Ali Ubaid-284951-C
Ali Ubaid-284951-C
Ali Ubaid-284951-C
PRACTRICAL HANDOUTS
ME-223 Advance Workshop Practice 1-1
Ali Ubaid
284951
ME-41-C
ME-223 Advance Workshop Practice (Lab Manual)
Table of Content
3. CNC
Description of CNC Lab layout and Overview of Computer Integrated
Manufacturing (CIM) System.
Usage of CNC lathe and CNC milling machines.
Part Fabrication using CNC machine.
4. 3D Scanning.
7. Forging.
8. Casting.
Centrifugal Casting and Sand Casting.
Introduction to Advanced Workshop
Workshop practice is a very vast one and it is very difficult for anyone to claim
a mastery over it. It provides the basic working knowledge of the production and
properties of different materials used in the industry. It also explains the use of
different tools, equipment’s, machinery and techniques of manufacturing, which
ultimately facilitate shaping of these materials into various usable forms. In
general, various mechanical workshops know by long training how to use
workshop tools, machine tools and equipment. Trained and competent persons
should be admitted to this type of mechanical works and permitted to operate
equipment.
This molten metal poured into mould to give commercial casting called ingots
From suitable process to obtain usable metal product of different shapes and sizes
Some of these finish the product to its usable form whereas others do not and it
requires further working to finish the component to the desired shape and size.
Wire drawing lead to the directly usable articles, which do not need further
processing before use.
Casting, forging, bending, rolling, drawing, power metal forging, etc.
Large number of components need further processing after primary processes known
as secondary operation to obtain desired shape and dimensional accuracy. These
operations require the use of one or more machine tools, various types of cutting
tools and cutters, job holding devices, marking and measuring instruments,
testing devices and gauges etc. Common machining operations are: Turning,
Threading. Drilling, Boring, Planning, Shaping, Sawing, Milling, Grinding,
Slotting, etc.
These processes are used for joining metal parts and in general fabrication work.
Such requirement usually occur when larger lengths of standard sections are
required or several pieces are to be joined together to fabricate a desired structure.
Common processes are Welding, Soldering, Brazing, Riveting, Screwing,
Pressing, etc.
2.1 Aim: To find the volume of rectangular block by using a Vernier calipers.
2.2 Aim: To find the thickness of the given wire and sphere using a screw
gauge and hence to find their volumes.
Apparatus: Screw gauge, thin wire, small sphere and meter scale.
Zero error=-------------------div
= --------- mm
Mean d= mm
Radius of the wire,r=d/2= -------- mm
Volume of the wire,V= πr2h
=----------
= ----------------- mm3
= -------------------- m3
1
2
3
4
5
6
Mean d= mm
Radius of the sphere,r=d/2
= ---------- mm
Volume of the sphere,V=(4/3) πr3
=---------------- mm3
= --------------- m3
Procedure:
1. Measure the Zero correction and least count of screw gauge.
2. Measure the diameter of the given wire and sphere using screw gauge
3. Find PSR,HSR and CHSR using screw gauge
4. Calculate PSR+(CHSRxLC).
5. Measure the length of the given wire by using metre scale.
6. Find volume of wire and sphere using the formulae V=
πr2h& V=(4/3) πr3
7. Repeat the experiment 4 or 5 times
Precautions:
But for CNC machine tape is fit once and the program is stored in the
memory and can be run repeatedly to produce repeated jobs. CNC or
computer numerical control is an NC system that employs a dedicated
microcomputer as a machine control unit.
1. Hardware,
2. Software and
3. Information.
1. Hardware:
A Hardware includes microprocessors that affect control system functions
and peripheral devices for data communication, machine tool status
monitoring and machine tool interfacing.
2. Software:
The software includes programs that are performed by system
microprocessors and there are different types of software associated
with CNC.
3. Information:
1. Input devices
2. Machine control unit (MCU)
3. Machine tool
4. Driving system
5. Feedback system
6. Display uni
1. Input Devices:
These are devices that are used to input the part program into a CNC
machine. There are three generally used input devices and these are
punch tape reader, magnetic tape reader and computer via RS-232-C
communication.
2. Machine Control Unit (MCU):
Machine control unit called the heart of the CNC machine. It performs all the
control functions of the CNC machine, there are various tasks performed by
MCU are.
It reads the coded instructions given in it.
A CNC machine tool always has a sliding table and a spindle to control the
position and speed. The table of the machine is controlled in the X and Y-
axis direction and the spindle is controlled in the Z-axis direction.
4. Driving System:
The driving system of a CNC machine include of an amplifier circuit, drive
motors and ball lead screws. The MCU supplies the signals (i.e., of position
and speed) of each axis to the amplifier circuits. The control signals are
then augmented (increased) to actuate the drive motors. And the actuated
drive motors rotate the ball lead screw to put in a position the machine
table.
5. Feed Back System:
The feedback system has the transducers that act as sensors. It is also
called a measuring system. It consists of position and speed transducers
that continuously monitor the position and speed of the cutting
tool located at any given moment. The MCU receives signals from
transducers and it uses the difference in reference signals and feedback
signals to generate control signals to correct position and speed errors.
6. Display Unit:
The MCU processes all the data and according to the program prepared, it
prepares all the motion commands and gives it to the driving system.
The drive system acts as motion commands sent by the MCU. The drive
system manages the motion and velocity of the machine tool.
The feedback system records the position and velocity measurements of the
machine tool and gives a feedback signal to the MCU.
