Manukau Institute of Technology

School of Professional Engineering

Manufacturing Process Assignment 1
Semester 2, 2016
This report is worth 30 % of the total course marks and is due at 4 pm
on 15 of August 2016.
Please also check course outlines for date of submission and regulations. Any
late submission will be penalised according to MIT regulations.
This is a research question and answer. You are required to find the information
to answer the following questions.
1. What are the main responsibilities of the employer and the employee
under Health and Safety Act 1992?
Every employer shall take all practicable steps to ensure the safety of
employees while at work; and in particular shall take all practicable steps
to
o Provide and maintain for employees a safe working environment.
Provide and maintain for employees while they are at work facilities for
their safety and health.
Ensure that plant used by any employee at work is so arranged, designed,
made, and maintained that it is safe for the employee to use.
Develop procedures for dealing with emergencies that may arise while
employees are at work.
2. In marking the choice of which type of cutting fluid to use, many factors
have to be considered. Name two of the important factors?
The main functions of cutting fluids are: Lubrication at low cutting speeds.
Cooling at high cutting speed.
3. What is the purpose of chip breakers in the Turning Process?
The function of a chip breaker is to improve chip control and to reduce
cutting resistance. A better balance between the two will increase the
machining performance. If chips can be broken into suitable lengths by the
chip breaker, they will not wrap around the workpiece, vibration will
decrease and tools will not be so easily damaged. Chip breakers also affect
cutting resistance. Reduced cutting resistance can avoid chipping and
fracturing of the cutting edge caused by vibration. Additionally, lower
cutting resistance can decrease the load and heat, and can delay the
development of tool wear.

 Figure:- chip breakers:

4. What effect would decrease the cutting speed have on tool life of a milling
cutter?
Ideal conditions for cutting speed are short cutting time, long tool life, and
high cutting accuracy. In order to obtain these conditions, selection of
efficient cutting conditions and tool, based on work material, hardness,
shape and machine capability is necessary.
5. Name two ways work can be held on a cylindrical grinder?
Cylindrical grinding is defined as having two essential actions: The work (object) must be constantly rotating.
The grinding wheel must be constantly rotating.
6. Who is feed specified on a drilling machine?
There are two types of drilling machines used by maintenance personnel
for repairing and fabricating needed parts: hand-feed or power-feed. Other
types of drilling machines, such as the radial drill press. Numerically
controlled drilling machine. Multiple spindle drilling machine, gang drilling
machine, and turret drill press, are all variations of the basic hand and
power-feed drilling machines. They are designed for high-speed production
and industrial shops
7. What is the difference between truing and dressing a grinding wheel?
In most grinding operations, small chips of workpiece material can become
lodged in the cutting surface of the grinding wheel. In addition, if the
wheel bonding hardness is excessive, dulled abrasive grains can remain in
the grinding wheel. Both of these conditions will impair the cutting
efficiency, and these particles must be removed as needed to maintain
proper cutting action. This process, termed dressing is important in
obtaining good a result in grinding. Dressing is the process of sharpening a
grinding wheel. Grinding wheel must run true with every point on its
cutting surface concentric with the machine spindle. As the wheel

becomes loaded with workpiece material, it must be dressed to restore

sharpness. It must also run in balance because of its great speed. These
procedures of truing, dressing, and balancing are important parts of
grinding operations and the purpose of this unit is to familiarize you with
them. Correctly position a single-point diamond dresser in relation to the
grinding wheel. Both truing and dressing remove a certain amount of
material from the grinding wheel. Wheels should be trued and dressed
only enough to establish concentricity or to expose new sharp abrasive
grains to the workpiece. Some estimates are that more abrasive material
is sacrificed by dressing than is actually used to remove material from
work pieces. Optimal matching of grinding wheels to the grinding
operation results in an essentially self-dressing condition, where the force
of the grinding action is sufficient to release dull abrasive grains from the
bond and keep the grinding wheel sharp.
8. In wire cut EDM, why does electrode wear not affect the accuracy of the
cut?
WEDM has some cutting characteristics that must be addressed to insure
successful operations. During cutting operations especially fast cutting
the middle of the wire tends to lag behind the guides slightly, with lowertensile strength wires being more susceptible to this wire lag. The amount
of this lag or interval can vary from several thousandths of an inch during
roughing and speed cuts, to practically nothing during precision skim
cutting. A thicker part will contribute to this condition because the wire
guides will be farther apart.
9. What is concurrent engineering?
It is a work methodology based on the parallelization of tasks which is
sometimes called Integrated Product Development (IPD). It refers to an
approach used in product development in which functions of design
engineering, manufacturing engineering and other functions are
integrated to reduce the elapsed time required to bring a new product to
the market.
10.In welding, what do the letters GTAW stand for?
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG)
welding, is an arc welding process that uses a non-consumable tungsten
electrode to produce the weld.
Figure:- GTAW:

11.Define break-even point when comparing two types of machines making

the same part?
A company's break-even point is the amount of sales or revenues that it
must generate in order to equal its expenses. In other words, it is the point
at which the company neither makes a profit nor suffers a loss. Calculating
the break-even point (through break-even analysis) can provide a simple,
yet powerful quantitative tool for managers. In its simplest form, breakeven analysis provides insight into whether or not revenue from a product
or service has the ability to cover the relevant costs of production of that
product or service. Managers can use this information in making a wide
range of business decisions, including setting prices, preparing
competitive bids, and applying for loans.
12.In machining operations, how does forming differ from generating?
Generating refers to the creation of work geometry due to the feed
trajectory of the cutting tool; examples include straight turning, taper
turning, and profile milling. Forming involves the creation of work
geometry due to the shape of the cutting tool; common examples include
form turning and drilling.

