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Showing content with the highest reputation since 09/27/2021 in Posts

  1. In reply to this post, I created a representation about types of manufacturing processes, process selection and about the latest technologies and processes of additive manufacturing, a very comprehensive and up to date 1-page graphical representation attached on drive with the QR code. Hope you will learn something..
    10 points
  2. 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.
    7 points
  3. 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.
    5 points
  4. 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.
    5 points
  5. 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. Diagram of the pultrusion process. Continuous roll of reinforced fibers/woven fiber mat Tension roller Resin impregnator Resin soaked fiber Die and heat source Pull mechanism Finished hardened fiber reinforced polymer
    4 points
  6. The best way to redesign and understand any thing is reverse engineering. The best possible practise can be done through 3 D scanner and 3D printer. This is how you can actually find what is the fault in any model/predesigned structure.
    4 points
  7. 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.
    3 points
  8. 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. 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. Flange width comparison between resistance spot weld and laser beam weld flange
    3 points
  9. Look at plain of base as flatness into infinite space. With index finger parallel to base x y with z depth. What are mathematical formula and forms can you "see" in graphic detail and what occurs if plain is tilted on 4 nonstandard axial rotation?
    3 points
  10. 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.
    2 points
  11. Smart tools are required for smart innovation, and use nano componen matereals for better production & better quality
    2 points
  12. 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.
    2 points
  13. 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
    2 points
  14. 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.
    2 points
  15. Crystallisation is the transformation of a solution into solid which in turn leads to the nucleation of supersaturated solution. During crystallization well-defined and uniform particle structures are formed.
    2 points
  16. Railways wagon manufacturing requires a high quality steel depending upon application such as for preventing rust iron cannot be used, so stainless steel is used. More research need to be done for rust proof material ,durable and cheaper.
    2 points
  17. Heat treatment is the process which improves physical (mechanical) Properties of the material.depending on the application different heat treatment processes are used. This process increases the product life which directly decreases maintenance cost and failure of the product
    2 points
  18. Hot Rolling It is a production process for getting finished product close to tolerance limit. It involves pre heating, rolling, quenching & tempering. Advantage 1. good surface finished 2. high production rate 3. close to tolerance limit 4. high strength
    2 points
  19. 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?
    2 points
  20. 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.
    2 points
  21. 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.
    2 points
  22. Interchangeability of jigs and fixtures is the essential requirement for shop floor since it helps to save set up time and cost of procurement of new jigs.
    2 points
  23. 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
    2 points
  24. Time is a measurement of motion in space and numbers are based only from geometry use that information WD40 and Duct tape and you can engineer anything even more universes...
    2 points
  25. GB Reid has given some very good advice. The question that remains is simply, is it worth doing? Will the modified support be stiff enough, or should you simply scrap that which you have and start again. I'd advise looking seriously at that question before investing much more time/money in this support. DrD
    1 point
  26. Friction Stir Welding 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.
    1 point
  27. 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.
    1 point
  28. I am especially interested in the use of hydraulic drives as more easily enabling smooth acceleration, giving regulated stall operation, and being entirely fire safe.
    1 point
  29. 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)
    1 point
  30. Need to be focused on the Industrial Revolution. Currently Industry 4.0 impacted to the manufacturing society. But it need to be implemented in the real world scenario to know it's proper impact. Although many researchers working on it but Manufacturing Industries need to be implemented in Indian scenario.
    1 point
  31. Foundry and Castings are the basics of Production Technology, which originated since ancient times. Even the first chapter we studied is this only. Now, very advanced modern techniques evolved, even though the critical structures are manufactured using foundry only.
    1 point
  32. 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 The heat treatment of different gears is a very important n precise process which has an impact on quality n life of the produce.
    1 point
  33. Advanced manufacturing technologies have lead the industry to think about smart materials. The use of sensors and electronic devices has developed the various manufactured products and processes to work on mechatronic systems, fuzzy logic and artificial intelligence.
    1 point
  34. A manufacturing business may need many parts for the complicated assembly of a quality of the product. Keeping production costs to a minimum, having good quality and control with reducing the risk in any of manufacturing.
    1 point
  35. 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.
    1 point
  36. Hello my dear! I'm a new solidwork user. I think You can make a seek on youtube.
    1 point
  37. Check the club section https://mechanical-engg.com/clubs/28-fluid-mechanics/
    1 point
  38. This made me Smile! As I said in my post, I have discussed this and had the detail in the "Seapower" sketches expanded on in the past, so I understand where the diagram is coming from and the idea itself...it is a little "unclear" from the above but the concept IS the "Seapower" diagram, the umbrella, a potential drive facilitator for the bubbles.
    1 point
  39. pms engineers

