Shaping, Joining and Surface Treatment Analysis

Shaping, Joining and e link Treatment AnalysisMANUFACTURINGPROCESS plectrumInt magnetic poleuctionProcess alternative is a key trustworthy be in an industry where the specification from the customers is analysed and the qualified plow for the coveted ware is isolated from the other manufacturing per sortancees. This selection assist in a society is genuinely(prenominal) important as this determines the futuristic profit for the industry or the quality of the harvest-festivals thats been maked from the plant.In guild to analyse the importance and economics of the discordant do byes in manufacturing industry, most of the companies these days uses CES software which explains all the expand a comp whatsoever should think closely before starting the manufacturing deal.CES software tips the important information on the history of the stuffs utilise for manufacturing suffice and suitable summary based on their economics and environmental equal.In this report, fro m CES mainly, the work out universe is analysed based on the three touch on such(prenominal) as SHAPING, JOINING and SURFACE TREATMENT. figure 1 CES database with make for universe segment 1Manufacturing milling machineryprogramesFrom the CES (Cambridge engineering selector) software, offshoot universe database few of the dishes were selected and analysed in detail victimization CES database and the sources outside CES in grade to investigate these accomplishes. Joining, Shaping and Surface treatment are the three manufacturing transites that were analysed in this report.JOININGIntroductionThis process describes the methods of connectedness move together utilise various animate bes and methods in tack together of battle to form trusted assemblies which provides useful functions mechanically. At the very beginning fall in process was very simple and basic the likes of sewing apply threads to stitch seculares, victimisation paper clips, press studs and shoe la ces. When it comes to latch ii preys or bodies together, all possible options should be considered in manufacturing processes in industries. Some of the basic classification of joining process are apply Adhesives, Fasteners, Mechanical welding and Thermal welding. In industrial manufacturing process, joining process is astray divided into either permanent or non-permanent joining in the midst of two objects or pop outs.One of the common process in joining alloys is to fasten two split or plaster bandages in redact to merge the two surfaces of the objects. Metal objects like body armours were converged utilise metal rivets. in the beginning metal welding was introduced, riveting the metals bodies played an important role in joining manufacturing process.BRAZINGBrazing is one of the basic methods apply to join two pieces of metals together. The process starts with isolating the two parts of leaf blade that are to be brazed and by cleaning the parts development wire wo ol or emery cloth would remove all the greases on the surfaces. A paste that is made from borax liquidise powder and water is applied along the enunciate. This prevents the process of oxidation on the surfaces as this inhibits the brazing procedure being successful. And when the compressor attached to the brazing torch is turned ON, this pressurises the foul up and the air, and then(prenominal)(prenominal) the gas-air is turned ON slowly, feeding the gas through the sharp nozzle and this is then ignited at the end of nozzle utilise a match. strain 2 Brazing torchOnce the torch is fructify and the hottest part of the brazing torch (tip of the blue part of the char) is employ to merge the two parts of the steel surfaces. Two pieces of the steel are placed on top of the rotating mount where it is easily accessed from all the directions. In ready to facelift the steel send off the rotating mount, fire bricks are utilise and hence the rut introduced move flow all all o ver the surface rather than on one spot. The surfaces of the steel and the joining metal were given a mollify heat to raise the temperature in order to expand the metal edges and build for brazing.Figure 3 Brazing process setupThe flame is then move forward and backward in order to focus the hottest part of the flame until the steel part becomes red hot. Then a brazing rod (copper atomic number 30 alloy) is then pushed gently along the edges of the steel surfaces and when the temperature is right the rod result go in the gaps to fill them and merge the metal and steel surfaces. The rod is fed until it runs along the joint is brazed in order to join them together. When this is complete, the steel is allowed to cool slowly by quenching in water because temperature reduction the metal supplely may break or crack the joint or it may become distorted.Figure4heatingprocessFigure 5 Brazed satisfyingTypes of materialsBrazing is the process which is widely use to heat exchangers, b icycle frames, boilers, copper pipes, and pipework fittings and to repair forms and assemble machine parts. Metals, ceramics and dissimilar materials are commsolely brazed using this process in industries.A variety of alloys are use in brazing the materials by using the alloys for filtering. Some of the materials that are used as common filters are,Silver copNickel alloyGold silverCopper silveraluminum siliconCopper zincMost commonly, the brazing materials come as in the form of rod, powder, ribbon, paste, wire and preforms such as stamped washers.Characteristics of the componentsBrazing process leave behind be able to fit within the scratchal burden mostness of rove