The Machining Process and the Different Types of Machining Operations !

The Machining Process and the Different Types of Machining Operations !

زهرة شوبينج اونلاين    May 12, 2022   

 Introduction:

 

There are many different types of machining operations, each of which can produce a different part geometry and surface texture.Turning and milling are the two most common machining techniques. Other processes may be included into or done independently of these processes. A drill bit, for example, can be mounted on a turning lathe or tossed into a drill press. Previously, there was a distinction between turning, in which the part turns, and milling, in which the tool revolves. With the introduction of machining centres and turning centres that can conduct all of the functions of many machines in a single machine, this distinction has become somewhat blurred.

1.   Turning: 

1.     Turning

A single point turning tool rotates axially down the side of the workpiece, removing material to generate various characteristics such as steps, tapers, chamfers, and contours. Typically, these features are machined with a shallow radial depth of cut and many passes until the end diameter is reached.

2.     Facing

turnin operations

A single-point turning tool rotates radially around the workpiece's end, removing a small layer of material to create a smooth flat surface. The face's depth, which is normally very small, can be machined in a single pass or by making successive passes at a reduced axial depth of cut.

3.     Grooving

 A single-point turning tool cuts a groove the same width as the cutting tool by moving radially into the side of the workpiece. Multiple cuts can be performed to build grooves that are larger than the tool width, and specific form tools can be used to generate grooves with different geometries.

4.     Cut-off 

A single-point cut-off tool advances radially into the side of the workpiece, similar to grooving, and continues until the workpiece's centre or inner diameter is reached, thus parting or cutting off a segment of the workpiece.

5.     Thread cutting

A single-point threading tool glides axially down the side of the workpiece, cutting threads into the outside surface, usually with a 60 degree pointed nose. Threads can be cut to a specific length and pitch, and thread formation may need numerous passes.

6.     Drilling

7.     Boring

turning operations

A single-point threading tool slides axially down the side of the workpiece, cutting threads into the outside surface. It commonly has a 60 degree pointed tip. Threads can be cut to a specific length and pitch, and the formation of the threads may need numerous passes.

8.     Reaming

A reamer enlarges an existing hole to the diameter of the tool by entering the workpiece axially through the end. Reaming removes only a small amount of material and is frequently used after drilling to get a more precise diameter and a better internal finish.

9.     Tapping

A tap cuts internal threads into an existing hole by entering the workpiece axially through the end. The appropriate tap drill size that will accept the desired tap is normally drilled into the existing hole.

2.   Milling:

 is the process of removing material from a workpiece by advancing a cutter into it with rotary cutters. This can be accomplished by changing the direction[2] of one or more axes, as well as the cutter head speed and pressure. [3] Milling encompasses a wide range of procedures and machinery, ranging from small single pieces to huge, heavy-duty gang milling operations. It's one of the most used methods for producing custom parts with tight tolerances. A variety of machine tools can be used to mill. The milling machine was the first type of machine tool for milling (often called a mill). Milling machines evolved into machining centres after the introduction of computer numerical control (CNC) in the 1960s: milling machines with automatic tool changers, tool changers, and tool changers. Enclosures, tool magazines or carousels, CNC capabilities, cooling systems Vertical machining centres (VMCs) and horizontal machining centres (HMCs) are the two types of milling centres (HMCs).

milling machine

3.   Drilling:

Drilling uses drill bits to generate cylindrical holes in solid materials; it is one of the most significant machining techniques since the holes created are typically used to aid with assembly. Drill presses are frequently employed, however lathes can also be used. Drilling is a preparatory step in most manufacturing operations for producing finished holes, which are then tapped, reamed, bored, etc. to generate threaded holes or bring hole dimensions within acceptable tolerances. Due to the bit's flexibility and tendency to seek the route of least resistance, drill bits will typically cut holes larger than their nominal size and holes that are not always straight or round. 

As a result, drilling is frequently specified undersize. After that, another machining operation is performed to get the hole to its final size. 

 

drilling machine

Types of drilling machines

Drilling machines come in a variety of shapes and sizes, depending on the type of operation, amount of feed, cut depth, spindle speeds, spindle movement method, and needed accuracy.

The following are the various types of drilling machines:

1. Hand drilling machine or portable drilling machine

2. Bench drilling machine (or sensitive drilling machine)

3. Upright drilling machine

4. Radial drilling machine

5. Gang drilling machine

6. Multiple spindle drilling machine

7. Deep hole drilling machine 

Tensile Testing

Tensile Testing

زهرة شوبينج اونلاين    March 03, 2012   

Tensile test overview

Tensile Testing

What does tensile testing entai?