    Bearings

    PMS Engineers is an established supplier of world class bearings and power transmission products. We are the first-choice channel partners for some of the world’s biggest bearing and lubricant manufacturers including Timken, NSK-RHP, NIKKI, Gamet Bearings and Motherson Sumitomo – Solid Carbide Cutting Tools. With a powerful distribution network and support team in place, we collaborate with clients round the clock to minimize downtime, reduce working costs and improve the overall quality of operations.
    1 point
  40. Hetal Patel

    Bearings

    Types of Bearings There are many specialized types of bearings. Here are a few you might see in your everyday life while making awesome stuff: · “Normal” Radial Ball Bearing – What someone would normally think of as a bearing, with two concentric metal circles separated by little metal balls. These simple bearings can be found in everything from skateboards to drills. · Pillow Block Bearing – These bearings are a radial load bearing encased in a housing that can be attached to a surface parallel to the axis of rotation. · Cam Follower Bearing – A radial load bearing with a threaded rod attached to it. Generally meant to ride on a cam to cause linear motion, these could have other interesting applications. · Ball Bushing (Linear) Bearing – This type of bearing is used extensively to allow for the smooth motion of 3D printer and CNC router heads. Their purpose, unlike the other bearings here, is to restrict radial motion, while allowing smooth linear motion. · Automotive Wheel Bearing – These are generally allowing for both radial and axial load to be overcome. · Thrust Bearings – These have many uses (especially automotive), but lazy susans and bar stools are what immediately come to mind as easy examples of their use. They could also be useful for anything else that needs to rotate smoothly, like a camera panning device.
    1 point
  41. JAG: Only a government could keep a straight face and insist this made any sense. Amen, amen, amen!! DrD
    1 point
  42. Dr. D’s story reminded me of two related stories, then another and then another...but I will stop with two. The follow appeared in the Wall Street Journal 15-20 years ago. The happy ending was that the supplier finally won the court case against the US government. The unhappy part of the story, was that it cost the company much time and money. The article went on to say that a lot of companies go bankrupt from similar situations, but I digress. The government contracted with a commercial supplier to produce a device. The full-up device had a performance specification. The government was to provide the power supply that would be part of the final product. The government was never able to provide a power supply that met the government's own specifications, yet the government expected the supplier to provide an end item that was to specification, using an out of specification power supply. Only a government could keep a straight face and insist this made any sense. The other example can be found at the link below, titled What do you mean you made it as we told you to? https://www.linkedin.com/pulse/what-do-you-mean-made-we-told-joseph-a-gulino-pe?published=t At the above LinkedIn site you will find other articles by me.
    1 point
  43. well in except that both of them are Dassault Systèmes's products . there is a little difference between them. Basically , Solidworks is a CAD (computer aided design) software - the best of it's kind i assume - Simple to manipulate , easy to learn and used by almost every single industry in the world . CATIA is A CAM software , indeed it's better than solidworks in some modules such as surfacing and kinematics. But the main idea is that in CATIA you can not only create a mechanism , but a factory in which it will be produced, the machining processes required, and even you can simulate ergonomics studies as well, like weather the current layout of a plant will be comfortable for workers to work or not. So you can simulate the whole thing within a virtual reality, including, and of course, rendering. However CATIA is almost exclusively used in Aviation and Automotive industries. So there is no doubt you need to learn them both ... because let's say if you want to create an airplane Use CATIA to create the surface and to simulate the manufacturing process and Solidworks would easily handle the engines
    1 point
  44. Waseem, why did you come to NYC without a job in hand to come to? How will you live until you find a job? How will you maintain a professional status if the only job you can find is taxi cab driver, waiter, or similar? Your coming with no job in hand looks like a serious mistake to me. DrD
    1 point





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