SULTANATE OF OMAN SULTAN QABOOS UNIVERSIY COLLEGE OF ENGINEERING DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING APPLIED MATHAMATIC FOR

ENGINEERS (MEIE 4182) FALL SEMESTER 2011

Industrial Visit Report for

United Engineering Services LLC

Instructor: Dr. Ramanathan Arunachalam

Group names: A) Abdullah AL-Abri B) Muhanna Al-Abri C) Omar Al-Rushaidi 82200 82184 83780

Industry Visit Report (United Engineering Services)

Abstract:
This report was conducted after the industrial visit to united Engineering service machine shop .It describe the manufacturing process that is performed in UES machine shop and the equipment used in the manufacturing process especially CNC(control digital center).It is also contained some information about the manufacturing process used to fabricate the CNC machine components.

Table of contents:

Subject
i. ii. iii. iv. v. vi. vii. viii. ix. Profile of the company UES services UEs machine shop Machine center Vertical machine center Manufacturing process for VMC components UES products(spools) Conclusion References

page
2 2 3 3 4 6 8 9 9

Profile of the company:

United Engineering Services LLC (UES) is a multi-disciplinary Engineering Sales and Oilfield Services company covering the Oil, Gas and Water industries in Oman and the Gulf Region. Established in 1979, UES is among the leading oil field services companies in Oman and is 100% owned by the MB Holding Group. Utilizing its well-equipped facilities at Ghala with satellite operating bases and workshops in Fahud, Nimr and Sur, the UES management expertise, a team of skilled engineers, technicians and experienced sales force guarantee a high level of quality performance and service to its clients and principals.

UES Services:
United engineering services provide a lot of services in machining, welding, designing and testing in the following lines there is a description of these services and UES
         

API Oilfield and General Machine Shops (incorporating premium thread connections such as VAM, NSPT and NKK) Mechanical Design (pressure vessels, heat exchangers, tanks and structures) Welding and Site Services (Fabrication and repair of pressure vessels, tanks, chemical injection skids and other oilfield equipment) Refinery shutdown support services Surface Preparation and Coating Scaffolding, Blasting, Insulation and Painting Contracting Service Instrumentation and Calibration Electric Motor and Generator Rewind Services Rental of Drilling Equipment, Tools, Milling and Fishing Services Licensed Repair Facility for Oilfield Equipment (tools & tubulars)

UES Machine Shop

The UES machine shop offers comprehensive threading, recutting, rework and refurbishment.

The machine shop is equipped with oil country lathes and has CNC capability upto 14.5 inch hollow spindle, boring mills, surface grinders, shaping, drilling and milling machines. Specialized welding and heat treatment, plus a full stress relieving service is provided in conjunction with machining and welding services.

Machining centre(CNC):
A milling machine is a machine tool used to machine solid materials. Milling machines center are often classed in two basic forms, horizontal and vertical, which refers to the orientation of the main spindle. This machine is digitally automated computer numerical control.UES has a vertical machine center which is can machine from simple to complex parts and the company uses a lot during it is manufacturing operations

Vertical Milling Center Machine (VMC):

In the VMC the cutting piece is arranged vertically on the mill and drops down to cut into the material. There are two types of VMC which are turret mill and bed mill. In UES they use bed mill. In the bed mill the table moves only perpendicular to the spindle's axis, while the spindle itself moves parallel to its own axis. The VMC machine components similar to the manuel except that are operate using digital computer by entering the codes in the computers. The basic parts of VMC are: y Spindle: it is provide the rotation to the cutting tool or bit.

The Vice: The Vice is what holds the material which is to be cut or molded. It is important that the vice must be tight; so the material will be held securely and keep the material in the right position.

The Guard: The Guard is work as a protection for the worker who works in the VNC. It protect him from the scrape material that releases when the machining is perform.

The Chuck: The chuck holds the cutting tool. Sophisticated designs require maximum chuck precision so the actual design can be realized.

The motor: The motor rotates the chuck at very high speed. It is hidden and protected inside the machine. Cooling and lubrication is automated in VMC machines. Usually, if this part doesn't function well, it is the most difficult to treat. .

Machine Bed (Lathe bed): The machine bed is the base of CNC machine. It is connected to the headstock and aids the carriage and tailstock to be parallel with the spindle's axis. It is securely bolted so it remains unshaken by the vibration of the machine when it starts operating.

The Cutting tool: This is the where the first-level shaping occurs. The cutter is usually made from high quality steel so as to cut the specific material fed to the CNC machine. There are many types of cutting tools such as:

a. End Mills Commonly used for facing, slotting and profile milling.

b. Rough Cut End Mills For rapid metal removal. c. Slot Drills For producing pockets without drilling a hole beforehand.

d. Face Milling Cutters For heavy cutting.