Tensile tests are used to see how materials react under tension. A materials sample is typically tugged to its breaking point in a simple tensile test to determine the material's ultimate tensile strength. Throughout the test, the amount of force (F) applied to the sample and its materials elongation (L) are measured. Stress (force per unit area) and strain (percent change in length) are two concepts used to describe material qualities. The force readings are divided by the sample's cross sectional area to obtain stress (= F/A). Strain measurements are calculated by dividing the change in length by the sample's original length (ε = ∆ L/L). The stress-strain curve is an XY figure that displays these numbers. Measurement and testing The processes differ depending on the substance being evaluated and its intended use.

Tension / tensile tests are performed  test accurately and reliably by ADMET material testing devices. Metals, polymers, textiles, adhesives, medical devices, and a variety of other items and components can all benefit from our technologies. ADMET testing devices precisely determine mechanical parameters such as tensile strength, peak load, elongation, tensile modulus, and yield as they pull materials apart.

Tensile Testing Fundamentals

The key concepts of tensile testing will be discussed in the next section. An ADMET MTESTQuattro-equipped tensile tester provided all software output screens.

Tensile test Strain and Stress 

Tensile test these are the fundamental aspects of material science. The amount of force per unit cross sectional area is known as stress. The ratio of the change in length to the initial length, stated as a percentage, is known as strain. The results of tensile tests are displayed as plots of stress versus strain.

Tensile test Deformation of Elasticity

In tensile testing The region on the stress-strain curve where deformation can be reversed by releasing stress is known as elastic deformation. It's also where tension and strain are mostly proportionate. The initial linear segment of a stress-strain curve can be identified as such. test

 Tensile testing Modulus of Young

Tensile testing the elastic modulus, commonly known as Young's modulus, is a quantity that relates the proportion of stress to strain during elastic deformation. It is the initial slope of the linear section of the graph on a stress-strain curve. The equation =E• represents this relationship. Hooke's Law, which was designed to represent the behaviour of springs, is the name of this relationship.

Tensile testing  Proportional by Proportion

In Tensile testing The first time the plot deviates from the line indicating Young's modulus on the stress-strain curve. This divergence is usually gradual and material-dependent.Performing a Tensile Test

In general, the following equipment is required to do tension testing:

Frame for universal testing machines

Controller and/or indicator for load cells

To hold your sample, you'll need the right grips and fixturing.

The universal test machine frame gives the sample the structure and rigidity it needs to be pulled apart at the proper rate. With a wide range of capabilities, frames are offered in electromechanical 

and servo-hydraulic variants. It's critical to choose a frame that can bear the force required to examine the sample.

Load cells are used to determine how much force is being delivered to the sample. These, like frames, come in a range of sizes. If you use a load cell with a capacity lower than the specified breaking strength, the load cell will break before the sample. In contrast, a load cell with too high a capacity would produce test results that are less precise than required, as load cell resolution often falls below 1%. A 1,000-pound load cell, for example, would have far too much capacity for a sample that breaks under 1 pound of force.

A controller or an indicator may be required depending on your system configuration. The test frame's behaviour during testing, including test speed and displacement, is controlled by controllers, as the name implies. In certain cases, all that is required is an indicator. The test data is captured and displayed through indicators, but they do not control the equipment.

Tension testing can be done with a variety of grips and fasteners. To hold different materials properly, different fixturing is required. Because of how the materials respond when tensile stresses are applied, a sample made of metal, for example, requires different grips than a stretchy piece of rubber. In order to achieve accurate results, you must choose the right grips for your application.

Why Should You Do a Tensile Test?

Tensile testing can be used to determine many qualities of a material. Tensile testing determines the strength and ductility of metals when subjected to uniaxial tensile stresses. The ability of a metal to sustain tensile loads without failing is defined by its tensile strength. Because brittle metals are more likely to break, this is a significant consideration in the metal forming process. A tensile test is often used to choose a material for a specific purpose, to ensure quality, and to predict how a material will behave to various forces. WMT&R offers a variety of tensile testing services, all of which are conducted to established or bespoke specifications. Tensile tests can be carried out at room temperature, at extreme temperatures (-452 to 2200°F), and with a variety of specimen types, fittings, and test protocols.

Tension Testing Problems

Tension Testing Problems One of the most common reasons of erroneous tensile readings is non-axial loading. When utilising a load sensor or force gauge, even minor off-center loading might result in measurement inaccuracies of up to 0.5 percent. It's crucial to make sure the load cell, top test fixture, sample, and bottom test fixture are all perpendicular to one another.

Accurate and consistent results require the use of a correctly sized force gauge or load cell sensor depending on the projected load measurement. A good rule of thumb is to use a sensor that measures between 20% and 80% of the projected load. This will eliminate or reduce errors caused by mechanical noise at the low end. It will aid in the prevention of overloading at the top end of the measurement range. Because most sensors are calibrated and have accuracy specifications based on full scale, the closer you get to zero, the more the accepted error influences your measurement.

