Power Consumption = I × V = 15 A × 220 V = 3.3 kW

Energy Consumption = 3.3 kW × 15 min × 1 hour/60 min= 0.825 kWh

Cost = 0.825 KWh × 25 Pkr/KWh = 20.6 Pkr

So, cost of electricity for 100 gears is 2060 Pkr

Cost of workpiece :

Price of steel (Pkr/tonne) = 97,545 Pkr

Weight of work piece= 500 grams

Cost of one work piece = 500 g × 97545 Pkr/tonne × 1 tonne/10^6

grams

= 48.8 Pkr

Cost of 100 workpieces is 4880 Pkr

Drilling Machine Cost:

Drilling machine cost would be same for all process i.e 68.75Pkr

Total Cost:

Total cost = Cost of work piece + Energy Consumption for Milling

Total cost = 4880 + 2060 + 68.75 = 7008.75 Pkr

Powdered Metalurgy:
Cost analysis:

Power Consumption = I × V = 40 A × 220 V = 8.8 kW

Energy Consumption = 8.8 kW × 1 hour = 8.8 kWh

Cost = 8.8 kWh ×25 Pkr/kWh = 220 Pkr

Cost of 100 Pieces = Cost for pre heat + (Cost for 25 pieces ) × 4

Total cost = 220 + 880 = 1100 Pkr

Drilling Machine Cost:

Drilling machine is used to drill holes into gears

Time required for a single gear is approx. 30 sec

Power Consumption = I × V = 15 A × 220V = 3.3kW

Energy Consumption = 3.3 kW× 0.5 min × 1 hour/60 min = 0.0275 kWh

Cost = 0.0275 kWh ×25 Pkr/kWh =0.6875 Pkr

So, cost of electricity for 100 gears is 68.75 Pkr

Cost of material:

Powdered steel:

Cost of one work piece = 500 gram × 148.7 Pkr/ Kg × 1kg/1000 grams =
74.35 Pkr

Cost of 100 gears = 7435 Pkr

Nickel, Chromium, etc. metals:

Others metal price = 1000 Pkr

Total Price:

Total price = 1000 + 7435 + 1100 + 68.75 = 9603.75 Pkr

By Analysing aboie calculations and Manfacturing Processess we

estimated our work shop worth ialue equals to 3 million pkrs.If we
Produce yearly 10% of total iniestmnt return and contribute about 5%
in total for production of new material and keeping in infation rate
upto 10 % so we are incured to get to recoier our total cost within 5
years.As if e raise our production and sale rate it can be recoiered
within three years.

Conclusion:

Afer the completion of complex engineering problem we concluded

that the Casting, Moulding, Forming, Machining, Joining processes we
deieloped our workshop for manufacturing of gears. We implemented
our manufacturing engineering knowledge and to perform different
manufacturing operations in our workshop also we are concerned with
commercial basis workshop so we make batch production of gears to
proiide to meet market ialues. Also, we calculated worth of our
workshop and obseried our recoiery of our iniestment. Market is
changing rapidly with the ongoing expansion of the industry.
Adiancement in the technology has proiided today’s businesses with
multifaceted adiantages resulting in daily economic shifs. Thus, it is
iery important for a company to comprehend the paterns of the
market moiements in order to strategiie beter. Afer comparing
different ways of producing gears aboie mentioned process was
selected as the best suitable process keeping in mind the following
restrictions i.e. number of parts, accuracy, carbon emission and cost. By
following these methods one can generate gears with minimum cost.
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