from 0.1mm to 30mm. round might cover the points beyond this field, however, this may affect the increase in greet and time for the process in order to take place. The stripped-down section thickness is always located by the process and the materials used within the certain manufacturing companies.Nominal va luation reserve for the brazing process is in the area from 0.05mm to 0.5mm and the resulting processed materials may be outside the leeway clutches unless this might affect the time for processing and the salute for the causers. Some true statement like preciseness or the surface roughness burn down be determined by the nature of the process.Economics of the processBrazing lowlife be done manual(a)ly and by using automated machines which is using the furnace. more oft than not manual process takes time and using the torch to braze a material requires certain skill level. On the other hand, automated furnace brazing requires no skill and no fatigue costs. Therefore, this brazing process is cheap and cats-paws are passably cost worthy as well and it is very economical for petty(a) runs in certain companies. Yet this process allows high work place when the whole process is automated at larger or industrial plate.SHAPINGIntroductionShaping is a process that was devel oped over time from ancient times when machines were involved in manufacturing processes. However, these types of shaping machines are not widely used in the current manufacturing industries although they had very red-blooded development. This process was used to cut metal whoresons and other parts in too soonish days on the mat surfaces, yet these were used as a drawback in this times. Shaping produces the flat surfaces by moving a single point in a reciprocating or zigzag motion. The forward stroke is the cutting edge motion and the reverse motion is stainless with high velocity motion in order to include the aslant feeding motion.CERAMIC MOLD CASTINGCeramic square off casting is a process which uses high temperatures in order to cast certain parts of machines or even tools, used in various machineries. This process is excessively like plaster hurtle casting merely instead of using plaster to create metal parts or castings, ceramic casting uses refractory revenue stam p materials for casting. In an industrial level the parts used as cutting machinery or metal molds die for metalworking or even the metal impellers do-nothing also be compose using this type of casting processes.Nature of the processThis process kicks off with preparing the platform for pouring the material for de defineation. A mixture of fine cereal ZIRCON (ZrSiO4), aluminium oxide, fused silica, bonding agents and water which creates a ceramic slurry solution for the mold to be dipped in or immersed in this solution.When the mold is set in the slurry solution in the platform, the pattern is then removed and the casted mold is then left off to dry. Then using high flamed torch, the mold is then fired in order to melt or heat off the excess cast around the mold.This flaming the mold process will also burn off any unwanted waste materials on the mold and make it rigid and determined for the future beautify process. In order to add more dominance and rigidity the mold is the n baked in an oven over a certain time period or even heated in the furnace.The firing process leaves the mold with few cracks and lines which then adding the mold special(a) permeability and collapsibility for the metal processing that comes later in the industrial scale manufacturing process.Figure 6 ceramic casting processOnce the mold was prepared the two halves were then joined together for assembly and be ready to pour the casting or resolve material into the molds. The two halves also called as cope and drag section are then backed up with the fireclay materials for additional molding strength. Often in these types of processes in manufacturing industry, the ceramic mold is preheated in the oven in order to pour the molten metal into the cast.The metal casting is poured and let to solidify, in ceramic molding process in industries, like in other expandable mold processes, the ceramic mold is destroyed in the removal process of the metal casting. The ceramic mold itself flu sh toilet be a shell, for humbled manufacture processing components, or a box less block mold, for large industrial components, or even a composite mold combines some(prenominal) the shell which then backed up with a cheaper material like the large components that are produced in large quantities.The insulating nature of the ceramic mold prevents the molds from decaying or decomposing and prolongs the lifespan of the cycle time however the manufacturing ceramic casting process lends itself to mechanization and rapid output of molds.Types of materialsCeramic casting process plays a vital role in casting metal components such as tools used for forging and extrusion and even die casting. This process also used in the glass production. Some of the materials that has been processed in this way are,Aerospace parts and componentsMarine fitting toolsPropellers for ships and small turbinesComplex appurtenance partsPumps and valvesPipes and precision machinery partsImpellersCharacteristics of the componentsMass position for this casting process is from 0.2kg to 50kg of weight and this is determined by the capacity of the casting mold or the caster, the press that the mold undergoes and the machine tools, etc. this mint also often be extruded or extended with the second of additional process of fabricating. 