Another major source of faulty tensile measurements is using the wrong test fixture. A fixture that is either too large for the sample or applies too much gripping force to the sample during tensile movement can cause the sample to fracture outside of the prescribed gauge length area. The test fixture should be sized according to the expected load characteristics of the sample. Wedge-action test fixtures function well on ductile samples but are less dependable on brittle materials because they apply load to the brittle material.

as axial loading increases, the sample When pneumatically operated test fixtures that adjust the gripping force onto the sample are used, brittle materials tend to test more consistently.

Inconsistent and erroneous characterisation might result from poor sample preparation. The sample should be prepared to the necessary dimensions when testing to a specific international standard. The component will typically be used in its completed state for force measurement applications. Material testing, on the other hand, employs specifically prepared specimens in a variety of shapes and sizes. Their cross-sections can be circular, rectangular, or square, and their gauge length is known.

Another common reason why tensile measurement may not be optimal is testing at too fast or too slow a velocity. Testing should be done in line with a known and accepted standard whenever possible.

ASTM, ISO, DIN, or other recognised testing standards The test speed is fully described in these standards, ensuring accurate measurement.Temperature can have a big impact on tensile outcomes. The elasticity of a sample can be dramatically reduced as the temperature rises.

Welding

Welding

زهرة شوبينج اونلاين    February 17, 2011   

Welding  is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with soldering and brazing, which involve melting a lower-melting-point material between the workpieces to form a bond between them, without melting the workpieces.

Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding can be done in many different environments, including open air, under water and in outer space. Regardless of location, welding remains dangerous, and precautions are taken to avoid burns, electric shock, eye damage, poisonous fumes, and overexposure to ultraviolet light.

Until the end of the 19th century, the only welding process was forge welding, which blacksmiths had used for centuries to join iron and steel by heating and hammering them. Arc welding and oxyfuel welding were among the first processes to develop late in the century, and resistance welding followed soon after. Welding technology advanced quickly during the early 20th century as World War I and World War II drove the demand for reliable and inexpensive joining methods. Following the wars, several modern welding techniques were developed, including manual methods like shielded metal arc welding, now one of the most popular welding methods, as well as semi-automatic and automatic processes such as gas metal arc welding, submerged arc welding, flux-cored arc welding and electroslag welding. Developments continued with the invention of laser beam welding and electron beam welding in the latter half of the century. Today, the science continues to advance. Robot welding is becoming more commonplace in industrial settings, and researchers continue to develop new welding methods and gain greater understanding of weld quality and properties

What is the role of a Production Engineer?

What is the role of a Production Engineer?

زهرة شوبينج اونلاين    February 16, 2011   

What is the role of a Production Engineer?

Production engineering

 is a combination of manufacturing technology with management science. He should typically has a wide knowledge of engineering practices and is aware of the challenges related to production. The goal is to accomplish the production in the smoothest, most-judicious and most-economical way.

Also encompasses castings, joining processes, metal cutting & tool design, metrology, machine tools, machining systems, automation, jigs and fixtures, and die and mould design. Products engineering overlaps substantially with manufacturing engineering and industrial engineering.

In industry, once the design is realized, production engineering concepts regarding work-study, ergonomics, operation research, manufacturing management, materials, production planning, etc., play important roles in efficient production processes. These deal with integrated design and efficient planning of the entire manufacturing system, which is becoming increasingly complex with the emergence of sophisticated production methods and control systems.

Production Engineer

Work opportunities are available in public and  may be in private sector manufacturing organizations engaged in implementation, development of new production processes, information and control systems, and computer skills controlled inspection, assembly and handling.

What is the role of a Production Engineer?

A Production Engineer devises and implements techniques for improving manufacturing operations. Examines current processes and devises methods to boost productivity or cut expenses. A Production Engineer ensures that established production procedures and quality standards are followed. A bachelor's degree in engineering is required. Production Engineers usually report to a manager or the head of a unit or department. A Production Engineer normally has 10+ years of expertise in the field. Works on advanced, complex technical projects or commercial issues that require cutting-edge technical or industry expertise. Works independently. Goals are usually expressed in terms of "solutions" or "project goals." Because of his or her specialisation, he or she may be able to lead the work group.

Jobs and career in Production Engineering, Salary, and Top Recruiters

Production engineers have a huge job market in worldwide. Individuals with a degree in engineering are employed in a variety of industries, including pharmaceuticals, research labs, manufacturing, communication, travel, sports, health, and information technology, among others.