13.What are the two forms of broaching and what types of machine is used
for each form?
The following are the two types of broaching and types of machine used
for each form:o

Surface broaches:The slab broach is the simplest surface broach. It is a general purpose tool
for cutting flat surfaces. Slot broaches (G & H) are for cutting slots of
various dimensions at high production rates. Slot broaching is much
quicker than milling when more than one slot needs to be machined,

because multiple broaches can be run through the part at the same time
on the same broaching machine. Contour broaches are designed to cut
concave, convex, cam, contoured, and irregular shaped.
o

Internal broaches:Solid broaches are the most common type; they are made from one solid
piece of material. For broaches that wear out quickly shell broaches are
used; these broaches are similar to a solid broach, except there is a hole
through the center where it mounts on an arbor. Shell broaches cost more
initially, but save the cost overall if the broach must be replaced often
because the pilots are on the mandrel and do not have to be reproduced
with each replacement. Modular broaches are commonly used for large
internal broaching applications. They are similar to shell broaches in that
they are a multi-piece construction. This design is used because it is
cheaper to build and resharpen and is more flexible than a solid design.

14.What is difference between a CNC machining centre and a universal

milling machine?
The term machining center describes almost any CNC milling and
drilling machine that includes an automatic toolchanger and a table that
clamps the workpiece in place. On a machining center, the tool rotates,
but the work does not. The orientation of the spindle is the most
fundamental defining characteristic of a machining center. Vertical
machining centers generally favor precision while horizontal machining
centers generally favor production but these are loose generalizations,
and plenty of machining centers break out of them. Another common
machining center type is the five-axis machining center, which is able to
pivot the tool and/or the part in order to mill and drill at various
orientations.
15.State an essential requirement for a lathe, which is intended to be used
with diamond tooling?
In diamond turning, a computer-controlled lathe with a diamond-tipped
tool is used to make precision optical surfaces in glass or other optical
materials. Glass-working lathes are similar in design to other lathes, but
differ markedly in how the workpiece is modified. Glass-working lathes
slowly rotate a hollow glass vessel over a fixed- or variable-temperature
flame. The source of the flame may be either hand-held or mounted to a
banjo/cross-slide that can be moved along the lathe bed. The flame serves
to soften the glass being worked, so that the glass in a specific area of the
workpiece becomes ductile and subject to forming either by inflation
glassblowing or by deformation with a heat-resistant tool.

16.What type of machining process would be used to cut an external keyway

in a shaft?
o Broaching:-

 Broaching is primarily used to cut square cornered external keyways. The

specific broach, bushing and guide are used for each given keyway crosssection, which makes this process more expensive than most of the
alternatives. However, it can produce the most accurate keyway out of all
the processes. There are three main steps in broaching a keyway: First, the
workpiece is set on the arbor press and the bushing is placed in the
opening of the workpiece. Next, the broach is inserted and pushed
through, cutting the keyway. Finally, shims are placed between the
bushing and the broach to achieve the correct depth necessary for the key.
17.Define what is meant by CAD CAM?
CAD/CAM (computer-aided design and computer-aided manufacturing)
refers to computer software that is used to both design and manufacture
products. CAD is the use of computer technology for design and design
documentation. CAD/CAM applications are used to both design a product
and program manufacturing processes, specifically, CNC machining. CAM
software uses the models and assemblies created in CAD software to
generate tool paths that drive the machines that turn the designs into
physical parts. CAD/CAM software is most often used for machining of
prototypes and finished parts.
Figure:- CAD-CAM:-

18.Name two materials used to produce EDM electrodes for a sink type
machine?
EDM is a process of the electrode and the work piece wearing each other
off, therefore, it is best if the physical, chemical, and mechanical
properties of the electrodes are taken to be the most durable. This will
help the process result in excellent results with least amount of resources.
Electrical Conductivity is one of the most important factors for any
material to be suitable for an electrode. Higher conductivity and lower
resistivity helps on efficient cutting.

Melting Point for an electrode must be higher than that of work piece,
because if electrode melts before the work piece the whole system fails. It
is best if electrode has as high melting point as possible with excellent
conductivity.

19.What feature controls the cutting speed of a milling centre?