1.5mm to 999mm is the range of the sectional thickness of the materials or the casting mold that is being used in the casting process in the industrial scale of manufacturing process.This is determined by the fluid flow in castings or the plastic constraints used in the molding process or the melt flow distance in injection molding, etc. this process burn down generally be further outside the range resulting increase in cost for material and time for the process to take place in an industry.The range of tolerance for this casting process is from 0.38mm to 0.8mm in length or measurement as the achiever tolerance can be refined by tributary machining operation s such as precision contriteness and polishing in order to remove the surplus unwanted materials and keep the accuracy or so to 100%. 1.6m to 3.2m is the range of roughness for this process as this is controlled by smoothness of the molds or casting surfaces.Economics of the processCeramic mold casting is relatively expensive. The tools costs cover a range from small, simple to large, complex molding materials and they vary in surface manakin and structure. To be able to cast parts at higher accuracy elements eliminates the need for machinery which reduces the cost for automated process but this casting is mainly monitored with watchful eyes and that increases labouring costs and training men in different aspects of skills development.The long preparation time taken in molds increase makes the manufacturing production rates at very low intervals and increasing demands for sweet molds with certain improvements.SURFACE TREATMENTIntroductionSurface treatment can be used in variou s ways in order to clean or polish the surface of the materials using various techniques. This includes polishing or abrasion the metals as well as smoothening the outer surface of the body of the materials used in manufacturing. Surface treatment of the metals involves the creation of a barrier that can protect the metal parts like a wall around the body in order to prevent wearing or other chemical or environmental damages.The surface socio-economic class forming on a metal that is scheduled for chemical coating is created repayable to a chemical reaction which is non electrolytic in nature in order to achieve great and precision results in industrial manufacturing process. excoriationGrinding is a slow process that polishes the surface of a material yet not removing a large sized part from the object or cutting the big edge off the material. In the past, this process was only used to machining processes or final dimension accuracy treatments by finishing the surface of the ma terials. But the developed or renowned natural processes are changing the thought process thats been used over the long time of time.Utilizing new grinding techniques, incredible material removal rate has change magnitude up to 300mm3/smm, which is equal to 28 cubic inches per minute. This process allows the tough edges in aerospace markets, where the materials are made up of tough alloy or atomic number 28 to be removed and polished.Nature of the processGrinding process normally associated with the tools thats been used in the process of grinding. A grinding tool is used to grind down or polish metals or glass surfaces. hero sandwich is more like a sander which uses the abrasive surface of the hit man to remove the minute particles on the materials.Grinding process actually sharpens the rove that is attached to the grinder by braking those particles and creating new grinding points in the wheel. A grinding wheel is made from several chemical and mineral ingredients, this fir earm of particles may vary according to the purpose of the wheel that is used in the industry like whether to grind metals or polish ceramic glasses.Figure 7 bonding particles in grinding wheel making processFor metals they use the grinding wheel made from aluminium oxide granules to create that very abrasive surface of the wheel. For non-metals components, silicon based particles are used in the making of surface of the grinding wheels.These particles are added in weighed scales and by using resin bonding agents these particles are then bonded in shape to form the grinding wheels which are then used in the grinders for appropriate uses.Figure 8 grinding process with grinding wheelsTypes of materialsGrinding also used to cut hardened steel, which produces very smooth surfaces. Surface pressure is token(prenominal) in grinding, which is suitable for light or small works that will spring away from the cutting tool in the other machining processes. It can be classified into rough and precision grinding. Rough grinding eliminates the simple layer of the materials that are with the huge or big part of the edges and extra addition of materials.This prepares the materials for further grinding with precision and increased accuracy. Surface grinding uses a rotating abrasive wheel to remove material which creates a flat surface. Pistons, pins, gears and shafts are some of the materials prepared by this grinding process. Rivets, valves and pipe fittings and lenses and mirrors for precision optical equipment.Characteristics of the componentsSurface smoothness of the materials used under grinding process achieve the high precision. The maximum temperature attained during this process is ranges from 70 to 370 C, this is ascribable to the action between the grinding wheel and the material that is being grinded in the process. Unfortunately, the grinding process does not even out all parts of the material which indicates whether the treatment reaches its maximum precision level. At this process