ME3072

Mini Project

2011

09 Batch

Total attainable for final grading: 20 Marks

This project is a continuation of the project done under ME2022 (Manufacturing Engineering I). You have to consider about the same product used for the previsions project. If you think that change of the objective product is necessary, discuss with the lecturer and finalised on that within the first two weeks of the semester. Suppose you are a manufacturing engineer, and you are given to re-engineer the modified product. You will have to incorporate the modifications/ improvements suggested. You may use any literature that referred or made for ME2022 mini project. Marks will be awarded out 100, and it will account 20 marks of the final grading.

Submission -1 Submission format Due date & time Report 07/10/2011 before 15:00 hours

20 Marks

1. Material removal processes

1.1. The product you selected is an assembly of several components. Each of these components probably comprises of several features, and to produce a particular feature different machining techniques may be used. These techniques may require several machining operations in different sequences. 1.1.1. Select one component from your assembly. Describe the machining operations needed to manufacture the part starting from a primitive work-piece. If the part material is nonmetallic, assume a suitable metal for the part. [4 Marks] 1.1.2. Explain the sequence of operations with reasons. [4 Marks] 1.1.3. Sketch the geometry of the part before and after each machining operation. [4 Marks] 1.1.4. Discuss how you consider about tolerances and surface finish, when selecting the machining operations. [4 Marks] 1.2. Identify one turning, one milling and one drilling operation has to be done for manufacturing of any of the five different parts, and select suitable machining tool for each operation. Determine the tool geometry, material, etc explaining the reasons for decisions. [4 Marks]

ME3072

Last updated-11/05/2011

Page 1

Submission -2 Submission format Due date & time Report 21/10/2011 before 15:00 hours

40 Marks

2. Casting processes 2.1. Select one component from the assembly. Preferably a metallic component, or assume the material to be a metal. Discuss the suitability of following casting processes for manufacturing the selected part. Explain the materials properties may changed due to the process. 2.1.1. Sand casting [5 Marks] 2.1.2. Investment casting [5 Marks] 2.1.3. Low pressure die-casting [5 Marks] 2.1.4. Pressure die-casting [5 Marks]
2.2. Select the best process to manufacture the concerned part out of the given casting

processes. If none of above is suitable explain the reasons, and recommend any other casting process applicable. [10 Marks]
2.3. Out of the casting processes discussed in the previous section, design the mould, pattern, and/ or any other tool required for one of the processes. [10 Marks]

Submission -3 Submission format Due date & time Report 04/11/2011 before 15:00 hours

40 Marks

3. Bulk forming processes 3.1. Each and every component selected from your assembly discuss the possibility and suitability of manufacturing using forming process/es belong in to following forming processes categories. Identify the changes to material properties due to the forming
operations done. An operation may be used to make the complete part, some features of the part, or as an initial preparation of the work-piece. 3.1.1. Extrusion [10 Marks] 3.1.2. Forging [10 Marks] 3.1.3. Rolling [10 Marks] 3.2. Out of the forming processes discussed in the previous section choose a forming

process from each category and design a die, punch or any other tool required for each forming operation. [10 Marks]

ME3072

Last updated-11/05/2011

Page 2