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7/29/2019 machining and casting report
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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
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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
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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
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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.
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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
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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.
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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
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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
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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
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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
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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.
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CHAPTER 3: METHODOLOGY
Process flow chart
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REFERENCES
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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