Production Technology - Knol Book of Readings

Manufacturing Technology and Materials
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Preface

Introduction

Materials

Materials and Structure

Physical and Manufacturing Properties of Materials

Metal Alloys

Ferrous Metals and  Alloys

Non-Ferrous Metals and Alloys

Polymers (Plastics)

Ceramics

Composite Materials

Nanomaterials

Wood

Production (Manufacturing) Processes

Carpentry

Metal Casting

Metal Rolling

Metal Forming

Drawing and Extrusion

Drawing and Extrusion

Sheet Metal Forming

Powder Metal Processing

Plastics Moulding and Other Processes

Production Processes for Ceramic Items

Theory of Machining

Machining Processes - Introduction

Cutting Tools - Materials and Geometry

Cutting Fluids

Turning and Lathes

Turning and Lathes (new link)

Milling

Milling - Chapter - Knol Collection

Shaping  and Planing

Grinding and Other Surface Finishing Processes

Miscellaneous Machining Processes

Automatic Machines and CNC Machines  (new link)

Joining Processes

Welding

Welding

Assembling

Measuring Instruments and Metrology

Manufacturing Processes for Specific Components and Products

Manufacturing Processes for Specific Components and Products

Machine and Machine Tools Selection

Machining Processes - Industrial Engineering

Micromachining

Unconventional Machining Processes - Chapter

Manufacturing Processes - Interesting Web Pages

Production Technology - Videos - Knol Book 

Machine Tools - Links to Various Brands and Products


Knol search link for production, manufacturing, and fabrication

Original knol - http://knol.google.com/k/narayana-rao/production-technology-knol-book-of/2utb2lsm2k7a/ 3218

IC Engine - Car Engine Specifications - For Crankshaft Design

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Mercedes-Benz SLS AMG "Gullwing"

2009

The SLS AMG is powered by a 6208cc V8 engine, called the M159, which is based on the M156 as used in the E 63 AMG and certain other AMG models in the Mercedes-Benz lineup. 

The bore and stroke remains at 102.2 mm and 94.6 mm, but high-strength components, forged pistons, improved dry sump lubrication, an optmised crankcase structure and reduced overall weight make this engine an even better performer than the M156.

In this application it boasts some 571 PS (420 kW) at 6800 rpm and 650 Nm of torque at 4750 rpm. This is enough to propel the 1620 kg coupé to 100 km/h from rest in a claimed 3.8 seconds, and on to an electronically-limited top speed of 317 km/h. 

Source:

http://www.carfolio.com/article/?id=234

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Aston Martin V12 Vantage.

2009

The engine features a number of enhancements over the standard 6.0-litre V12 found in the DB9. These include a ‘by-pass’ engine air intake port that opens up at 5500 rpm, a revised induction system and re-profiled air inlet ports that further improve airflow into the combustion chamber to improve performance. 

The naturally aspirated 6.0-litre V12 hand-built engine produces 510 bhp (380 kW / 517 PS) at 6500 rpm and 570 Nm (420 lb ft) of torque giving the driver access to high levels of power and torque at all engine speeds. Unique to the V12 Vantage is a ‘Sport’ button which allows the driver to choose between two powertrain modes. 

The default ‘normal’ provides a more progressive, throttle response, suited to more everyday situations, such as driving in urban areas, heavy traffic, or in challenging weather conditions. Selecting ‘Sport’ mode delivers a sharper throttle response together with a sportier exhaust note. This mode is designed for use in more dynamic driving situations where sharper responses are required. 

http://www.carfolio.com/article/?id=230

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Maruti 800

Engine

Swept volume (cc) 796

Engine type 3 cylinder inline, FC engine 2 valves per cylinder, MPFI

Max. power (bhp @ rpm) - Petrol 37 @ 5000 37 

                                                  LPG 35 @ 5000  

Max. torque (Nm @ rpm) - Petrol 59 @ 2500  

                                                  LPG 56 @ 2500  

Car weight

Weight

Kerb Weight (Kg) 683

Gross Vehicle Weight (Kg) 1000

Source: http://www.maruti800.com/specifications.asp

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Original knol - http://knol.google.com/k/narayana-rao/ic-engine-car-engine-specifications-for/2utb2lsm2k7a/ 2325

Crankshaft Casting, Forging, Machining - Organizations

 

One of the series of knols on Crankshaft Design and Machining

 

Industrial Engineering Projects and Opportunities in Crankshaft Design and Production

 

Crank Shaft Machining - For Reference in Industrial Engineering Course

 

IC Engines and Parts - Videos

 

IC Engine - Car Engine Specifications - For Crankshaft Design

 

 

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Germany

 

Alfing Large Crankshafts

http://www.marintec.german-pavilion.com/gp/marin09/exhibitors/dateien/05_Alfing_Image_L_englisch_050109.pdf

 

 

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India

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Bharat Forge Crankshaft Machining   

Current annual capacity : 650,000 nos.