In the MCU, the feedback signals are compared with reference signals
and if errors occur, it corrects it and sends new signals to the machine tool
to be corrected.
The display unit is used to see all the programs, commands, and other
data. It works like the eye of the machine.
It consists of two separate controls, a CNC controller that doses the function
of program decoding interpolation, diagnostics machine actuation, etc.
Another is the programmable logic controller (PLC), which dose spindle on-
off, coolant on-off, turret operation etc. Slides are transferred via their own
feed drive (AC or DC) servomotors or ball screws and nut drives. The feed
drive controllers the feed drive motors. Suitable transducers have been fitted
to either the table or the motor, which measures the slide position. Also, the
position is monitored and checked through the feedback transducers to
ensure the accuracy of positioning. The spindle is provided with stepped
motors of AC or DC. A suitable control is used to vary is the speed of the
spindle motor. A suitable feedback device connected to the shaft monitors the
speed. This is how the CNC machine works.
1. Aerospace equipment.
2. Automobile parts.
3. Complex shapes.
4. Electronic industry uses CNC e.g. Printed circuit board.
5. Electrical industry uses CNC e.g. Coil winding.
6. For small to medium batch quantity.
7. Where the set-ups are very large.
8. It used where tool storage is a problem.
9. Where much metal needs to be removed.
10. When the part geometry is so complex.
11. The operations are very complex.
12. For parts subjected to regularly design changes.
13. When the inspection is required 100%.
14. It used when the lead time does not permit the conventional tooling
manufacture.
15. When the machining time is very less as compared to down.
16. Where tool storage is a problem.
17. Where repetitive operations are required on the work
4. 3D Scanning
processing step.
4.2 Advantage:
Tracked 3D scanner very good accuracy and excellent precision through out
the measurement volume. Removing the need for a physical link between
the scanner and the object being scanned provides freedom of movements.
4.3 Limitation:
The optical link that is a strength of this technology is also one of its
limitation. The Tracker must always have a clear and direct line of sight the
the scanning parameters add complexity to the process and can induce
5. 3D Printing
1. Modelling:
It takes virtual blueprints from modeling software and “slices” them into digital cross-sections for
the machine to successively use as a guideline for printing.
2. Printing:
To perform a print, the machine reads the design from an .stl file and lays down successive layers of
liquid, powder, paper or sheet material to build the model from a series of cross section.
3. Finishing:
2.Stereolithography
6.1 Introduction
Series of operation that involve cutting, bending and drawing sheet metal. Sheet metal (from
0.4mm or 1/64in to 6mm or 1/4in thickness); Plate (from 6mm upwards). Operations are
usually performed as cold working.
When subjected to a tensile force there are three deformations to be measured: the longitudinal strain, the
strain in the width direction and the strain in the thickness direction. The material is anisotropic.
6.4 Blanking:
Blanking is a cutting process in which a piece of sheet metal is removed from a larger piece
of stock by applying a great enough shearing force. In this process, the piece removed,
called the blank, is not scrap but rather the desired part. Blanking can be used to cutout
parts in almost any 2D shape, but is most commonly used to cut workpieces with simple
geometries that will be further shaped in subsequent processes.
6.5 Punching:
Punching is a cutting process in which material is removed from a piece of sheet metal by applying a
great enough shearing force. Punching is very similar to blanking except that the removed material,
called the slug, is scrap and leaves behind the desired internal feature in the sheet, such as a hole or slot.
Punching can be used to produce holes and cutouts of various shapes and sizes. The most common
punched holes are simple geometric shapes (circle, square, rectangle, etc.) or combinations thereof. The
edges of these punched features will have some burrs from being sheared but are of fairly good quality.
Secondary finishing operations are typically performed to attain smoother edges.
6.6 Clearance:
In blanking operation, the die size is taken as the blank size and the punch is made
smaller giving the necessary clearance between the die and the punch. Die size =
blank size
Punch size = blank size – 2 x clearance
Clearance = k .t τ.
where t = shear strength of material, t = thickness of sheet metal stock, and k is a constant
whose value may be taken as 0.003.
6.7 Bending:
Bending is a manufacturing process; it is defined as the straining of the sheet metal
around a straight edge. It produces a V-shape, U-shape, or channel shape along a straight
axis in ductile materials called sheet metal.
Bending induces plastic deformation in the material, so the part retains its shape after the bending
force is released.
Types of bending:
V – Bending
Edge Bending
Rotary bending
Spring Back
At the end of the bending operation, when the pressure on the metal is released, there is
an elastic recovery of the material. This cause a decrease in the bend angle and this
phenomenon is called as spring back.
BEND ALLOWANCE:
BA = α(R + kt)
Where
k = constant,
whose value may be taken as 1/3 when R < 2t, and as 1/2 when R ³ 2t.
Bending Force :
The bending force is required to perform bending depends on the geometry of the punch
and die, strength, thickness and width of the sheet metal. The bending force can be
F = Bending force
dimension
Bending Operation:
Flanging
Straight
Stretch
Shrink
Hemming
Flat
Open
Seaming : two sheet metal edges are assembled
Curling : form the edges of the part in to a roll or curl as shown in figure
Drawing:
Drawing is sheet-metal forming operation used to make cup-shaped, box shaped or other
more complex-curved, hollow shaped parts. It is performed by placing a sheet metal blank
over die cavity and then pushing the metal into the opening with a punch, as shown in
figure The blank must usually be held down flat against the die by a blank holder.