SYNOPSIS ON PROFESSIONAL PRACTICE PROJECT

(GEAR, INDUSTRIAL VISIT & EXPERT LECTURE)

The traditional gear machining methods such as hobbing and shaping pose limitations on
manufacturer's ability to efficiently manufacture gears in small and medium batches. In recent
years, two new gear machining methods have been developed that allow use of standard multi
tasking machines and standard tools to provide a solution to these limitations. This paper
describes the two techniques and compares their quality and production times with those of
traditional gear manufacturing techniques. The paper discusses additional benefits of the two
new methods in enabling new gear design strategies and efficient machining of special gear
forms. In conclusion, it was found that the new methods are capable of providing better quality
gears than the traditional methods in pre heat operations. While there is no single method which
gives the best cycle time for all gears, multi tasking machines provide the flexibility to use the
method that best satisfies customer needs.

In this project, I will produce the learning outcome from the industrial visit.

I will also conclude the technical knowledge which I will gain through the technical seminars
and expert lecture groups.
SYNOPSIS ON PROFESSIONAL PRACTICE PROJECT
(HEAT TREATMENT, INDUSTRIAL VISIT & EXPERT LECTURE)
Heat Treating Metals - Basically, heat treatment of steel consists of raising the material some
specified temperature. The process is performed to change certain characteristics of steel to make
them more suitable for a particular kind of service. Some of the reasons for heat treating are:

1. To soften a part so that it can be machined more easily

2. To relieve internal stresses so that a part will maintain its dimensional stability (i.e., not warp
or fail prematurely due to locked-in stresses)

3. To refine the grain structure so that the part will be less apt to fracture abruptly (or to toughen)

4. To thoroughly harden a part so that it will be stronger

5. To case harden a part so that it will be more wear resistant

Heat Treatment Processes: Annealing: Generally refers to the heating and controlled cooling of a
material to remove stresses, make it softer, refine its structure, or change its ductility, toughness,
or other properties.

Carburizing: Adding carbon to iron-base alloys by absorption through heating the metal at a
temperature below its melting point in contact with carbonaceous materials. Such treatment
followed by appropriate quenching hardens the surface of the metal. This is the oldest method of
quenching.

Flame hardening: In this method of hardening, the surface layer of a medium- or high-carbon
steel is heated by a high-temperature torch and then quenched.

Induction hardening: A hardening process in which the part is heated above the transformation
range by electrical induction.

Nitriding: Adding nitrogen to solid iron-base alloys by heating at a temperature below the critical
temperature in contact with ammonia or other nitrogenous material.

Hardening (as applied to the heat treatment of steel): Heating and quenching to produce
increased hardness and increased strength, respectively.

Normalizing: Heating to about 100°F above the critical temperature and cooling to room
temperature in still air. Provision is often made in normalizing for controlled cooling at a slower
rate, but when the cooling is prolonged, the term used is annealing.
Stress relieving: Reducing residual stresses in a metal by heating to a suitable temperature for a
certain period. This method relieves stresses caused by casting, quenching, normalizing,
machining, cold working, or welding.

Tempering: Reheating after hardening to a temperature below the critical temperature and then
cooling.

In this project, I will produce the learning outcome from the industrial visit.

I will also conclude the technical knowledge which I will gain through the technical seminars
and expert lecture groups.
SYNOPSIS ON PROFESSIONAL PRACTICE PROJECT
(USE OF PLASTICS IN AUTOMOBILES, INDUSTRIAL VISIT & EXPERT
LECTURE)
The application of polymeric materials in automobiles is constantly increasing and this trend is
expected to continue. The key factors in selecting the polymeric materials in relation to other
materials applied in automobiles are the today's appearance of automobiles, their functionality
and more economic manufacture, as well as reduced fuel consumption. Although the reduction
of the mass of parts is the main reason of choosing polymeric materials, the future growth of
their usage will result in new applications in automobiles related to comfort, safety and
possibility of parts integration. The application of polymeric materials allows more freedom in
design, and in many cases only these materials can allow safe geometrical or economic solution
for the construction of parts. The automobile parts which are made of polymeric materials are
divided into four categories: internal parts, external parts, parts in the engine compartment, and
bodywork and engine parts.

The automotive industry is on the brink of a revolution, and the plastics industry poised to play a
major role. The real plastics revolution in automotive industry began in 1950 when
thermoplastics made their debut, starting with ABS and going on to polyamide, polyacetal and
polycarbonate together with introduction of alloys and blends of various polymers. The ongoing
development of advanced, high-performance polymers has dramatically increased their usage.
Originally plastics were specified because they offered good mechanical properties combined
with excellent appearance, including the possibility of self-coloring. The application of plastic
components in the automotive industry has been increasing over the last decades. Nowadays, the
plastics are used mainly to make cars more energy efficient by reducing weight, together with
providing durability, corrosion resistance, toughness, design flexibility, resiliency and high
performance at low cost.

The automotive industry uses engineered polymer composites and plastics in a wide range of
applications, as the second most common class of automotive materials after ferrous metals and
alloys (cast iron, steel, nickel) which represent 68% by weight; other non-ferrous metals used
include copper, zinc, aluminum, magnesium, titanium and their alloys (Fig. 2). The plastics
contents of commercial vehicles comprise about 50 % of all interior components, including
safety subsystems, door and seat assemblies.

In this project, I will produce the learning outcome from the industrial visit.

I will also conclude the technical knowledge which I will gain through the technical seminars
and expert lecture groups.
SYNOPSIS ON PROFESSIONAL PRACTICE PROJECT
(LATHE MACHINE, INDUSTRIAL VISIT & EXPERT LECTURE)
The challenge of modern machining industries is mainly focused on the achievement of high
quality in terms of dimensional accuracy, surface finish, high production rate, less wear on the
cutting tools, economy of machining and increase in the performance of the product with
reduced environmental impact. Surface roughness plays an important role in many areas and is a
factor of great importance in the evaluation of machining accuracy. Till date many researchers
have developed mathematical models to optimize the cutting parameters to get lowest surface
roughness by turning process. The variation in alloying elements present in the work piece
material and their mechanical properties, workpiece and tool material combination, vibration
between work piece-- machine tool--cutting tool combination, lubricants used and process
parameters such as speed, feed, depth of cut, tool geometry affect the surface roughness and tool
wear. Turning has emerged as a viable alternative to grinding for finished machining of hardened
steel due to its reduced capital cost, multi operations in single chucking, reduced setup times,
faster cycle time, high precision, easy automation, less electricity etc. A major factor leading to
the use of hard turning in place of grinding has been the development of carbide cutting tools,
which enable machining of high-strength materials with a geometrically defined cutting edge.

Since dry hard turning reduces machining time, it not only saves the cost but also reduces
environmental pollution, as there is no coolant to be disposed off. Finished hard turning is
increasingly used in industrial applications and hence there is a need for further exploration in
order to improve the productivity and to provide a wide database useful to industries.

In this project, I will produce the learning outcome from the industrial visit.

I will also conclude the technical knowledge which I will gain through the technical seminars
and expert lecture groups.