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Manningham
converting raw materials into products
Higher
Backbone
level of manufacturing the
higher standard of living
of a
healthy economy

what is manufacturing?
Involves activities in which manufactured products to make other
used products
¥

are .

Manufacturing involves
making products from materials by machinery and operations
¥

raw various processes

,

Word something that

means is
producing
¥

Manufacturing must adhere

Product must meet
to the
following
design parameters and
specifications
¥
.

¥
Produced in most economical manner

Quality must increase

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Manufacturing Layout
Design Process
Selecting Materials
Assembly
Product
quality
automation

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Properties of materials
-

Strength
-

Toughness
-

Ductility
-
Hardness

Fatigue
-

Creep
-

Strength to
weight ratio

Stiffness to ratio
-

weight

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Selecting Manufacturing Processes

Casting &
¥

Forming Shaping
¥

Machining
¥

Joining
 Manufacturing TechniquesCasting :

Casting molten left to solidify

when material
poured into shape holding mechanism structure and then
¥
is is a -

0 Mould is then removed to

expose the new part .

Casting
Expendable Mould
L Production rate
. limited by time to make mould rather than the product itself
¥
Permanent Mould
Lom
Higher production rate

Tm z
Sand Casting
Mostly widely used
Molten metal the mould
poured into sand mould
allowing to solidify and the
breaking up
¥

the
to
Pattern
remove
casting
↳ Full-size model of the part
³
Wood
³ Theta

³ plastic
¥

Solid Pattern
-

Split Pattern
Match Plate pattern
Cope and
Drag pattern
¥

sand casting

aggrandizement
↳ Silica

↳
High temperatures
↳ Grain size
permeability
↳ Water clay or bonding agent mixture
,

Flask vs Flaskless
moulding
↳_
Thermosetting resin binders used in sand

Surface to molten metal

smoother
flow
↳

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↳ Good
↳ More
dimensional
expensive metal
accuracy
pattern -

large quantities

NƒNNNNY
Vacuum
moulding
↳ binders
Recovery of the sands with no

↳ Moisture related defects are absent

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Expanded Polystyrene Process
↳ Lost Foam Process
↳
Evaporative foam process
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Investment
casting
melted to the molten metal
away prior pouring
↳
High
accuracy and
intricate detail.

↳ Close dimensional control

↳
Good surface
Wax recovered
finishing
↳
Relatively expensive
↳ Small in size

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" " " " " " " " ~ mTzy
Permanent mould
" "" ""
castings
" " "" ""
↳
High temperature detrimental to the mould .

↳ Cores
collapsible for removal

Advantages
-
Good Surface Finishing
-

Close dimensional control

More
rapid solidification thus stronger casting due to smaller size
-

grain .

Disadvantages
-

Simple part geometries

-

Expensive mould

Variations of Permanently mould

casting
slash
Casting
¥ Hollow
casting is
formed by inverting the mould to drain
after partially freezing at monty
surface
¥
Low-pressure Casting
Vacuum Permanent Mould
¥

Cleaning molten metal

being introduced
↳
Casting
Improved mechanical properties Greater strength

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Die
casting
↳ Permanent mould
higher casting metal injected under pressure
it solidifies

Advantages Disadvantage
High production quantities
-

Shape restriction
-

Close tolerances possible

od

Thin sections
surface finishing
possible
-

are

Rapid cooling greater strength

-
 Centrifugal Castingat rotational speed forces
¥

Centrifugal force high the materials into outer

region
the cavity
of
³ Tr u e
Centrifugal Casting

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Calculations
Centrifugal Mpg
Force
f- =

Gravitational Force
W=mg
G- Factor GF=

N - revolutions
velocity>
v=Z1TgRoN_ per minute
d " "" " "
radii
qq.gg#)z R radii

6µg¬*
GF : inn
nnmeettree !

) Rl "¥
"

gp=mmgÖ=
GE> Given
=

rg g. 9,8

Ver tical Centrifugal Casting

The inside will take on a
parabolic shape with the difference in the inside
radius between the top and bottom
given by