Manufacturing Process for VMC parts:

The mechanical components of the machine must be have certain properties such as High static stiffness against bending and torsion, good dynamic characteristics as reflected by high natural frequency and high damping ratio, easy in production, good long term dimensional Stability, reasonably low coefficient of expansion, low cost and low material requirements are the basic properties of machine . These properties affect the material and manufacturing process used for the component.

a) Machine bed : The bed of Vertical machine center of UES is made of cast iron. The properties and the density of the cast iron make it suitable for absorbing vibrations which desire in machine bed. For the machine bed the more suitable manufacturing oberation to create it is sand casting. In sand casting there are five basic steps for casting: 1. Pattern making: This step necessary for making the shape of machine bed . A pattern is a duplicate part for the machine bed use to create the mold cavity. 2. Core making: If there is any need to use core to provide the hollow or internal features for the machine bed.

3.

Molding making: In this step the sand and mold are prepared to receive the molten cast iron.

4.

Melting and pouring : The cast iron is melted in Electric-arc furnaces to prepare for melting. Then the melting cast iron is poured in the mold until it solidify. After that the part is removed.

5.

Cleaning: After removing the part from the mold the risers and gate system is removed and the machine is clean and coatings , By that the n=machine bed become ready to assemble with the CNC machine.

b)

Vice: The vice is made from high tensile cast iron that to hold the part accrual and observe the vibrations. The process of manufactured is usually die casting to improve it properties, reduce defect and for mass production.

c)

Guard : Since the guard should protect the user from the scrap materials that fly from the VMC ,It is

manufactured using impact resistant clear polycarbonate and gives good visibility.
6

d)

Chunk: The chunk usually made of hot-rolled steel or aluminum. It made usually by permanent mold

casting methods and the machined by milling machine. e) Motor:

CNC motors manufacturing process is same as other motors process with considering the high speed and minimizes the vibrations of the shaft. The manufacturing processes include stator core assembly (lamination selection, welding ), stator insulating, Stator winding and injection, Stator forming and lacing and machine controls. f) Cutting tools: Because cutting processes involve high local stresses, frictions, and considerable heat generation, cutting-tool material must combine strength, toughness, hardness, and wear resistance at elevated temperatures. These requirements are met in varying degrees by such cutting-tool materials as carbon steels (steel containing 1 to 1.2 percent carbon), high-speed steels (iron alloys containing tungsten, chromium, vanadium, and carbon), tungsten carbide, and diamonds and by such recently developed materials as ceramic, carbide ceramic, and aluminum oxide.

UES Products(spools):
As we mentioned before UES make various types of products such as Tubing Pup Joint, spools, cross-overs, Casing Pup Joint, Millout Extension, Blast Joints and Various premium threaded cross-overs (VAM, NKK, NSIT) etc. In this section we consider spools and we will follow the various operations that it undergoes.

To produce spool it undergoes under several operations: 1) Turning The basic geometry of the spool is created by means of turning in lathe machine

2) Milling/drilling Milling and drilling performed in VMC machine or in the other drilling machines.

3) Honing This process improves the geometry, finish and dimension control of holes in the spool.

4) Edge breaking to ensures that the edges of the spools are sharp but still smooth.

5) Debarring Manual deburring is used to remove ragged edges and protutions.

6) Rough Grinding This undergoes varies machine to smooth the surfacre of the spools by this the final tolerances of the spool was achived .

7) Measuring & testing: In the control room of rhw wnited engineering servicesm is performed during many of the steps in the manufacturing process depending on the tolerance demands. Thread checking performe to ensure that the part met the drawing. Also many other test for harding and other material properties are performed in this stage.

8) Packaging & sales: After the spool is pakged in suitable carton box and it store until it send to the client.

Conclustion:
Through this industria visit the machinies operations and manufacturing process in UES were identfied . Furthere more the equipment and devices that used in this operations were observed. Also the all the facilties and products that company introduced were recognized. it welalty visit that add many things in manufacturing for all of us.

Refrences:
1) Industrila visite for United engineering services LTD in Ghala, Date 19/10/2011 . 2) Gecesevca & Panjan, Light carborad production and cutiing tools life time, 2007. 3) Kinematic systems and operations of lathes, Version 2 ME, IIT Kharagpur 4) Syath Abuthakeer & Mohanram & Mohan Kumar , Structrual Redsigning of a CNC Lathe Bed to Improve its Static and Dynamic Characteristics, Department of Mechanical Engineering, PSG College of Technology, India 5) Standard Machine Shop Guards, NESLA ,England . 6) UES website, http://www.uesoman.com, 7) http://www.indiamart.com/grd-design-technologies/cnc-machine-guards.html 8) http://www.xflzx.com/an-overview-of-widespread-methods-to-produce-plastic-rapidprototypes.html 9) http://www.cnczone.com/forums/diy-cnc_router_table_machines/27319diy_cnc_molds.html 10) http://www.machinesafety.co.uk/nelsa-milling-machine-guards/Page-4/