...SEMINOR TOPIC ASSESSMENT ON EFFECT OF CUTTING FLUID ON MACHINING COURSE NAME GRADUATE SEMINOR COMPILED BY: TESFAYE KASSAHUN MSC/00017/03 SUBMITTED TO: Professor (Dr.) RANTAM UPPULA September, 2013 Abstract During machining operation, friction between workpiece-cutting tool and cutting tool-chip interfaces result high temperature on cutting tool. At such elevated temperature the cutting tool if not enough hot hard may lose their form or stability quickly, wear out rapidly, resulting in increased cutting forces, higher surface roughness, shorter tool life and lowers the dimensional sensitiveness of work material. Different methods have been reported to protect cutting tool from the generated heat during machining operations. The selection of coated cutting tools is an expensive alternative and generally it is a suitable approach for machining hard materials. Another alternative is to apply cutting fluids in machining operation. Cutting fluids used to provide lubrication and cooling effects between cutting tool and workpiece and cutting tool and chip during machining operation. As a result, important benefits would be achieved such longer tool life, easy chip flow and higher machining quality in the machining processes. The selection, method of application, storage and disposal of cutting fluids should be carefully carried out to obtain optimum result in machining processes. Metal cutting fluids change the performance of machining operations because of their lubrication, cooling,...
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...EXPERIMENTAL STUDY OF MICRO ULTRASONIC MACHINING PROCESS Sreenidhi Cherku, Murali M Sundaram, and K P Rajurkar Center for Nontraditional Manufacturing Research University of Nebraska-Lincoln Lincoln, Nebraska, USA INTRODUCTION Micro ultrasonic machining (micro USM), is one of the efficient material removal processes especially suitable for the micromachining of hard and brittle materials. The principle of micro USM is shown in Figure 1. In micro USM workpiece which is placed on the workpiece table vibrates at ultrasonic frequency (40 KHz). Abrasive slurry is injected on the top of the workpiece. There is a rotating tool which hits the abrasive particles in the slurry which in turn hit the workpiece and chip away the material from it. The vibrations given to the workpiece aid in refreshing the slurry so that fresh abrasive particles are in contact with the workpiece and also in removing the debris from the tool workpiece gap [1-4]. In many conventional machining processes like grinding, milling and broaching processes oil has been successfully used as cutting fluid. These oils can be used either as straight oils, which are pure petroleum based oils or emulsifiers which are water based oils. Use of straight oils have excellent lubricating properties and are used especially for machining process involving low speeds, low clearance requiring high quality surface finish. These oils have more viscosity and good lubricating properties than water...
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...From: Anis Mansuri <anis_im@ymail.com> Date: November 14, 2013 Subject: Manufacturing of C-Clamp report No. 2 The manufacturing of C-Clamp has progressed well during September 24 to November 12 periods. We are almost done with the all manufacturing processes as per schedule. The grinding process of C-Clamp will be done by the next week. We expect to finish our C-Clamp by November 26, 2103. The process started on September 24 by submitting layouts and engineering drawings of C-Clamp to our professor. We started machining process with bench work the week after. Drilling and trade calculations were done during the week of October 22. As drilling is very convenient and fast, we were one week ahead from our schedule. We started milling operation as it is a lengthy machining process and hard because we have to be very careful with our measurements, and it took two weeks to finish. We just finished turning and threading operation on the lathe machine last week. Three problems affected the manufacturing process during this period: 1. There was an accident with one student at milling machine, so the professor stopped all processes for a week. We did milling in the next week but on that week we did trade calculations so there was not a big problem. 2. During the turning process on the lathe machine, the diameter of the cylindrical bar was less than the threshold range and there was no extra bar in the warehouse, so it took two days to get a new one. Our professor explained...
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...Reduction of Wrinkling Defect in Deep Drawing Process Abstract. The aim of this experiment is to obtain the best parameters for reducing wrinkle defect during deep drawing process. Deep drawing is a sheet metal forming process where a punch is utilized to force a flat sheet metal to flow into the gap between the punch and die surfaces. Due to that, the sheet metal will deformed into the desired shape. Some of the most common outcomes in deep drawing process are tearing and wrinkling or the formation of uneven height at the top rim of a drawn part due to the material anisotropy. Wrinkling as become a serious obstacle to forming quality and part functions and finally results in scraps. This defects are caused due to change in parameters like blank holder force, Die radius, punch radius, blank diameter, friction, and blank thickness. This project involves the experimental studies of the die design to investigate the formability of sheet metal. From the data documentation, the result were concluded to determine the effect of different parameters on wrinkling phenomenon during sheet metal forming process. Keywords: deep drawing, wrinkling defect, sheet metal, drawing punch, drawing die 1. Introduction In this experiment, 20 tonnage deep drawing machine was used to draw a sheet metal of 1mm thickness to produce a cup of diameter 50 mm. At first, sheet metal was cut into the required shape and placed on the die. Punch is fixed on the top of machine which give compressive force on the...