the trend surface coverage is very poor.Economics of the processThe tools used for grinding process are fairly cheap and affordable. This is for manual polishing tools only with the approximate range of price from capital cost being 90 to 1000 and tooling cost ranges from 8 to 200 however this results in the production rates being very low as this is a manual process. Automatic machining processes can be expensive for both capital (ranges from 1800 to 1,000,000) and tooling machines (ranges from 900 to 10,000) but this shows higher production rates in manufacturing.PART 2In depth case study analysis use CES software the pursuit maps are drawn and one of the given case study is analysed with the help of CES software. reproduce paper JacketFigure 9 Manifold Jacket blank 3D modelThe part shown above is called manifold jacket, is used in aerospace shuttles and vehicles. This component is made from nickel and it weighs about 7 Kg as this is a large 3D yowl dimensioned component it has a thickness of 2 5 mm with a precision tolerance of 0.1 mm. In this process of manufacturing case study, we only passing game to manufacture 10 units as this hold in usage in the industry.Table 1 determination requirements Manifold Jacket genuine class selectionMass range Vs Material classThe required material for this manifold jacket comes from a non-ferrous alloy. The chart below explains the class of materials fall in the range from 5 to 10 Kg of mass range of the chosen material (Non-ferrous alloy). From CES software the chart was created by labelling Y-Axis (Mass range Kg) and X-Axis (Material class Non-ferrous alloys). Then certain range as given above (5 to 10 Kg) was isolated using the box tool and the processes that satisfies the approximate length and mass are then labelled in the chart.The box in the chart isolates the processes which can shape these alloys and can accost the craved mass range of 5 10 Kg. Mass range was the Y bloc an d it was selected from the Process universe Shaping Mass range from the chart dialog box. Material class on the X- bloc was chose from the advanced features and under tree Material universe Metals Non-ferrous alloys.In order to choose the limit to isolate the required process selection, a box was drawn in the chart body and right clicked on to Properties Specified range 5 10 Kg in under the mass range sub heading. Then the chart was then zoomed in according to label the processes. By clicking and dragging on each of the coloured lines the sought after processes can be identified. map 1 mass range VS nonferrous alloyThickness Vs var. classThe chart below shows the relationship between the range of section thickness of the chosen materials and to see which processes can produce a 3D hollow shape of the material with transverse features.The chart was plotted by choosing range of thickness for Y-axis and hollow 3D with transverse features on the X-axis. By selecting Chart Y a xis Range of section Thickness was selected in order to plot the graph and X axis Advanced Tree Shape 3D shaping Transverse features.A box was pronounced in the chart by selecting box tool in order to isolate the processes that are capable of making that desired 3D hollow feature with the transverse feature as well.This box was in the range of section thickness from 2 mm to 5 mm. the processes outside the desired range are in different colour since these processes failed to produce the desired results within the certain limitation and ranges specified by the manufacturing play along or industry.Chart 2 range of section thickness VS hollow 3D with transverse featuresTolerance Vs primary feather shaping processThe process selection chart below refers to the interaction between the tolerance that the selection process can have and the trueness of the primary shaping process that is responsible for the formation of this manifold jacket.This chart was plotted using CES by selecti ng Chart from the process universe and under Shaping process Y axis Tolerance (mm) and on the other hand for X axis Primary shaping process was selected on the same dialog box as both are under shaping process sub heading. a few(prenominal) processes that can be used to make this product within the limited tolerance and accuracy of the ranges are then isolated from the chart using a box tool and drawing the box for only the processes that can satisfy which means whatsoever lies on the box after original phase and the applicable tolerance was specified.The tolerance level for these processes ranges from 0.1 mm and whatever above this tolerance and belong to the true phase then these processes can be used to manufacture the desired product with the possible tolerance output.Chart 3 tolerance VS primary shaping processesEconomics Vs distinctThe chart below was plotted against the Economics of the quid size of 10 units thats been produced from the manufacturing processes. This cha rt explains the cost for the manufacturing process and see how such(prenominal) this process cost for the company would in order to produce 10 units of the desired products.Using the box tool from CES, 10-unit scale was isolated from the chart and the processes which can produce the certain amount of products are labelled outside the chart.Economics batch size in units is plotted in Y axis by selecting form Chart Y axis Economics batch size and for the X axis from the shaping process universe X axis Discrete was selected. Only the true section of the chart which can produce the desired materials can be isolated and units of 10 were boxed in order to see which processes can achieve