The milling process removes material by performing many separate, small
cuts. This is accomplished by using a cutter with many teeth, spinning the
cutter at high speed, or advancing the material through the cutter slowly;
most often it is some combination of these three approaches. The speeds
and feeds used are varied to suit a combination of variables. The speed at
which the piece advances through the cutter is called feed rate, or just
feed. It is most often measured in length of material per full revolution of
the cutter.
20.What is the main difference in the type of materials that can be machined
when using either EDM or Water Jet cutting process?
There are two types of water jet cutting; plain or pure water jet cutting,
and abrasive water jet cutting. A waterjet cutting system operates by
directing water through a special nozzle under ultra-high pressure to cut
various workpiece materials. A basic waterjet system consists of an ultrahigh pressure pump system, the nozzle and catcher, and a filtration
system. Filtration is especially important in waterjet cutting because any
contamination within the pumps and plumbing can wear and abrade pump
and seal components, reducing service life. Therefore, filter precision is
very important. Unlike EDM, water jets can cut many non-conductive work
pieces, a major advantage.
21.Compare 2 of the following casting processes on surface finish, accuracy,
type of pattern and cost
a. Sand moulding
Sand casting is relatively cheap and sufficiently refractory even for steel
foundry use. In addition to the sand, a suitable bonding agent (usually
clay) is mixed or occurs with the sand. The mixture is moistened, typically
with water, but sometimes with other substances, to develop the strength
and plasticity of the clay and to make the aggregate suitable for molding.
b. Shell moulding
Shell moulding, also known as shell-mould casting, is an expendable mold
casting process that uses a resin covered sand to form the mold. As
compared to sand casting, this process has better dimensional accuracy, a
higher productivity rate, and lower labor requirements. It is used for small
to medium parts that require high precision. Shell mold casting is a metal
casting process similar to sand casting, in that molten metal is poured into
an expendable mold.
c. Gravity die casting
In gravity die casting makes it possible to manufacture items with
complicated inner shapes in a cost effective way in small and medium
quantities. Typical products produced this way are e.g. air intake
components for diesel engines, valves for flow systems, tanks for air

conditioning systems etc. Typically they have curved inner shapes which
are optimized for gas or liquid flow. Using shell sand cores gives close
tolerances and relatively good surface quality also for the surfaces
solidifying against the sand core.
d. Pressure die casting
Die casting is a precision, high volume production process in which molten
metal is injected under high pressure into a die having a cavity in the
desired shape of the part. Upon solidification, facilitated by a coolant
flowing through the die sections, die clamping is relaxed and the part is
ejected for additional cooling (quenching) and any required finishing,
trimming, or machining. Die casting production rates can range from
dozens to thousands of parts per hour.
22.Explain the purpose for which the investment casting process is used.
Indicate the type of material that can be cast and some general estimate
of the finish and accuracy obtained
Investment casting is an industrial process based on lost-wax casting, one
of the oldest known metal-forming techniques.
o Advantages of investment casting: Excellent surface finish
High dimensional accuracy
Extremely intricate parts are castable
Almost any metal can be cast
No flash or parting lines
23.Explain clearly the difference between the HOT and COLD chamber die
casting processes, giving the types of material casting in each process?
Die casting is a manufacturing process that can produce geometrically
complex metal parts through the use of reusable molds, called dies. The
die casting process involves the use of a furnace, metal, die casting
machine, and die. The metal, typically a non-ferrous alloy such as
aluminium or zinc, is melted in the furnace and then injected into the dies
in the die casting machine. There are two main types of die casting
machines - hot chamber machines (used for alloys with low melting
temperatures, such as zinc) and cold chamber machines (used for alloys
with high melting temperatures, such as aluminium). The differences
between these machines will be detailed in the sections on equipment and
tooling. However, in both machines, after the molten metal is injected into
the dies, it rapidly cools and solidifies into the final part, called the casting.

Figure:- Die casting hot chamber machine overview

 Figure:- die casting cold chamber machine overview

24.Giving examples of each show the difference between injection moulded

and compression moulded plastic parts?
Injection molding - In Injection Molding, melted plastic is forced into a mold
cavity. Once cooled, the mold can be removed. This plastic molding
process is commonly used in mass-production or prototyping of a product.
Injection molding machines were made in the 1930s. These can be used
to mass produce toys, kitchen utensils, bottle caps, and cell phone stands
to name a few.
Compression molded- In this type of plastic molding, a slug of hard plastic
is pressed between two heated mold halves. Compression molding usually
uses vertical presses instead of the horizontal presses used for injection
and blow molding. The parts formed are then air-cooled. Prices of
equipments used for compression molding are moderate. Examples are
helmets and safety shoes.

25.What is the main difference between Hot Rolling and Cold Rolling, Giving
examples of each process?
Hot rolling:o The initial breakdown of ingots into blooms and billets is generally done by
hot-rolling. This is followed by further hot rolling into plate, sheet, rod, bar,
pipe, rail. When the steel cools off it will shrink slightly thus giving less
control on the size and shape of the finished product when compared to
cold rolled.
Cold rolling:o The cold rolling of metals has played a major role in industry by providing
sheet, strip, foil with good surface finishes and increased mechanical
strength with close control of product dimensions. The term Cold Rolled is
mistakenly used on all products, when actually the product name refers to
the rolling of flat rolled sheet and coil products.

Figure: - hot rolling and cold rolling