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Manufacturing & Production technology online conference Oct 5th to 14th 2021


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Attn  Conference extended till 14th Oct 21

Guidelines & Rules for open ended conference 

Write one statement or few lines related to (any) Manufacturing & Production technology which may include 

  • process introduction
  • application 
  • Cost benefit analysis
  • pros and cons 
  • Diagrammatic representation 
  • latest trends
  • And.....no limits

 

  • Collective (joint) effort from all participants should be such that, none of the topic remain untouched.
  • Your creative and innovative approach will lead to an interesting presentation in just few sentences.
  • Do not repeat which has been already posted before your post 
  • Preference to English language only 
  • Do not post twice... If needed edit your already written post. 
  • 3 Participants each from Lucky draws will be chosen and awarded Amazon gift card $10 (750 INR), but they must have 5 likes to their posts 

 

Look forward for your active participation... and please do encourage all your mechanical engineer friends to participate 

Please appreciate the post of other members by liking the same.

I am writing the first statement to give it a start 

Gears can be manufactured by a variety of processes, including casting, forging, extrusion, powder metallurgy, and blanking.

Next member can chip in to extend his talk on the gear manufacturing or can write on other manufacturing process.

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One innovative aspect relates to the possibility of using solid state laser cooling to accelerate by leaps and bounds what seems to be the main bottleneck in metallurgical  (or any material ) formation / fabrication (starting from extraction) processes, i.e the thermodynamic aspects of heating / cooling (which can now be carried out using precisely controlled laser power pulses / waves 

 

I am reposting this though i had posted the same as a reply to another comment since i was not sure about the formalities

One innovative aspect relates to the possibility of using solid state laser cooling to accelerate by leaps and bounds what seems to be the main bottleneck in metallurgical  (or any material ) formation / fabrication (starting from extraction) processes, i.e the thermodynamic aspects of heating / cooling (which can now be carried out using precisely controlled laser power pulses / waves 

 

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Industrial safety cannot be overemphasis in manufacturing process.High degree of safety can only by achieved only by ensure every opportunity is geared to create awareness among people and adequate fire consciousness trainings to all stakeholders.

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MANUFACTURE OF PLASTIC COMPONENTS FOR AUTOMOBILE BODIES

Amidst increasing fuel prices and its impact on the environment, electric vehicles are finding a permanent spot in every garages these days. While advances are being made every day in terms of battery and motor performances in these vehicles, as a mechanical design engineer, one can start looking for suitable materials for the manufacture of vehicle bodies. While traditional steel and aluminium structures are being replaced by plastics, the manufacturing process for the same is a topic worth mentioning. Let us take a look at one of the most widely used manufacturing process for a typical thermoplastic component: Injection Moulding.

INJECTION MOULDING

Injection moulding is the most widely used process for the high-volume production of relatively complex thermoplastic parts. In this process, plastic material is melted and injected into a mould to create a part. Once this part cools, the mould opens, and the part drops out.

Granules of raw material are fed by gravity from a hopper into a cavity that lies ahead of a moving plunger. As the plunger advances, the material is forced through a preheating chamber and on through a torpedo section, where it is mixed, melted, and superheated. The superheated material is then driven through a nozzle that seats against a mould. Sprues and runners then channel the molten material into one or more closed-die cavities. Because the dies remain cool, the plastic solidifies almost as soon as the mould is filled.  The mould halves must clamp tightly together during moulding and then be easily separated for part ejection.

Injection moulding is an established process for many exterior automotive components, including fenders, grilles, bumpers, door panels, floor rails, light housings, etc. Other applications include instrumentation components, interior surfaces, dashboard faceplates, door handles, glove compartments, air vents etc.

NOTE: Hand drawing sketch of the injection moulding process has been attached along with this write up.