Following are some of the occupations available to production engineers after completing a course in the field:

1. Production Engineer
2. Engineering Plant Production Manager
3. Process Engineer
4. product engineer
5. Industrial Managers
6. Quality Engineers
7. process engineer
8. Management Engineer
9. Operations Analyst
10. Manufacturing and design Engineer
11. Architectural and Engineering Managers
12. Cost Estimators
13. Health and Safety Engineers
14. Industrial Engineering Technicians
15. Industrial Production Managers
16. maintenance engineer
17. Logisticians
18. Management Analysts

Salary for Production Engineers

A production engineer's remuneration varies depending on their level of experience. It is entirely determined by the years of experience and skill set required for the position. See the estimated average yearly salary for the various levels is E£ 61,042.

Production Engineer Responsibilities:

1. Supervising manufacturing processes and ensuring that will work is completed in a safe and efficient manner are among the responsibilities of him.
2. Collaboration with other engineers on initiatives to enhance production, costs, and labour requirements.
3. Identifying production line issues and giving advice and training.
4. Creating safety processes and standards that consider the workers' well-being while simultaneously reducing the carbon footprint.
5. Keeping up with engineering and production advances and exchanging knowledge with coworkers.
6. Unsafe practises must be identified, documented, and reported.
7. Creating project production schedules and budgets.
8. Meetings with appropriate departments and stakeholders are being planned.
9. Analyzing and recommending improvements to all aspects of productiona.
10. Obtaining any necessary materials and equipment.

Modern technology tools and software desien products 

• SolidWorks

 is  an mechanical engineering software  and a computer programme for CAD modelling that was created by Dassault Systèmes.

SolidWorks is an industrial standard for generating physical object designs and make design specifications, with over 165,000 organisations using it as of 2013.

• AutoCAD

Autodesk's AutoCAD is an example of a CAD modelling computer programme. CAD modelling and CAE are also common uses for AutoCad. 

Product life cycle management (PLM) tools and analysis tools used to run complicated simulations are two other CAE applications often utilised by product manufacturers. Product response to expected loads, including fatigue life and manufacturability, can be predicted using analysis techniques. Finite element analysis (FEA), computational fluid dynamics (CFD), and computer-aided manufacturing are examples of these techniques (CAM). A mechanical design team can iterate the design process fast and cheaply using CAE systems to build a product that better satisfies cost, performance, and other limitations. There's no need to build a real prototype until the design is nearly finished, allowing hundreds or thousands of people to test it.

CAE analysis programmes can also model difficult physical phenomena that are impossible to address by hand, such as viscoelasticity, complex contact between mating components, and non-Newtonian flows.

Multidisciplinary design optimization (MDO) is being utilised with other CAE tools to automate and optimise the iterative design process, just as manufacturing engineering is integrated with other disciplines like mechatronics.

 MDO solutions automate the trial-and-error procedure employed by traditional engineers by wrapping around existing CAE processes. MDO employs a computer-based technique that seeks for superior alternatives iteratively from an initial guess within defined parameters. This process is used by MDO to determine the optimum design outcome and to list numerous possibilities. 

What qualifications are required of a Production Engineer?

When considering a position like this, you must consider your talents and abilities. The capacity to excel in this profession is contingent on the following abilities: Process Engineering, Process Mapping, Process Optimization, and Production Engineering are all examples of mathematical modelling. Although not always required, knowing how to use CAD software, CAE software, and a quality management system might be beneficial (QMS). Attempt to convey your mastery of these talents during an interview.

Industrial engineers design efficient systems that integrate employees, equipment, materials, information, and energy in order to produce a product or provide a service.

Working Conditions

Industrial engineers work in offices or in the environments they are aiming to change, depending on their job. When observing difficulties, they may, for example, see industrial workers assembling parts. They may be in an office at a computer, looking at data that they or others have acquired when solving problems.

What Does It Take to Become an Industrial Engineer?

A bachelor's degree in industrial engineering or a similar discipline, such as mechanical or electrical engineering, or industrial engineering technologies, is often required of industrial engineers.

Pay

In May 2021, the median yearly wage for industrial engineers was $95,300.

Job Prospects

Industrial engineers' employment is expected to expand 14% between 2020 and 2030, faster than the average for all occupations.

On average, throughout the next decade, there will be about 23,300 jobs for industrial engineers. Many of those positions are projected to arise as a result of the need to replace people who change occupations or leave the workforce for other reasons, such as retirement.

Data by State and Region

Find job and wage information for industrial engineers by state and region.

Occupational Groups

Industrial engineers have similar job duties, education, job growth, and salary to other occupations.

Making Your Mark

Manufacturing engineering majors are beneficial in both engineering and business operations. Almost all manufacturing engineering graduates have begun their professions or completed their education within six months of graduation in recent years. Boeing, John Deere, Borgwarner, HNI, Caterpillar, Deublin, and Kohler are among the companies where they work.