Turning Milling Polishing Abrasive jet machining Drilling Electro chemical machining Buffing Ultrasonic machining Planing Electro

Discharge machining Lapping Water Shaping Laser Grinding beam machining jet machining Plasma beam machining Honing Magnetic abrasive finishing Broaching Superfinishing Gear cutting Boring

MECHANICAL ENGINEERING DEPARTMENT MBB 4012 FINAL YEAR PROJECT 1 EXTENDED PROPOSAL

NAME ID PROPOSED TITLE SUPERVISORS

: AHMAD FAIZ BIN MD YUNUS : 12511 : COMPARATIVE STUDY ON MANUFACTURING PROCESSES OF A SWIRLER : AP. DR. IR. MOHD AMIN BIN ABDUL MAJID

Abstract
The project is involved the comparative on machining and casting process for manufacturing the swirler. Both of the processes could be used in manufacturing the swirler with different kind of approach. The selection process done among the wide variety type of machining and casting process which available today. In order to decide the most appropriate manufacturing process, the critical analysis should be carried out by focusing on material selection, process planning including machines, tooling and fixtures requirement. The process is analyses by computer simulation software and support by data from industrial. The process times and cost production of the swirler is expected to below than conventional manufacturing process

TABLE OF CONTENTS

CHAPTER 1: INTRODUCTION
1.1 Objective 1. To analyze the differences between the two manufacturing processes of casting and machining for manufacturing the swirler. 2. To assess the appropriate manufacturing process for the swirler in term of flexibility, reliability, low cost production and less consuming of time. 3. To develop a process planning in order to estimate the process time and cost production. 1.2 Scope of Study The scopes of the study for the project are: 1. To compare the casting and machining process for manufacturing the swirler. 2. To select the proper material and determined process planning including machines, tooling and fixtures requirement for manufacturing the swirler. 3. To estimate the process times and cost requirement to manufacture the swirler. 1.3 Problem Statement A manufacturing process of the swirler can be carried out by both of the processes that been compared which is machining and casting. Basically, both of processes are obviously have different outcome especially in term of cost production and time requirement. Therefore, the study will cover on each type of machining and casting available. However, deciding the right manufacturing process need a critical analysis task but has very little detailed data included due to secrecy policy in each manufacturer company. The available information tends to be sales orientated and again, the data is not sufficiently detailed to indicate the most suitable process in manufacturing process. A study and research need to be conducted in order to increase the productivity and efficiency for manufacturing process of swirler. Analyze will be focusing to find a way to reduce cost and time but still maintain the quality of product in same time

CHAPTER 2: LITERATURE REVIEW

2.1 Type of Machining and Casting Processes

Type of Machining Processes Machining is the process subtracting excess material in the form of chips from a workpiece through a certain type of cutting tool to

achieve the desired geometric dimensions. The machining process can classified into three major type as illustrate in figure 2.

Figure 2: Classification of Machining Processes [2]

Type of Casting Processes Casting process can be defined as a manufacturing process involves pouring of liquid metal into a mould cavity and then allowing it to solidify. The final shape of the metal was determined by the shape of the mould cavity. The solidified metal is also refers as a casting. The casting processes can be broadly classified by the type of mould used as illustrate in figure 8. The expandable mould is non reusable mould and usually destroyed to remove out the solidified cast. In contrast, the permanent can be reuse to make other casting.

Figure 8: Classifications of Casting Processes

2.2

Parameter

of

selection

Machining

and

Casting

Processes Machinability In order to accomplish the manufacturing process effectively, efficiently and economically, there are parameters need to follow in manufacturing process. For machining process, the selection of process depends on machinability of the workpiece. The term machinability is used for rating workpiece material respect to type of cutting tool material, geometry, and type of machining operation. In the other words, machinability can be defined as [ ]: The ability of the work material to be machined, How easily and fast a material can be machined, and Material response to machining. A good machinability material will be had criteria as per below: a. Low power consumption

The forces required to cut the workpiece related to the rate of power consumption by machine tool. A good machinability material needs only little electrical power consumption for removal part. b. Shorter process time The machining process is done smoothly and easily. c. Good surface finishing Type of material which is not suitable for the particular machining process tends to form build up edge (BUE) which give the poor surface finishing. d. Long tool life. The tool does not wear too much due to machining process and allowing the tool life last longer.

Figure: Parameter of machinability Castability The term castability is used to refer of ease of producing casting without a defect at minimum cost and lead-time. The castability can achieve by doing the process at high compatibility between the process and material properties. The major factor s that influenced castability explained in detail as follow: a) Material selection According to Prof. Dr. Ahmet Aran, the properties of material that influenced the castability are: i. Low melting point: The material has low melting point is better due to casting temperature has to higher than melting temperature. If melting temperature is too high, the mold material has to be more refractory and probably expensive.The temperature also must be controlled according to casting technique and the complexity of the casting. ii. Good Fluidity: An ability of metals and alloys to flow through the gating system filling the cavity of the casting mold and conforming its shape. iii. Low specific heat: Less energy requirement to reach melting temperature and fast solidification process.

iv. Low latent heat of fusion: Less energy required to change material state to another state. v. Low viscosity and Low surface tension: The metal cast fill better the mould cavity. vi. Shrinkage: For measurement shrinkage allowance for the pattern. vii. Low chemical affinity: No reaction between materials with environment. viii. High thermal diffusivity: Rather than conductivity, thermal diffusivity determined the rate of disturbance to heat travel in material. ix. Resistance to crack formation: Material should have high ductility. b) Geometry Designing Product geometry will be determined the complexity of process, tool used and cost effective. c) Surface quality According Dmitri Kopeliovich, surface quality determined by: The surface quality of the mold walls, The mold coating material properties, Gassing of the mold or coating materials, Chemical reaction between the mold material and the alloy, Casting pressure.

