Manufacturing Engineering Project: Design, Manufacturing, and Quality

This project encompasses a comprehensive analysis of a manufacturing engineering task. Task 1 focuses on redesigning an AC control valve, minimizing components while maintaining functionality, and evaluating design efficiency. Task 2 delves into manufacturing processes, including calculations for machining parameters like chip load, surface speed, and material removal rate. It also explores the selection of appropriate manufacturing methods such as milling and EDM, and the use of DMLS for component printing. Task 3 addresses quality control, including calculations for feed rate, tolerance analysis, and the creation of control charts to monitor and optimize the manufacturing process. The project also includes an evaluation of acceptance sampling plans to assess product quality, along with relevant references.

Manufacturing
Engineering

Task 1 Design for Assembly
In this project, we have to redesign the given AC control valve. The given design
contains 12 components on it. Among them frame, valve plate and control stick are the major
components. These three components are essential for the functioning of the valve. Without
these three components not possible to achieve the functioning of the valve. So the minimum
number of parts is “three” for the given design.
Justifications
 The given component has two main functions. One is “Control the flow rate of the gas”
and another one is “Act as an extension pipe”.
 Frame, control valve plate and control stick is enough to do that.
 Here the other components like bush, rings and sheet metal cases are used to improve the
performance of the valve. But these are not the major functional parts.
 So the major functional parts of the design are three.
Redesigning process
Dimensions of the major components
Dimensions of Frame
1

Dimensions of valve plate
Dimensions of control rod
2

Components
Assembly view
Exploded view
3

Design Efficiency (Choi and Guda, 2000)
Where A minimum number of components
B Actual number of components
For given design
Total number of components = 12
Minimum number of components = 3
Design Efficiency of the given design = (3/(3+12)) = 20%
Design efficiency of the proposed design
Total number of components = 7
Design efficiency of the proposed design = (3/(3+7)) = 30%
Solid works design attached.
4

Task 2 Manufacturing processes
2.1 Machining parameters
Question 1
Chip load (Yang, Wu and Srivatsa, 2011)
Parameters Values
Feed Rate(mm/min) 300
Spindle Speed (RPM) 6500
No of Teeth 2
Chip load
(mm/tooth/revolution) 0.023076923
Question 2
Parameters Value
Diameter(mm) 20
Spindle
Speed(RPM) 6500
Surface
Speed(m/min) 408.2
Question 3
5

MRR=Cutting Depth*Cutting width*Feed rate
Parameters Value
Cutting Depth
(mm) 3
Cutting Width
(mm) 7
Feed rate 300
Spindle Speed 6500
MRR(mm3/min) 6300
Question 4
Pc = ((3*7*408*350)/(60*106*0.9))*1000
Pc = 5.533 W
Question 5
6

D – Dia. of the cutter (mm)
d – Cutting Depth (mm)
Calculation of leading in distance & Leading out distance.
For peripheral milling leading out distance is zero.
Parameters Value
Cutting Depth (mm) 3
Dia. meter of Cutter
(mm) 20
A
7.14142842
9
O 0
Machining time calculation
Machining Time = (Total length of tool travel/ Feed rate)
Total length of tool travel = Leading in distance + length + Leading out
Machining Time = (Leading in distance + length + Leading out)/ (Feed Rate). Min
7

2.2Manufacturing processes
Question 1
Question 2
For making keyway milling process is suggested. Other than milling process some other methods
are also available like keyway broaching, key seating etc.
 Both vertical milling and horizontal milling techniques are suitable for making keys on
the shaft.
8

 Other techniques require some special kind of machines. For example, consider the
broaching process it requires a broaching machine. A milling machine is one of the most
common machines in the workshops (Matt, 2013).
 Relatively it is a cheaper process for making single elements.
 But it is only useful for cutting keyway on shafts, making internal keyways on hubs and
gears is much complicated.
Question 3
It is possible to machine the tool steel using unconventional machining process. EDM Process is
suggested. And the reasons for selecting EDM are listed below.
 Suitable machining all the electrically conductive materials.
 Parts can be machined directly on the hardened material.
Question 4
DMLS- “Direct Metal Laser Sintering” technique is suggested for printing the components.
There is no any other special processes are required after printing. Because here the printer prints
the material layer by layer. This method is capable of producing more intricate shapes.
For the following reasons DMLS method is suggested. And they are listed below.
 Higher accuracy
 Capable of producing complex geometries
 Suitable for rapid prototyping
 No further treatments required.
 Relatively fast method.
Task 3 Quality control
9

3.1 Quality control
Question 1
Feed rate = 2000 * 2 * 0.023076923
Feed rate = 92 mm/rev
Calculations excel file attached,
Question 2
10

For Achieving Length tolerance
Allowable tolerance on the length is “± 0.1”.
USL = 40.10
LSL = 39.90
Std. Deviation Cp
Machine A 0.005 6.66
Machine B 0.01 3.33
Machine C 0.02 1.66
Machine C is good enough for achieving the tolerance limit.
Std. Deviation Cp (for dia)
Machine A 0.005 3.33
Machine B 0.01 1.66
Machine C 0.02 0.833
Machine B is suitable for maintaining both diametrical and length tolerances.
11