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Abstract
In an internal combustion engine of the reciprocating type, the oil pan is the housing of the crankshaft. The enclosure
forms the largest cavity in the engine and is located below the cylinder(s), which in a multi cylinder engine are usually
integrated in to one or several cylinder blocks.
Oil pan is located at the bottom of engine. It is used to store the engine oil. Oil will be pumped to the engine from the oil
pan when required.
In this project modeling of oil pan used in submarine engine will be done.
The aim of the project is to model oil pan, designing a casting tool and generate cnc program for the same and reduction
of weight will be done at unnecessary areas.
Initially data will be collected to design mold tool and for the conditions of analysis.
In next stage a model will be generated using pro-engineer for further study.
Mold design calculations will be done to model the mold assembly.
After mold preparation structural analysis will be conducted to optimize the die structure for weight reduction.
Modeling, tool design and manufacturing (CNC) will be done using CREO 2.0 (PRO/ENGINEER) software.
*Corresponding Author:
Maloth.Mohankumar,
Mother Theresa Institute of Technology(mist) Sanketika Nagar
Sathupally Khammam,India
Introduction
Todays dynamic production environment is characterized by a large volume of uncertainty such as
rapid market changes, increased product variety,
competitive prices and short product life cycles.
Therefore, it is of prime importance to introduce
flexible manufacturing systems (FMS) so that these
uncertainties can be handled in an effective manner.
FMS is characterized as an integrated, computer
controlled complex arrangement of automated material handling devices and computer numerically
controlled (CNC) machine tools that can simultane-
prices change. Each situation must be studied individually to determine which practice will give a maximum of accuracy in cost figures with a minimum
of accounting and clerical effort. Once the choice
has been made, records must be set up to charge
materials to operations based on requisitions. Indirect material is necessary to the completion of the
product, but its consumption with regard to the final product is either so small or so complex that it
would be futile to treat it as a direct material item.
Design for Assembly
After management decisions have been made regarding policy, practices, and long-range objectives, decisions must be made about the best combination of
a multitude of characteristics of the product. These
include the goals to be achieved by it: its salability,
functionality, safety, targeted life, reparability, recyclability, ease of use, size, shape, color, and many
other considerations, some reinforcing others and
some in conflict with others. Designing the product for ease and economy of fabrication, assembly,
test, handling, shipping, and installation are some
important considerations. Then, the basis of all of
the above determinations, decisions can be made
regarding the best levels and mix of auto- facturing.
That includes deciding which portions of the product should be made by people, hard automation, or
programmable devices, since the size, shape, and
features of its several parts may be different and
better suited for one mode over the others.
Investment casting:
Tooling costs are moderate depending on the complexity
Equipment costs are low
Direct labor costs are high
Material costs are low
Die casting:
Tooling and equipment costs are high
Direct labor costs are low to moderate
Material utilization is high
DIE
EQUIPMENT
LABOUR
PRODUCTIONRATE
SAND
L-M
<20
SHELL MOLD
L-M
M-H
L-M
<50
PLASTER
L-M
M-H
<10
INVESTMENT
M-H
L-M
<1000
PARIMENT MOLD M
L-M
<60
DIE-CASTING
L-M
<200
CENTRIFUGAL
L-M
<50
Introduction to Cad
Computer-aided design (CAD), also known as
computer-aided design and drafting (CADD), is the
use of computer technology for the process of design
and design-documentation. Computer Aided Drafting describes the process of drafting with a computer. CADD software, or environments, provides the
user with input-tools for the purpose of streamlin-
Die Casting
Introduction
Die casting is a versatile process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds. These
molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and
repeatability. Parts can be sharply defined, with
smooth or textured surfaces, and are suitable for a
wide variety of attractive and serviceable finishes.
Die castings are among the highest volume, massproduced items manufactured by the metalworking
industry, and they can be found in thousands of
consumer, commercial and industrial products. Die
cast parts are important components of products
ranging from automobiles to toys. Parts can be as
simple as a sink faucet or as complex as a connector housing.