IMG_20210824_194221.jpg

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Manufacturing n Production industry is back bone of economy for industrialised world.The day to day challenges should be tackled thru the human experts and available digitalised resources to achieve higher efficiency n productivity ratio within the quality assurance stds

On 10/5/2021 at 3:28 PM, admin said:

Guidelines & Rules for open ended conference 

Write one statement or few lines related to (any) Manufacturing & Production technology which may include 

  • process introduction
  • application 
  • Cost benefit analysis
  • pros and cons 
  • Diagrammatic representation 
  • latest trends
  • And.....no limits

 

  • Collective (joint) effort from all participants should be such that, none of the topic remain untouched.
  • Your creative and innovative approach will lead to an interesting presentation in just few sentences.
  • Do not repeat which has been already posted before your post 
  • Preference to English language only 
  • Do not post twice... If needed edit your already written post. 
  • 3 Participants each from Lucky draws will be chosen and awarded Amazon gift card $10 (750 INR), but they must have 5 likes to their posts 

Look forward for your active participation... and please do encourage all your mechanical engineer friends to participate 

Please appreciate the post of other members by liking the same.

I am writing the first statement to give it a start 

Gears can be manufactured by a variety of processes, including casting, forging, extrusion, powder metallurgy, and blanking.

Next member can chip in to extend his talk on the gear manufacturing or can write on other manufacturing process.

The heat treatment of different gears is a very important n precise process which has an impact on quality n life of the produce.

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We have found casting some of our parts makes them able to handle much higher torque levels. We are always keen to use the best possible components for the Thompson Couplings to enable us to offer a reliable, maintenance free option. Having the end users in mind and thinking of their- experience and needs for their production or plant at the heart of decisions creates a much more reliable, long lasting quality product. Focus should always be the customers needs and quality products. We have also used 3D printing to create samples.

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Screw compressor is one of the most used compressor in industrial air production. Most important and most neglected part of the screw compressor is air filter. For the other spare parts like oil filter, oil separator, cooling oil we remain alert, but normally we do not care about air filter mostly. Just clean it mostly..... 

Damaged Air filter cause maximum problem of the compressor. As it can not be cleaned so good. So timely replacement of the air filter is the best practice to run the screw compressor in good condition.

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Modern CAD CAM practices have enhanced our engineering capabilities as compared to earlier methods such as using mock ups, by being able to achieve high standards of work, quality of work and cutting the cost of production in the long run. Quick question though, does reverse engineering protect intellectual property rights?

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Laser Beam Welding

Laser beam welding (LBW) is a welding technique used to join pieces of metal or thermoplastics using a laser. The beam provides a concentrated heat source, allowing for narrow, deep welds and high welding rates. The depth of penetration is proportional to the amount of power supplied but is also dependent on the location of the focal point.

image.png.27597121025f9afd6a960d873031029f.png

Audi Q5 aluminum tailgate with weld [Pic Source]

 

Laser Welding – Key Benefits

       Can be easily automated using a CAD/CAM setup.

       No electrode is used in the process and no form of tool wear occurs.

       High level of accuracy and ultimate precision.

       High-quality welds are obtained through the use of a laser, capable of creating complicated joints.

       The beam provides a concentrated heat source, allowing for narrow, deep welds and high welding rates.

       Weight saving potential due to reduced flange sizes.

 

Weight saving can be achieved by the modification of the flanges. While a spot weld connection usually requires a flange width of about 16 mm for all bonded parts to guarantee accessibility for the spot welding gun, a laser beam weld necessitates only circa 8 mm of flange width, since the laser gun itself does not need to physically access the flange.

 

image.png.484deeabecb141700e58fb88bc3332ee.png

Flange width comparison between resistance spot weld and laser beam weld flange

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For manufacturing ideas, I think we should has new side view about the purposed a product created in manufacturing line. In decade we can see pandemic (specially sars Cov. 2) has made impact for role maufacturing produces. They iterally choose robotic and AI (Automation inteligent) for their main production line. If we don't update our knowledge , we never know how it happen and only know how it used to . (SFMBE)

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I am from Air Filtration industry segment. We will discuss on filter classification. There are 3 simple rule of filter classification. (As per latest ISO 16890:2016)

1. Reported efficiency- It is an average between initial and discharged efficiency.

2. To be able to report - Initial new efficiency needs to be over 50%

3. Discharged efficiency needs to be over 50% (ePM 1 and ePM 2.5)

Other applicable standards in air Filtration industry are EN779:2012, EN 1822-5 (For high efficiency filters) and ASHRAE 52.2 - 2017.