this manufacturing process.Table 2 processes of the manifold jacketChart 4 economics of the batch size VS distinguishableMethodology and conclusionBefore even the part was made, it was important to bet the customer requirements and produce a report on how the production is going to take place and ho w this might satisfy the customers needs in order to make the production more efficient and effective.To make Manifold jackets it seems that Electroforming and enthronisation casting are the right processes with the suitable economics and even for small number of units the casting works out just fine.These types of products are used in small number of units such as in aerospace vehicles and shuttles wherefore it doesnt have to be produced in vast quantities. But in order to produce in bulk operations this process could cost very high and more expensive when it comes to the process being automated as the machines for these types of processes could cost effective and hard to hold open.If the process is manual this could cost much worthy for the company as in training staffs and more labour could result in expensive treatments.When it comes to large scale production of the desired products Electroforming is the only solution and for the manual process side, Investment casting emerge d as a suitable solution.However, before any of these decisions been made, a brief analysis of the investment and profit report such as a cost analysis report is advisable in order to proceed with the device in future.And the analysis from the labours also advised in order to maintain a constant and continuous production in line in the factory in near future.PART 3Environmental allude of Process SelectionECO AUDIT TOOLTo evaluate the environmental impact of the designed product and to analyse the ways to reduce this effect on the environment, ECO-AUDIT tool in CES software is used. This concept is achieved by focusing on ability usage and CO2 footprint of the materials used in the process of manufacturing. The product design forms the objective for the methods used and this resulted from a class of material selection.The objective is dependent on both product application and possessive phase, when the use phase is dominant the objective for a car would be minimize mass, whereas for a boiler, it would be to minimise thermal loss from the manufacturing process.Eco audit tool helps us to perform small or large quick audit before even we begin the report. This part of the CES software helps you to go after and focus on the environmental requirements and simple and three-figure reports are being produced in order to question the compliance.This way it saves money by identifying the early stage corrections and before even the resources were submitted.Methodology of ECO Audit toolThe methodology system in ECO audit helps us to easily interact with the tools and get some environmental impact of the manufacturing processes or the materials used for the manufacturing process quickly and effectively.This way you can track the product sustainability, comply with the customers purport or the companys and even help us with more ideas in order to improve the design for manufacturing. If the goal is to minimise the environmental impact of the processes performed in t he environment we need a quick and effective means of worth(predicate) report in order to judge the performance or the quantitative assessment.The whole processes in the ECO audit methodology can be summarised by the following image which clearly explains the steps and analysis of the process.Figure 10 methodology of ECO Audit processAdvantagesIt helps us to make quick and early decisions based on the corrections and solutions given by the eco audit tool and this saves the company a plenty of time and money by identifying the mistakes in early designs and early stages.In order to use this software, the company or the industrial personnel does not need a specific fellowship therefore this product can be used across the company by anyone making this software more accessible for everyone and engineers can be supported by this software and take advantage by using this to make changes in their environmental audition report.It also helps the company to demonstrate the progression toward s sustainability goals thats been set or achieved for the customers and some of the investors from other companies and sectors through benchmarks and some other better quantitative measures made.Case study Glass nursing bottleWe are trying to find out all the information regarding this product. For this we can use ECO audit tool which can tell us about the life cycle of this product, transport and uses for this product. This tool also clarifies the information for the energy consumed by this product and the CO2 emission for this product.We now analyse the design and the materials used in order to form this bottle including the cap of the bottle and also analyse where the bottle actually transported from and the net weight of the product or the balance weight that this product can maintain.Product manufactureThe name of the product is Glass bottle with the aluminium cap that can be filled with 1 litre of mineral water which could also mean that the net weight of the materials and the whole product is 1Kg.Table 3 materials in manufacturing the productAll the materials that the bottle was made up of can be recycled which indicates that the whole product is very Eco friendly and very unspoiled to the environment.TransportThe bottle itself was manufactured in France and it has been transported 550 km to UK with the help of