The Future
Refinements continue in both the alloys used in die
casting and the process itself, expanding die casting applications into almost every known market.
Once limited to simple lead type, todays die casters
can produce castings in a variety of sizes, shapes
and wall thicknesses that are strong, durable and
dimensionally precise.
Methods
Die casting is a method of producing alloy castings
by injecting molten metal into metallic mold under
pressure. Die casting process can be classified into
a)
Hot Chamber Process
b)
Cold Chamber Process
The basic die-casting process consists of injecting
molten metal under high pressure into a steel mold
called a die. Die casting is an efficient, economical
process offering a broader range of shapes and components than any other manufacturing technique.
Parts have a longer service life when compared to
plastics. Die casting provides complex shapes within
closer tolerances than many other mass production
processes. Little or no machining is required, and
thousands of identical castings can be produced
before additional tooling is required. Die casting
produces parts that are durable and dimensionally
stable, while maintaining close tolerances. Die cast
parts are stronger than plastic injection moldings
having the same dimensions. Thin-wall castings are
stronger and lighter than those possible with other
casting methods. Die castings provide integral fastening elements, such as bosses and studs.
In this technique, the mould is generally not destroyed at each cast but is permanent, being made
of a metal such as cast iron or steel. There are a
number of die casting processes, as summarized in
Figure 2. No Fig No. to the figures
Manufacturing Consideration
Functional Dimensions
Position of gate
Ejection
Die maintenance
Type of machine
Side cores
Over flows
Provide area for gases and cold metal to be
gathered
Air Vents are provided from overflows
Act as ejector pads
Allow more metal to flow through the system
adding heat to the die
Factors Affecting Ejection
[639037+95855+127807+526692+175570.4]
x
7
The above image is showing oil pan with feed system for the preparation of mould.
The above image is showing oil pan with parting surface and work piece for the preparation of mould.
Cavity
10
11
EJECTOR PLATE
Back Plate
12
EJECTOR PINS
HOUSING
13
14
Introduction to Fea
Finite Element Analysis (FEA) was first developed in 1943 by R. Courant, who utilized the Ritz method of numerical analysis
and minimization of variational calculus
to obtain approximate solutions to vibra-
The above image is the imported model of casting tool. Modeling was done in Creo 2.0and imported with the
help of IGES (Initial Graphical Exchanging Specification).
15
The above image showing the meshed modal. Default solid Brick element was used to mesh the components.
The shown mesh method was called Tetra Hydra Mesh.
Meshing is used to deconstruct complex problem into number of small problems based on finite element
method
RESULTS
Displacement
16
17
18
Structural Analysis on Casting Tool for Oilpan With Modified Core Part
RESULTS
Displacement
19
Thermal Analysis on Casting Tool for Oilpan With Modified Core Part
20
Manufacturing
This process gives over view of manufacturing process in pro/engineer with step by step images
21
Finishing
22
Core Roughing
23
Finishing
24
25
Displacement
stress
strain
Temperature
Total heat flux
Thermal error
Conclusion
STRUCTURAL ANALYSIS
EXISTING
0.62896
942.99
0.0047982
THERMAL ANALYSIS
688.61
0.14644
1.0825e6
MODIFIED
0.63003
369.24
0.0020717
693.46
0.17937
9.5415e5
References
1. Kennedy J, Eberhart RC (1995) Particle swarm
optimization. In: Proceedings of the 1995 IEEE
International Conference on Neural Networks
(ICNN95), Perth, Australia, November/December
1995, vol 4, pp 19421948
2. Jerald J, Asokan P, Prabaharan G, Saravanan
R (2005) Scheduling optimisation of flexible manufacturing systems using particle swarm optimisation algorithm. Int J AdvManufTechnol 25:964971
3. K.Vidyarthi and M.K.Tiwari. Machine loading
problem of FMS: a fuzzy-based heuristic approach,
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Maloth.Mohankumar
D.Gopichand
Qualification: m.tech
Designation: assistant profressor
Experience :4 yr in teaching & 2 yr experience in
InfoTech as design engineer
27