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I am involved in the mining industry over 38 years and in my travels world wide and not mentioning any specific OEM the reliability, durability with high production and low maintenance costs is the highest priority for all of them. Huge costs is used every year by these OEM`s to improve on their equipment and machinery using IoT and even go autonomous.

Everyone is actually missing 1 important point " The Human Factor" , 75% of machinery breakdowns is directly linked to human error causing self inflicted breakdowns.

Some of the machines have very sensitive and state of the art hydraulic systems and control valves with tolerance's less than 4 microns. All this help nothing if the system is not maintained properly and parts / components is not replaced in a 100% clean manner and correct tightening torques ect.

When talking about lubricants in use there can be a million of books written about it but the basics stays the basics. Keep hydraulic oil clean, below 80 degrees Celsius, correct viscosity, correct grade and regular sampling tests. 

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Product Development of production machinery is expensive and time consuming, building a machine and throwing it into production with minimal testing can be risky and rewarding at the same time.  Once you have started to produce a consumer product and a customer demand, it can be detrimental to the business when your proprietary machinery breaks down at regular intervals or for long periods of time, causing unpredictability in your supply chain.  It is good if possible to have multiple machines that produce the same product so that downtime is available for maintenance, repair, and upgrade without compromising the supply of product to your customer.  

Many times in my career, I have been asked to build a machine or device to accomplish a specific purpose.  Before I start designing, I do a thorough investigation to see if there are any machines that accomplish the same or similar purpose.  On many occasions I have made some minor modifications to an existing machine that was readily available to accomplish the objective of my project.  By doing this I can harness the time that the manufacturer has invested in the development of that machine and avoid costly down time. 

In the recent past, I was tasked to design and produce some custom conveyors that need to be a size that was a few inches wider than anything available in the time frame that they were needed.  I gave it my best effort and we produced hundreds of thousands of dollars worth of conveyors and put them into production.  I based my design off of a conveyor that we had purchased and made enough changes in the construction methods to avoid any patent infringement.  I missed one key element, the leg weldments of the existing conveyor is a substantial weldment that provides stability and keeps the frame of the conveyor square.  I designed the legs for my conveyor out of bent sheet metal and minimal welding that bolt together to allow them to be disassembled for shipping. Unfortunately they do not have structural ability to keep the roller support frame of the conveyor square.  We discovered that if the line of conveyors got bumped by a forklift, it was possible for the frames of the conveyors to be out of square enough to cause resistance in the rollers and cause a high load fault in the electrical drive.  I was aware of the issue and designed a brace to add to the roller support frame, but was never given the time or the resources to add it to the many conveyors that had already been placed in production.  I have since been informed that they have discontinued use of these conveyors and have replaced them.  

Lessons learned: Build a prototype and thoroughly test it before rushing into production. Shortcuts often cause more problems in the long run. The devil is in the details, some of the smallest issues that seem inconsequential can kill the whole project. The process of Product Development is expensive and takes time, just because you have the capability to build something doesn't mean that you should.  

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On 10/5/2021 at 3:58 PM, admin said:

Guidelines & Rules for open ended conference 

Write one statement or few lines related to (any) Manufacturing & Production technology which may include 

  • process introduction
  • application 
  • Cost benefit analysis
  • pros and cons 
  • Diagrammatic representation 
  • latest trends
  • And.....no limits

 

  • Collective (joint) effort from all participants should be such that, none of the topic remain untouched.
  • Your creative and innovative approach will lead to an interesting presentation in just few sentences.
  • Do not repeat which has been already posted before your post 
  • Preference to English language only 
  • Do not post twice... If needed edit your already written post. 
  • 3 Participants each from Lucky draws will be chosen and awarded Amazon gift card $10 (750 INR), but they must have 5 likes to their posts 

Look forward for your active participation... and please do encourage all your mechanical engineer friends to participate 

Please appreciate the post of other members by liking the same.