Figure: The major factors influenced castability material

2.3

Process

Equipment

for

Machining

and

Casting

Processes Machining Process Equipment A. Drilling machine Drilling machine used for producing circular hole in the workpiece by using rotating cutter called drill. The machine can performed some operation as illustrate in the figure below:

Figure: Operation can be performed by drilling machine.

B.

Milling machine.

Milling is the process removal material by feeding a workpiece pass through a rotating multiple tooth cutter. Milling machined can produced slots of various shapes, making flat surfaces, grooving, slitting, and parting. C. Grinding machine

The grinding usually applied when material is too hard to be machined or the workpiece need high accuracy parameter and small tolerances value. On that reasons, the major advantages of grinding process is has high dimensional accuracy, good surface finish, good form and applicable to both hardened and unhardened material. In grinding, an abrasive tool is forced to rub against the workpiece in order to remove a very small amount of material. D. Lathe machine

Lathe machine been used for reducing the outside diameter of cylindrical workpiece. It performed the process called turning, in which the workpiece is rotated and a single-point cutting tool is brought against it. The machine also capable performed of drilling, boring, thread cutting, and other operations.

Casting Process Equipment In casting process, the raw materials are considered as formless substance as liquid and being poured into mould to become solid body. In this technique, the mould is acting as manufacturing equipment whereas the raw materials been used called sintering which come in powder or granular form. For this project, the expandable mould will been used rather than permanent mould due to only need for one unit production and lower cost needed. A general picture of the casting techniques available for production is given in Figure

Figure: Casting production techniques

2.4

Process Tool for Machining and Casting Processes

Machining Process Tool The process tool for machining are depend on process been done. Stated below are the processes involved in manufacturing of swirler to represent the cutting tool needed: a) For cylindrical part Face Milling In face milling, the cutter is mounted on a spindle having an axis of rotation perpendicular to the workpiece surface. The milled surface results from the action of cutting edges located on the periphery and face of the cutter. End Milling The cutter in end milling generally rotates on an axis vertical to the workpiece. It can be tilted to machine tapered surfaces. Cutting teeth are located on both the end face of the cutter and the periphery of the cutter body. Surface contouring This kind of operation is performed by computer controlled milling machines in which a ball-end mill is fed back and forth across the workpiece along a curvilinear path at close intervals to produce complex three-dimensional surfaces. Turning process Turning is the removal process of the outer diameter for cylindrical in part shape by a single point cutting tool using

lathe machine. In this project, the type of turning operations will be done are: Taper turning: the cutting tool allocated in certain inclined angle to get tape shape. Cutting-off: used for parting or cutting off a section of the workpiece. Straight turning: Used for reducing the diameter of a part to a desired dimension. The resulting machined surface is cylindrical

a) For hole part Drilling Drilling is the process of using a multi-point tool to penetrate the surface of a workpiece and make a round hole. The type of drilling process involved as followed: Spot drill: This process used to make a mark for hole part. Center drill: A short & stubby drill to produce holes so that work piece can be mounted between lathe center. Twist Drills: To remove the maximum volume of metals in a minimum period of time. It does not produce a precision hole: however, this can be achieved by a reaming operation. Boring Boring is the process of enlarging a hole that has already been drilled. A boring tool can be inserted into the drilling machine and bore any size hole into which the tool holder will fit. A boring bar with a tool bit installed is used for boring on the larger drilling machines. To bore accurately, the setup must be rigid, machine must be steady, and power feed must be used. Reaming Reaming process can be performed by drilling machine. The process will ensure the hole of workpiece has better tolerance of its diameter and to improve surface finish.

CHAPTER 3: METHODOLOGY
Process flow chart

REFERENCES

1. Reference: Groover M.P., (1996),Fundamentals of Modern Manufacturing, Materials, Processes and Systems, International Editions, Prentice Hall. 2. Casting machine. Retrieved Feb 22,2013, from The KVT : http://www.kvt.sjf.stuba.sk/WEB/02_chapter.pdf 3. M F Ashby, Material Selection in Mechanical Design, Butterworth-Heinemann, 1999. 4. M. F. Ashby, Materials Selection in Mechanical Design, 2nd Edition, Elsevier, new Delhi, 2005 5. Todd, H. Robert; Allen, K. Dell; Alting, Leo (1994), Manufacturing Processes Reference Guide (1st ed.), Industrial Press Inc., p. 198-199, ISBN 0-8311-3049-0.