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...NON TRADITIONAL MACHNING PROCESS SUBMITTED BY :-HARMOHAN SINGH11011102ROLL NO. A23 | TERM PAPER | TOPIC:- Micro ultrasonic machining and its application in MEMS | Ultrasonic machining Schematic of the ultrasonic machining operation Ultrasonic machining, also known as ultrasonic impact grinding,[1] is a machining operation in which a vibrating tool oscillating at ultrasonic frequencies is used to remove material from the workpiece, aided by an abrasive slurry that flows freely between the workpiece and the tool.[2] It differs from most other machining operations because very little heat is produced.[2] The tool never contacts the workpiece and as a result the grinding pressure is rarely more than 2 pounds,[1] which makes this operation perfect for machining extremely hard and brittle materials, such as glass, sapphire, ruby, diamond, and ceramics.[3] Contents [ * 1 Surface finish * 2 Machine time * 3 Mechanics of ultrasonic machining * 4 References | Surface finish The surface finish of ultrasonic machining depends upon the hardness of the workpiece/tool and the average diameter of the abrasive grain used. Up close, this process simply utilizes the plastic deformation of metal for the tool and the brittleness of the workpiece. As the tool vibrates, it pushes down on the abrasive slurry (containing many grains) until the grains impact the brittle workpiece. The workpiece is broken down while the tool bends very slightly. Commonly used tool material consist...
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...Beck’s Capacity Beck’s Capacity Name Candidate for Master of Business Administration May 6, 2013 Dr. Alvin Pexico Beck’s Capacity Beck Manufacturing has 5 Operational work stations. They are Milling, Grinding, Boring, Drilling and Assembly. The one work station that can easily be adjusted, according to the engineering department is the assembly station. The Milling station has 5 machines that can produce 2 pieces per minute. The Grinding department has 7 machines can produce 3 pieces per minute. The Boring department can produce 1 piece per minute. The Drilling department has 6 machines that can produce 2.5 pieces per minute. The following table shows each department and the total capacity per hour of each department. Table 1. |Machine Center |Capacity |pieces per hour | |Milling |(5 machines)(2 Pieces/min)(60min/hour)/(16 hours/day) = |37.5 p/hr | |Grinding |(7mach)(3 p/min)(60 min/hr)/(16 hr/day) = |78.75 p/hr | |Boring |(3 mach)(1 p/min)(60 min/hr) / (16 hr/day) = |11.25 p/hr | |Drilling |(6 mach)(2.5 p/min)(60 min/hr)/(16 hr/day) = ...
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...Production and Tooling Design | Box Jig | Engr. Awais Ahmad | 1/21/2013 | Submitted by: Saba Noor (2009-IME-108) Misbah Niamat (2009-IME-116) Asma Aslam (2009-IME-127) Contents: * What are Jigs and Fixtures? * Why Jigs and Fixtures are used? * Elements of Jigs and Fixtures * Important Considerations while designing a Jig * Box Type Jig * Designing a Box Type Jig * Benefits of Jigs * Drawbacks of Jigs * Conclusion What are Jigs and Fixtures? * Anything used to hold a work piece in a desired location * Locate parts for precision * Repeating process on a series of parts * Holding parts for machining, painting, assembly Why Jigs and Fixtures are used? Holding cylindrical parts to be drilled is one of major problems faced by the manufacturing company, especially small medium company. Sometimes they need expensive equipment to holds the parts to be drill. Today, customers request in industries is increasing. So, the company must find new methods to improve their productivity. Jigs are important part using in any industry. Before this, jigs always have limited function like just one part can be support for one process. This makes the production process slow and cannot fulfill the customers demand. Now days, there are several methods available to improve design to increase the productivity. Jigs are simplified locating and clamping of the work-piece. Tool guiding elements to ensure correct positioning of the tools with...