I am writing the first statement to give it a start 

Gears can be manufactured by a variety of processes, including casting, forging, extrusion, powder metallurgy, and blanking.

Next member can chip in to extend his talk on the gear manufacturing or can write on other manufacturing process.

As in forging there are two types o forging, hot forging and cold forging.

The gear is manufactured by either way, each way has its pros and cons.

I'll state about cold forging, it is a new method of gear manufacturing, not as new as state of the art but it is quite rarely used.

by cold forging of gears there are various stresses generated as metal is not adequate to deformation. Thus it is point of advantage if you want to develop compressive stresses as to improve the fatigue life.

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First day at work in a new Company and my director says that our main customer requires us to implement a Production Part Approval Process (PPAP) for their particular product stream.

My director says he doesn't particularly want, or have the time to be involved and can I just get on with the implementation?

This happened to me and was as perfect a Company introduction process as it would be possible to have!

Straight into meeting and discussions with relevant staff, introducing all the relevant quality and production control documentation, presenting the finished process to the customer and getting the initial sign off first time.

After 40 years in manufacturing it's great to still be able to learn and make progress

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There are dependencies at every level of manufacturing, consistent reliable construction materials being one of the most critical to positive results.  There has been a disturbing trend of sub-standard steel deliveries world wide, vendors cutting corners on specified deliveries.  In at least two cases structural components in completed buildings have been found sub-standard After the major structure was up, and steel delivered for component manufacturing is widely unreliable and out of standard. It is now necessary to keep an inspection crew testing deliveries, and in the case of large foreign shipments an inspection crew needs travel to inspect the steel Before shipment from marshaling yards.  

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  • admin changed the title to Manufacturing & Production technology online conference Oct 5th to 14th 2021

Manufacturing method for Composites - Pultrusion

The process of Pultrusion is utilised for the manufacture of the components which have a constant cross-sectional shape ( beams, rods, tubes etc.),and continuous lengths. In Pultrusion process, thermosetting resins are first used to impregnate continuous fiberrovings or tows; then they are pulled through a steel die which then provides the required shape to the stock and also sets the ratio resin/fibre. After this, the stock is then passed through a curing die which is precision machined so that it can give the final shape to it. This die is also heated to start curing of the resin matrix. Then the stock is drawn through the dies with the help of a pulling device. This step also determines the production speed as well. Glass, Aramid fibres and carbon are primary reinforcements materials, usually added in concentrations of approximately ranging from 40 and 70 vol%. The matrix materials commonly used in this process are polyesters, vinyl esters, and epoxy resins.

600px-Pultrusion_process_01.png

                                                                           Diagram of the pultrusion process.

  1. Continuous roll of reinforced fibers/woven fiber mat
  2. Tension roller
  3. Resin impregnator
  4. Resin soaked fiber
  5. Die and heat source
  6. Pull mechanism
  7. Finished hardened fiber reinforced polymer
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The Fourth Industrial Revolution (4IR or Industry 4.0) is the ongoing automation of traditional manufacturing and industrial practices, using modern smart technology. Large-scale machine-to-machine communication (M2M) and the internet of things (IoT) are integrated for increased automation, improved communication and self-monitoring, and production of smart machines that can analyze and diagnose issues without the need for human intervention. (e.g. 3 D printing deploying basic mechanical processes like metal powder spray done using smart automation.)

Best of Mechanical to collaborate with latest of digital to produce Mecha-digital outcomes.

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Friction Stir Weldingimages(3).jpg.83b7c4f287053c236da36e08a8ec8ed3.jpg

Manufacturing companies dealing with high stress and pressure [aerospace], typically avoid welds, because of the weakness it creates in the metal and its limitations. 

But mastering friction stir welding could result to a much stronger bonds than traditional welds. 

As you can join large, thin sheets of metal [ex. Light-weight alloys], and shave off pounds of weight by avoiding the use of rivets, fasteners, and other support structures. 

Making the manufactured device /machine, lighter and stronger. 

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