MANUFACTURING PROCESSES

(IM-203)
CEP ASSIGNMENT

Student Name: KHIZAR EJAZ

Roll # IM-078
Section : B

To be submitted to: Sir RAHEEL

Submission Date: 08-Jan-2024
 Manufacturing Processes (IM-203), Fall 2023

Complex Engineering Problem

Assignment
Course Learning Outcome: CLO-1
Taxonomy Level: C-2
Programme Learning Outcome: PLO-1
Total Marks: 10
Submission Date: 08-01-2024
Answer the following problem statements in your own words. Copy-paste contents are not allowed.
Please submit this assignment in softcopy form so that plagiarism can be checked.

Problem Statement 1: A large bolt is to be produced from extruded hexagonal stock by placing
the hex stock into a chuck and machining the cylindrical shank of the bolt by turning. List the
difficulties which may be presented by this operation.

Response: Machining the cylindrical shank of a bolt from hexagonal stock can have a few
challenges. Some difficulties that may arise include aligning the stock accurately in the chuck,
ensuring proper grip to prevent slipping, and maintaining consistent dimensions while turning.
And most importantly choosing the right cutting tools is essemtial for effective and accurate
machining as using the wrong tool can lead to poor finishing and smoothness. It's important to
have skilled operators and precise machinery to overcome these challenges.

Problem Statement 2: Which of the casting processes would be most suitable for making small
toys? Why.

Response: For making small toys, the most suitable casting process would be the "die casting"
method. Die casting involves injecting molten metal, such as zinc or aluminum, into a mold
under high pressure. This process allows for high precision and complex jobs, making it ideal for
creating small and detailes toy designs. Die casting also offers exccellent surface finish and
dimensional accuracy ensuring that the toys made should be smooth and nice looking.
Additionally, die casting is a cost-effective and efficient process, making it suitable for mass
production of small toys. So, die casting would be a great choice for creating those beautifull
little toys!
Problem Statement 3: Would you recommend broaching a keyway on a gear blank before or
after the teeth are machined? Explain.

Response: It is genereally recommend to brouch a keyway on a gear blank before the teeth
are machined. This because brouching a keyway involves removing material from the gear
blank, which could potentially affect the accuracy and alignment of the teeth if done after they
are machined. By broaching the keyway first, you ensure that the gear blank is in its final form
before moving on to machining the teeth. This helps maintain the integrity and precision of the
gear teeth, resulting in a well-functioning gear. It's like building a Lego car – first, you make the
wheels, and then you add the special slot (keyway) to connect it to the engine. For gears, it's
better to finish shaping the teeth before adding that connecting slot. This way, everything fits
well, and it's easier to do without any problems. It's like building step by step, making sure each
part is just right before moving on to the next.

Problem Statement 4: List and explain the considerations involved in determining whether a
cutting tool should be reconditioned, recycled, or discarded after use.

Response: When deciding whether a cutting tool should be recondittioned, recycled, or discarded
after use, there are several considerations to keep in mind.

Firstly the condition of the cutting tool plays a significant role. If the tool is heavily worn, damaged or has
lost its cutting edge it may not be suitable for reconditioning. In such cases it's usually best to discard the
tool as it may not perform properly even after reconditioning

Secondly, the material and type of the cutting tool should be considered. Some materials can be
reconditioned easily while others may be more difficult or not cost-effective to recondition. Tools made
of materials that can be easily recycled, such as certain types of steel, may be a good candidate for
recycling instead of reconditioning. Recycling a cutting tool can help reduce waste and conserve
resources, making it a more suiitable choice.

Additionally, the cost and time involved in reconditioning versus purchasing a new tool should be
evaluated. Reconditioning a tool may be more cost-effective if the tool is expensive or if it has
specialized features that are difficult to find in a new tool. However, if the cost of reconditioning is close
to or exceeds the cost of a new tool, it may be more practical to discard the old tool and invest in a new
one.

Ultimately, the decision to recondition, recycle or discard a cutting tool should be based on factors such
as its condition, material, cost, time, and environmental impact. Considering these factors will help
determine the most suitable action for the used cutting tool
Problem Statement 5: List the parameters that influence the temperature in machining, and explain
why and how to do so.

Response: There are several parameters that can influence the temperature in machining. Let's take
a look at a few of them:

1. Cutting Speed: The cutting speed refers to the speed at which the cutting tool moves across the
workpiece. Higher cutting speeds can generate more heat due to increased friction between the tool
and the workpiece. Slower cutting speeds can help reduce heat generation.

2. Feed Rate: The feed rate determines how fast the cutting tool advances into the workpiece. A higher
feed rate can lead to increased heat generation as the tool is in contact with the workpiece for a longer
time. Adjusting the feed rate can help control the temperature.

3. Depth of Cut: The depth of cut refers to the amount of material being removed in a single pass. A
larger depth of cut can result in more heat being generated. Adjusting the depth of cut can help manage
the temperature during machining.