Current variety : 1 cylinder to 12 cylinder

International customers :
Detroit Diesel Corporation, Daimler Chrysler, Caterpillar, Ford, Cummins, Wuxi, Yuchai, Iveco, Volkswagen, Man, Perkins, General Motors, etc.

Domestic customers :
Tata Motors, Ashok Leyland, Force Motors, Maruti, Tata Cummins

http://www.bharatforge.com/facilities/crankshaft_machining.asp
Accessed on 15.3.2010
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Mahindra Forgings Limited, Chakan

Presse
3000 MT      12 to 17 Kg     Crankshaft/Stub Axle/Camshaft/Knuckle
5000 MT     18 to 48  Kg    Crankshaft/Stub Axle/Steering Knuckle


Crankshaft Machining

An Overview of the Machining facility ….

The Machining set-up has strong capability and flexibility in-built for manufacturing products like 4 and 3 cylinder high quality crankshafts, Steering Knuckle and connecting rod for a wide range .
Planned capacity is 275 K Crankshafts , 500 K of Steering knuckles , 250 K sets of Connecting Rods.

It is a state of art Crankshaft Machining facility where in there is capability to machine Crankshaft for turbo charger requirements, that is, fillet hardened, as well as naturally aspirated Crankshaft.

In turning module they have Heller Turn-Turn Broach machines for journal and pin turning. These machines facilitate Crankshaft turning with lesser amount of stress induced in the component.

For oil hole drilling operation they  are using Makino Make –HMCs with through coolant solid carbide drills with coolant capacity of 70 Bar pressure, to generate burr-free cleaned oil hole galleries.

For induction hardening they are having 225 KW capacity medium frequency machines, with IGBT and CNC controlled fully automatic operation. These help achieve uniform hardness and consistent case depth. The hardening is followed by continuous flow tempering furnace.

The highlight of the post heat treatment, grinding operations is a new generation CBN Journal grinder that they use for main bearing grinding of Crankshaft at 120 m/sec. The machine gives an output quality of 0.25 micron Ra, surface finish on as ground diameters. This machine is totally CNC control including Dressing with multipoint cup dresser. This facilitates the radius blending with the side wall upto 90% .

All grinding machines are provided with Marposs in-process gauging systems as well as Marposs post process gauging systems for inspection of Crankshafts.

To achieve critical positional tolerances of flange holes and dowel holes we have established Makino-HMC with solid Carbides drills and Taps for consistency.

For post-grinding improvement of geometric tolerances (form correction) and surface finish we have installed a super finishing machine with a capability to deliver 2Rt requirements. This is builtt by an IMPCO, USA licensee in India.

Lastly, the pre-packing cleaning of the cranks is carried out on a Specific Hole and General washing machine, to demanding level of Millipore values.

The Process and allied equipment ensures that at every stage of crankshaft manufacturing, it gets validated, ensuring that highest, stringent quality levels are maintained at all times. The facilities are supported with the central Inspection equipments like ADCOL for roundness checking , Counter measurement system for inspection of fillet radius and surface finish parameters , CMM for detailed dimensional measurement, Surface hardness and Micro Hardness Testers.

The manufacturing process is established for ppk ≥1.67

The facility is run by a highly skilled team of specialist engineers and technical staff, having vast experience in manufacturing, machine building and projects.

http://mahindraforgings.com/infrastructure.htm
Accessed on 15.3.2010
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UK

 

Albion Automotive, 2001 news article

http://www.themanufacturer.com/uk/profile/272/Albion_Automotive

 

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Original knol - http://knol.google.com/k/narayana-rao/crankshaft-casting-forging-machining/2utb2lsm2k7a/ 2332

World's Largest Green Energy Venture - Airvoice Group Project - India

10,000 Megawatt Solar and 3000 Megawatt Wind Energy Project

Airvoice Green Energy Pvt Ltd, New Delhi, India, announced the launch of an ambitious project in the renewable energy sector. It proposes to set up 10,000 MW of Solar Power and 3,000 MW of wind power in the state of Karnataka. 