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...SECTION 3 REPORT 3.1 CLASSIFICATION AND DESCRIPTION OF THE MANUFACTURING TECHNIQUES IN FNSS Following techniques of manufacturing are being used in FNSS; * Chip Removal * Joining * Metal Forming * Testing * Chemical Operations 3.1.1 CHIP REMOVAL PROCESSES Metal cutting, commonly called machininh, is the removal of unwanted portions from a block,plate of material in the from o chips so as to obtain a finished product of desired dimensions, finish.Most of the manufactured products require machining at some stage of their production, ranging from rough work to high precision work.Hence metal cutting is the most important of the basic manufacturing processes. In all metal cutting operations an edged tool driven in to the material to remove chips from the main body and reach the desired geometry.Other actions that occurs are related to that action. In cutting operations, there are three cutting conditions; namely speed, feed and depth of cut.Speed is the primary cutting motion, which relates the velocity of the tool relative to work.Feed is the amaount of material removed per revolution.The depth of cut is the depth of cutting edge engaged in the workpiece. The properties of the workpiece are important in chip formation.High strength materials require larger forces than do materials of lower strength, causing greater tool and work deflection, increased friction and heat generation and operating temperatures,and requiring greater work input.The...
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...are widely used in aeronautical and automobile industries due to their excellent mechanical and physical properties. However machining this composites find difficult because of the reinforcement particles. Tools wear more quickly and reduce the life of the tool. This paper presents the experimental investigation on machining two different A356 matrix metal reinforced with 10 % and 20 % by weight of Silicon carbide (SiCp) particles is fabricated in house by stir casting method. Fabricated samples are turned on medium duty lathe with Poly crystalline Diamond (PCD) insert of 1600 grade at various cutting conditions. Parameters such as power consumed by main spindle, machined surface roughness and tool wear are studied and influence of SiC particles percentage on tool wear also discussed. Scanning Electron Microscope (SEM) images support the result. It is evident that, tool wear is strongly dependent on reinforcement percentage. Key words: A356 Alloy, PCD, Power consumed, Surface roughness, SiC percentage 1. Introduction Metallic matrix composites have found considerable applications in aerospace, automotive and electronic industries [1] because of their improved strength, stiffness and increased wear resistance over unreinforced alloys [2]. However, the final conversion of these composites in to engineering products is always associated with machining, either by turning or by milling. A...
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...for holding the workpiece directly on the table. With a combination of T-bolts and clamps workpieces with varying height can be held in a levelled position using the different steps on the step block. Figure 23 (Anon., n.d.) Drill jig When the production process requires the output to be in large numbers, drill jigs are used. It is a device that is designed to hold the work securely and makes sure that it guides to the tool at any desired position. In this the work can be fixed (with clamps) and removed with ease. Holes can be drilled at the same position on every other identical workpiece without the need to mark each workpiece individually. The workpiece is clamped below the jig and the holes are properly defined. To continue the machining process on the next workpiece the work is removed and the second work is clamped below the jig and the process is repeated. Figure 24 (Anon., n.d.) Clamps: These devices are small, portable vises or plates which bear against the work-piece and holding devices to steady job. These devices come with different shapes to meet the different operation. Common types of clamps are C-clamp, angle clamp, the bent tail machine clamp and the U-clamp. Figure 25 (Anon., n.d.) Geared drill chuck: In this devices drill with straight shanks are held in geared drill chuck which have three adjustable jaws to clamp onto the machine. The drill chuck come with standard two sizes 3/8 or ½ inches and this devices can be used for different...
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...Introduction (1) This career episode took four months, from June to October 2008. It was a machining process improvement project that I participated at XXXXXl. I was working as a Manufacturing Process Engineer with machining process, and in this particular case I made a validation of new cutting fluid for shaving process. Background (2) The main purpose of this project was validate a new kind of cutting fluid for shaving process of the gears for vehicle transmissions at Eaton (http://www.). These gears are the main parts of the transmission, which is manufactured in many machining steps, thermal treatment, assembly, and the project aim was improvement / cost reduction of cutting fluid usage. (3) Due to approval problems in the operation of shaving, the manufacturing team exchanged the current oil that time (integral oil plus chlorinated paraffin – usually used in shaving process) for new oil (soluble oil – called FLUCOR 405e) with thirty percent of concentration and seventy percent of water. There was no follow up for all costs involved and performance in the operation that could ensure that the usage of the new oil was advantageous for the company. (4) The facilitators were EHS department (Environment Health and Safety), Lubrication department, and Manufacturing department. As internal clients two areas of the company were considered the main departments with possible benefits, Manufacturing and Management tools. (5) Manager EHS Department ...