µ=
30
2g #Length
Rt
'
Rb
'
* -

Centrifuge casting
¥
Small Part
Radial not important
symmetry
¥

Inspection Methods
-
Visualsurfaces defects
-

Dimensional measurements
-

Metallurgical physical
,
& other tests
Pressure
testing for leaks
¥

Radiographic methods
¥

Magnetic particle tests

¥
Fluorescent penetrant.s
Ultrasonic
testing
¥

Repairs
Welding
¥

Grinding
 Metals for casting
F-errroouuss

³:: Ö: Ö:* ÖÖÖ"" EmD

¥
Cast Iron
↳
Typical pouring tempretire 1400¡C
¥
Steel

Better
Toughness
↳

↳ 4101 MPa
strength
-

↳Ease
of welding

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Öh3zy
¥
Alximiniuum

Very cast able

↳

↳ 600¡C
¥

Magnesium
↳
Lightest of all
castings
↳ Corrosion resistant
" "" ""
" "" " "
""
¥
Copper Alloy
↳
Attractive appearance
↳
Corrosion resistance

bearing qualities
↳ Good

↳ Pipe fittings ,
marine propeller blades , pump components ornamental
,
jewellery
¥ Tin
↳
Lowest melting point
↳ Low
strength
↳ Pewter
mugs

Ö:Ö
"
↳ Low
melting
Low creep
point
strength
↳

↳ Good hot strength

↳
Good corrosion resistance
↳
Jet engines rocket components
,

↳
High melting temperature difficult to cast
¥
Titanium
↳ Corrosion resistance
↳
High strength -
to -

weight ratio
↳
High melting tempretire ,
low
fluidity propensity
,
to oxidize at high tempretae make it
difficult to cast
.

Product
Design Considerations
-
>
Geometric simplicity ³ Sectional thickness should be
uniform
Corners C> Avoid
³
hotspots
↳ Avoid
sharp corners ³
Drafts
C > Generous
fillets
Forging
¥

forging is the controlled plastic deformation of heated materials into predetermined shapes
Pressure supplied by forging press/hammer
¥
a

¥
Open or closed die processes
Material forced to flow into die by dies
pressure
¥
on .

Forged components have higher mechanical strength and resistance to impact loads

Sheet Metalworking
Operations invaded
³
Cutting
³
Bending
³
Drawings
Sub -

operations of cutting
Shearing
¥

Blanking} Closely related

¥

Punching
¥

Engineering analysis
clearance The space allowance between
cc) -

punch and the die .

¥ 4% to 8% of stock thickness
Special fire blanking operations 1% stock thickness
¥

Factors that
affect clearance calculations
Thickness of
¥
the sheet
¥

Type of the material

Strength of the material

¥

c- at ± stock thickness c- -7
7
clearance
/
allowance
table
)
Given
Cutting force UNITS 31
NOTE > SYMBOLS
=¥^
=

¥ : .
-6A
F-
A
F- 5th ( shear
stength)
f- 0,7TSTLC Ultimate tensile
strength>
=

o[ MPa ]
f- [ N ]
b- [ mm ]
s[ MPa]
TSCMPA]

stiees 5- > shear

strength
TS Ultimate tensile
strength 1- ³ sheet metal thickness L
Lengthof cat
>
G-> >
-
-
 Punch and Die Size Determination
diameter
Blacking Process
Punching Process inside ,

¥
Punch size Db -2C Punch size.ph ± 3
my
=

Die size
=Db±T '
out-sid.gl?~etiei-
End of - a-
Die

a
size

factoring
=Dh+2c 3

1 Which type of casting process is most suitable to cast small parts ? -

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Centrifugal Lost wax

1,2 A 7

7
1,3C
44 A 755
µ
1,5 C- a. b-
C- 0,06 ¥
2
c -0112
C
Punch size -_ 20-20,12)
: . 19,76 7 12,2A

46 A D

117 ? A? B

118 Girl ? B

1,9 Girl ? D

c- - at inside
gia
-
etere

Die size.= Panth size+20,06 ¥

2)
Die size = 12 0,24
+

:
DrawinguT
ISOMETRIC DRAWING ( 3D)

continues Thick :( Viable Outlines 31 Visable Edges

Continues This :
Dimensioning
- - - - - -
- - - - - - - -

Dashed Thin : Hidden outlines 31

edges
-

Troop from top

Left f- if?ght

left Right

ORTHOGRAPHIC

Rules
Must be 2- 4cm apart
Must be inline !
Remember hidden detail
Remember dimensions

Fillets 31 Rounds

=
"
s

,py
Dimensioning
-

arrow used
must be
skinny
0 diametre
R
symbol
radius symbol For rounds
TOLERANCES

³
Surface Tolerances
↳Measure
of roughness or
degree of finish a
surface must adhere to during the
manufacturing process

³
Limits $ Fits
↳ The amount
of allowable variation on a dimension or a surface of machined parts

³
Geometrical tolerances
↳ Controls the shape and positional distribution of a component

Surface To l e r a n c e s

Indicates the surface obtained by the non removal of material ,

i. e. an
electroplating procesi

Indicates the surface obtained by removal of material

Indicates a surface tolerance where material removal is prohibited

machining process specification

Surface
¥ ±
Sampling length Cmm)
texture cµm)
↳
machining -a
Direction of
allowance marks
machining

Limits and fits

¥ All manufactured parts are subject to
manufacturing tolerances : NO 2 OBJECTS CAN BE EXACTLY
THE SAME
¥

One
might be tempted to think that an outside diametric of 10,03 could be
equal
to 10mm which
,
in most

cases would be true , except when this 10103min shaft needs to into a 10.00mm hole, then
go
theres is an interference between them .