The proposed solar power plant would be based on Photo Voltaic (PV) technology and will be implemented in . 12 high potential districts in the state of Karnataka.  This would be the largest solar power plant in the world till date. Currently the largest solar PV power plan in the world has a capacity of only 60MW based out of Spain. Sanjay Kapoor, the CMD of Airvoice Group, indicated in the press conference held at Villa Medici, The Taj Mahal Hotel in New Delhi, “this project alone would meet around half of the ambitious target of 20,000 MW as envisaged by the Jawaharlal National Solar Mission announced by the Honorable Prime Minister Sri Manmohan Singhji”. The Karnataka Renewable Energy Development Limited (KREDL), the nodal agency of renewable energy projects, has given in principle approval. The entire project would be done in 5 phases. Airvoice would be setting up a first phase pilot of 100MW capacity. The work has already started and it is expected that the detailed project report (DPR) would be submitted within the next 90 days.

Airvoice group has also identified 4 high potential districts where the wind farm would be set up. The first phase of the 3,000 MW wind farm project would be 200 MW and the work on the same has already started. It is expected that the DPR would be submitted in the next 4 months. 

Airvoice is entering into a JV partnership with Satluj Jal Vidyut Nigam Limited (SJVNL, Mini Navaratana) for the first phase of both the solar and wind power projects. S.P. Singh, GM of SJVNL, mentioned in the press conference that the board has in principle approved the partnership and the same would be submitted to the government.  SJVNL operates the largest hydro electric power plant in the country and now partnering with the largest renewable energy project in the world.

(Source: http://www.airvoicegroup.in/kar1.htm   )

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Video 10 minutes

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Original knol - http://knol.google.com/k/narayana-rao/world-s-largest-green-energy-venture/ 2utb2lsm2k7a/ 2286

Printed Circuit Board Manufacturing and Assembly Process

 

 

An overview is available in  http://www.radio-electronics.com/info/manufacture/manufacture/overview/assembly-production.php  .

 

The Optimization of PCB manufacturing by improving the drilling process productivity by Mirca Ancau, Computers and Industrial Engineering, September 2008, pp. 279-294.

 

Minimizing Cycle Time for PCB Assembly Lines:
An Integer Programming Model
and a Branch-and-Bound Approach
P. Ji Y. F. Wan
Hong Kong Polytechnic University Hong Kong Polytechnic University
Hong Kong Hong Kong
Information and Management Sciences
Volume 19, Number 2, pp. 237-243, 2008

Abstract
The problem is formulated into a pure integer programming model with the objective of minimizing the cycle time of the PCB
assembly line. Furthermore, the mathematical model is solved by the branch-and-bound
(B&B) algorithm in order to get the optimal solution. Finally, a numerical example is
presented to illustrate the mathematical model and the B&B algorithm.

 http://jims.ms.tku.edu.tw/PDF/M19N23.pdf .

 

Optimizing  PCB design to make it easily manufacturable on today's SMT equipment

 http://www.meccompanies.com/white_paper1.html  .

 

Inline Component Placement Inspection: Lowering PCB Assembly Costs with Continuous Quality Improvement
By Bob Kelley and John Weisgerber, GSI Lumonics

http://www.gsig.com/systems/PDFs/svs_inline_cpi.pdf   .

 

PCB Assembly Guidelines for Intersil Wafer Level Chip Scale Package Devices - A technical note is available in  http://www.intersil.com/data/tb/TB451.pdf  . (4 pages)

 

An article on redesign of circuit board assembly by Kelvin Cross is in Industrial Engineering Magazine of January 1988. pp. 52 to 56.

 

A Knol

How are PCBs made?

Original knol - http://knol.google.com/k/narayana-rao/printed-circuit-board-manufacturing-and/ 2utb2lsm2k7a/ 2477

Manufacturing Processes for Specific Components and Products

Printed Circuit Board Manufacturing and Assembly Process

How to Make A Spoon Carving Knife

Manufacturing of Boiler Drum

Original Knol - http://knol.google.com/k/narayana-rao/manufacturing-processes-for-specific/2utb2lsm2k7a/ 3654

Manufacturing Processes - Online Knowledge Bank

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http://www.engineersedge.com/manufacturing_design.shtml
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Large number of topics in all areas of manufacturing - content is rather brief in each topic