4. Cutting Fluid: The type and application of cutting fluid can significantly impact temperature control.
Using appropriate cutting fluids, such as coolant or lubricants, can help dissipate heat and reduce friction
between the tool and the workpiece.

5. Tool Material and Coating: The material and coating of the cutting tool can influence temperature.
Tools made from materials with good heat resistance, such as carbide or ceramic, can withstand higher
temperatures. Coatings like TiN or TiAlN can also provide heat resistance and reduce friction.

To control the temperature during machining, it's important to optimize these parameters based on the
specific machining operation and material being worked on. Adjusting cutting speeds, feed rates, and
depths of cut can help manage heat generation. Additionally, using appropriate cutting fluids and
selecting tools with suitable materials and coatings can aid in temperature control. Regular monitoring
and adjustments during the machining process can help maintain optimal temperature conditions for
efficient and accurate machining.

Problem Statement 6: List and explain the factors that contribute to poor surface finish in machining
operations.
Response: Poor surface finish in machining is caused by factors like tool wear, incorrect cuting speed
or feed, insufficient machine riggidity, vibrations, and inadequate coolant use. Tool wear and improper
cuting parameters can lead to rough surfaces, while machine instability and poor coolant management
contribute to the problem. To improve surface finish, it's difficult to address these issues through proper
tool maintenance, optimal cutting conditions, machine setup, as well as effective coolant application.

Problem Statement 7: Make a list of products, parts, or components that are not currently made of
plastics, and offer reasons why they are not.

Response: Aerospace Components: Key parts in aerospace, like jet engine turbines, often need tough
materials with resistance to high temperatures, such as titanium or nickel alloys. Plastics may lack the
necessary strength or heat tolerance for these critical applications.

Automotive Engine Parts: Components in car engines, including pistons and cylinder heads, demand
materials with exceptional heat resistance and strength. Metals like aluminum or steel are preferred
over plastics due to their ability to withstand the demanding conditions of engine operation.

Medical Implants: Materials used in medical implants, such as titanium or ceramics, must be
biocompatible with the human body. Plastics may not offer the same level of compatibility, making them
less suitable for medical applications.

High-Temperature Applications: Industries with extreme temperatures, like certain manufacturing

processes, require materials that can handle heat. Plastics often fall short in these situations, leading to
the preference for metals known for their heat resistance.

Construction Structural Components: Load-bearing elements in construction, such as steel beams and
concrete, are chosen over plastics for their superior strength and durability. Plastics may not provide the
required structural integrity for these applications.

Problem Statement 8: Explains the reasons that so many different welding processes have been
developed.

Response: Numerous welding proceses have been developed to cater to diverse engineering
applications, each methods are tailored to address specific challenges and requirements. The selection
of a welding process depends on many factors such as material type, thickness, joint configuration,
desired mechanical properties, and the environment in which the welding takes place. Different
processes offer unique advantages: Gas Metal Arc Welding (GMAW) excels in high-speed production and
automation, Shielded Metal Arc Welding (SMAW) provides versatility in various positions and
environments, while Laser Beam Welding (LBW) offers precise control in thin materials. The variety in
welding techniquues enables engineers to choose the most suitable method for a particular use,
optimizing efficiency, quality, and overall performance in welding operations across a broad spectrum of
industrial sectors.

Problem Statement 9: Are there common factors among the weldability, solderability, castability,
formability and machinability of metals? Explain by giving appropriate examples.

Response: The weldability, solderability, castability, formability, and machinability of metals share
common factors rooted in material properties and microstructural characteristics. For instance, metals
with similar crystal structures and atomic arrangements tend to exhibit comparable welding and
soldering characteristics. Alloying elements play a crucial role; elements that improve one aspect of
metal processing may have synergistic effects on others. For example, aluminum-silicon alloys
demonstrate good castability and weldability due to the eutectic nature of the alloy system. Similarly,
formability and machinability are influenced by factors such as grain size, inclusion content, and phase
distribution. Stainless steels, with their controlled grain boundaries and alloying elements like sulfur for
improved machinability, showcase how these properties can be interrelated. Understanding these
common factors is essential for materials engineers to optimize the overall manufacturability and
performance of metal components across various processes.

Problem Statement 10: Describe the procedures that would be involved in making a bronze statue.
Which casting process or processes would be suitable? Why?

Response: Creating a bronze statue typically involves the lost-wax casting process. Firstly, a model or
sculpture of the desired statue is made from a sculptor's material like clay or wax. A mold is then
created around the model. This mold is heated to remove the wax or other material, leaving a negative
space in the shape of the statue. Molten bronze is poured into this cavity, taking the form of the original
model. Once the bronze cools and solidifies, the mold is removed, revealing the cast bronze statue. Lost-
wax casting is suitable for bronze statues due to the fine details it can capture and the ability to
reproduce intricate designs faithfully. Additionally, bronze, with its low melting point and favorable
fluidity when molten, makes it well-suited for this casting method, ensuring a high-quality and detailed
final product.