Sometimes need to
specify
the
tightness# ƒ between components
¥

we
 Categories of fits

Clearance fits :
permit relative freedom of motion between a
shaft and a hole .

Transitionfits : outside ?

Interference Fits: Interference and transition fits certain amount of

secure a
tightness between parts
150 standards for fits between components specify a fit as follows :

( )
Oc
Hy gz
-

^
P [ to the
shaft and the numerical value the width of toleranceband
g refers
Baseor zero 044,2 ³ nun

line aliment

H refers to the hole and numerical value of width of the tolerance band

Example question : calculate tolerancesfor shaft 254-17 -

g 6)
Use table
Dia metre
given ,
determain the tolerances
for
the
given fit standard
¥

of 25 falls in section 18-30

¥ look for 1-17-

g6
they you find
¥
Where cross the anwse .

"

-
along
H -
is
g
step 2 For shaft the deviation for that
:
zero line for a base diametre
of 25mm with GG clearance f-it is shown as
:

-
7 and -20 this means

25,000-01007=24 993 ,

25,000-0,020=24,480

Step 3 : For the hole the deviation from the zero line for a base diameter of 25m -

with 1-17 clearance

f-it is shown as :

+0 31 +21 this means

25+0=25 25+01021=251021
Geometric To l e r a n c e s

Geometric tolerances are tolerances that control that shape and positional distribution of a

control the shape and positional distribution of a component .

Geometric tolerances add to manufacturing costs and should only be specified when :

a) the shape of the component is detrimental to the

functional of a
component .

OR
b) the
degree of accuracy obtained by normal manufacturing techniques is not
suffice + _ .

Single Feature

Straightness
Flatness
Roundness
Cylindicity
~
Profile of a line
-
Profile of a surface

Related Feature
Parallelism

Angularity
Squareness
Posisie
Concentriciteit
Symmetry
Run out -

SECTIONS
Note hating is
where it cuts there is
hatching
section Types
- Full section ( cut in half ) ( Horizontal , thickpart)
-

Half section [ only half of half)

-
Revolved sections
-

Removedsections

Offset section (thin half

-

section
aligned
-

- Partial Section

No hidden detail
 Sheet
metalworking
Operations:
Cutting
³

Bending
³

Drawing
³

cutting :

Shearing
³

³
Blanking => closed line piece is cut out
³
Punching piece cat
out is waste

ENGINEERING ANALYSIS

Clearance (c) }The space allowance between the punch and the die
¥
4% -
8% of stock thickness
¥

Special Fine
blanking operations 1% stock thickness

Factor that affect clearance calculations

Thickness of the sheet
of the material
Type
Strength of the material

c : at
C :
clearance
1- :
stock thickness
a: allowance
for type of metal

Force
cutting Csn)
F¥~ shear
strength and Ultimate tensile
strength (0,71-51-1)
measured in Newton
"

d = A

± ± area

stress [mini]
]
[Mpa

Blanking Process

PUNCH SIZE : Db 2C -

2- ±
clearance
Die

+2¥
Size
Punching Process

DIE SIZE : Dh
%
punch
size
ENGINEERING ANALYSIS

(BA)
Bending Allowance
Lengthfthearunder bending operation

BA=2–A( RI-kba.TN stock thickness

[
Bend angle inside stretching
3607 At A' = 180
Radius factor
neutral axis
= 0,33 if R42t o

¡ % plane
A
&
= 0,5 if R g2t
R
'

Spring back
Can be accounted for
A

by
:

(A A'b) / A' b
'
sB= -
7 Over-

bending
¥

±
Bottoming
7
± inside
inside
angle
angle before
after

Tensile
Bending Force
# strength [ Mpa]

F =
kbf ¥ TS.in?t2~width
6 [ stock thickness

stretching 5
Diametre
factor
V -

Bending :Kbf= 1,33

Edge Bending :kbf=Q33
OTHER BENDING AND RELATED FORMING OPERATIONS

Flanging to stiffen edge

¥

Stretch
Flanging
¥

¥
Shrink Flanging

Clearance for drawing

6=7,7 × t

Drawing Ratio

Db - Blank Diametre
DR=
Dp
±
Punch Diametro
DR 42 Upper limit to
:
successful operation
Material ductility radius of punch and die corners depth of draw all the
, ,
friction , influence maximum

draw ratio .
 REDUCTION Punch
-
diameter
'