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...CARIBBEAN EXAMINATIONS COUNCIL REPORT ON CANDIDATES’ WORK IN THE SECONDARY EDUCATION CERTIFICATE EXAMINATION MAY/JUNE 2008 MECHANICAL ENGINEERING TECHNOLOGY Copyright © 2008 Caribbean Examinations Council ® St Michael, Barbados All Rights reserved. -2MECHANICAL ENGINEERING TECHNOLOGY TECHNICAL PROFICIENCY EXAMINATION MAY/JUNE 2008 GENERAL COMMENTS 1 496 candidates were entered for the 2008 examination compared with 1 475 for the 2007 examination. Of the 1 496 candidates entered for the examination 82.34% of the candidates earned Grade III and above. This represented a 1.8% increase in performance over that of 2007. Candidates continue to do well on the practical project for the Internal Assessment component (SBA) but there is still the need for improvement on the written component of the (SBA). The candidates performed poorly on compulsory Question 1 on Paper 02, thus emphasizing the need for urgent attention to be paid to the question which requires candidates to demonstrate knowledge and application of the work done in module B8 of the Unit. DETAILED COMMENTS Paper 01 – Multiple Choice This paper consisted of 60 items testing the theoretical aspects of the Unit. There were 30 items testing the Knowledge profile and 30 items on the Application profile. The topics that most candidates found difficult were: 1. 2. 3. 4. 5. 6. 7. How to prepare work for turning between centres The engineering use of grey cast iron Identification of engineering fasteners Mechanisms used...
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...Q1. Cycle time & other details for ‘Rack cell’ are given below: |M/c no. |M/c |Operation |Cycle time in seconds | | | | |Unload/Load |Inspect |Walk |M/c auto | |1 |CNC turning |Turn 1st side |4 |- |4 |120 | |2 |CNC turning |Turn 2nd side |4 |- |4 |120 | |3 |Milling |Flat milling |6 |- |6 |60 | |4 |Broaching |Rack broaching |8 |4 |6 |40 | |5 |Induction |Rack hardening |8 |6 |4 |35 | | |hardening | | | | | | |6 |Buffing |Rack polishing |4 |4 |4 |40 | a) What is the expected output in a eight hour shift? b) How many persons are required to operate this cell? c) If the expected output is to be doubled; what action do you propose? ...
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...Using of anisotropic bars with a specific orientation of stiffness axis relative to the cutting forces, result in a significance increase in dynamic stability. Another technique involves making solid bars with materials having high youngs modulus or high damping materials. Typical examples include sintered tungsten carbide and sintered tungsten carbide alloyed with copper and nickel. These materials are expensive but give stable machining for l/ratios up to...
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...MOLD CASTINGS Mold casting application is a regular practice in the industry. Casting holds lubricant and enhances the mold life. The IHTC is naturally affected by the coating Alumina, fireclay, graphite are used as coatings. Hamsaid etal evaluated the influence of coating thickness and composition on IHTC which was found to be decrease by 50% as coating thickness increased by 50 to 100 micron miter. Griffith and Kawai showed that the effect of coating thickness varied of the pressure on the metal. Nyuyen etal studied Al-si alloy and reported that an inverse logarithmic relationship between coating thickness and IHTC. Prasanna kumar etal (p-134 vol 4-1990) concludes that the alumina coating of same thickness for all chill materials like Cu, CI and die steel. Hallam (2002) identified five thermal resistances for coated surfaces. Viz between chill and die cavity , die coating , gas voids between the casting and coatings , the area of actual contact between the cooling and casting surface and the oxide film of the casting. Summed up for finding final IHTCis affected by coating conductivity thickness and the type. When coating layer is applied the interface composed of casting , air gap ,coating and mold. The estimation of IHTC becomes very complicated. Narayan Prabhu etal(p-55-vol-2005) proved graphite coating increases heat flux by 20% and coating material on the mold affected significantly on thermal behavior of the mold. Sun etal (99-vol 3-2011) states IHTC is bound to increase...
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