40,5 Db Dp -

r= Db
± Blank
Diametre
Thickness to diametre ratio
1-
> 0,07
Db

Punching force maximum :

f- (IT Dp E)( TS
)( Dp
Db
= ¥

0,7
¥
-

Holding Force

Fn = 0,01541T[ Dri ( Dp +2,21-+2Rat ]

-

±
die corner
Yield
strength radius

Redrawing Operation Guidelines

³
First Draw : 40% -50% reduction
-
> Second Draw :
30% Reduction
³ Third draw :
1Gt .
Reduction

Drawing Without a Blank Holder

Db Dp 56-

Ty p i c a l Drawing Defects
³
Flange Wrinkling
Wall
³
wrinkling
³
Tearing
³
Earing
³
Surface scratch
 in which
Machining operations involve various processes
into a
material is processed accurately
piece of raw
carefully
a

by means of a
desired shape and size
removal process Usually , a form of
controlled material
.

also
many other processes
is used, although
cutting
exist .

will be applied
that
process
The type of machining of the part This process
final geometry
.

depends on the
tool moves relative
to the work

the way a cutting

governs
part .

operations
Machining
turning
¥

Milling
¥

Drilling
¥

Engineering Analysis
N =
Rotational Speed (rpm)
v =

Cutting speed ( ]¥–:)

Do =

Original Diameter ( distance)

Df= Final Diameter ( )
distance

D= Depth of cut ( distance )

f- Feed rate C]i¥m%e)
r=
distance
f- = Feed ( revolution
Tm = Time
MRR Material Removal Rate
-
-

(4%17)
↳
Length
V

N= ¥

Do

Do Df=2¥d
-

f-r=N¥f

MRR-v.f.cl
L
Tm =
fr
 Working Holding
Other Lathes and turnines

To o l Room Lathe

Speed Lathe
Turret Lathe

Chucking Lathe
Automatic Bar Machine
Numerical Control Lathe

Boring
³TYPE
Operations
OF TURNING OPERATIONS

Drilling
drilling is when a
fluted cutting tool and work part have a relative rotation to each other and

Drills
Types of
¥
Twist Drill
B¥¥a7h Hole
*
roughHole
Blind

OPERATIONS RELATED TO DRILLING

Reaming
-

Tapping
Counter
boring
-

Countersinking
-

Centre
Drilling
-

of
-

Spot Facing :
height
oneto
#

allowance

Equations for drilling approach Drill Point

6 ± Angle
speed cutting
( 90 E)
v
N= # 6
A- 0,5 Dtan -

1 Hole / Drill Bit

f. Diametre ±
rotational Hole /Drill Bit Dia metre
speed
1-+ A total distance that the drill
Tm
±
= must move to create the
fr
f- Nf
complete holes holes
r=
through .

± *
feed rate
g.
± feed Time
/ Drill Bit
Diameter
feed Hole
rate ± d # total depth of the hole up to the end at the
feed rate
,
2 tip
the blind hole of
Tm
fr
±
* 6 =
fr
MRR = 4
f-
±
material feed rate
romofatate
 Miling
2 Forms of Miling
-

Peripheral milling cuts = > parallel

to
surface
-

face milling = > cuts perpendicular to surface

TYPES OF PERIPHERAL MILLING

¥
Slab Milling
Slotting
¥

¥
Side milling
Straddle
milling
¥

Form
milling
¥

TYPES OF FACE MILLING

7 Conventional Face Milling
Partial Face
7
Miling
7
End Mailing
7 Profile Miling
Pocket
Miling
7

7 Surface Contouring

Equations :

fr= Feed rate ( mm /min )

ne = Number of teeth
f-r=N¥nt¥f f- =
Chip Load ( mm /tooth)
MRK-w.d.fr A- Approach (mm )
A- =
d( D- d) a- Overtravel ( mm )
<+ A d-
1-m= Depth of cut ( mn )
fr )
a- width of cut ( nm

A-
( nm )
WCD L
) Workpiece ten thg
= -
-
w _

N= Rotational speed (
Tm =L +2A rpm )
fr MRR= Material removal Rate
Tm -
-
Time
D= Hole / Drill Bit Dia metre (nm )
Blanking Punching :.

) strip
(scraps
} Part

} Blanking +
slugcscrap)