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The Hong Kong Polytechnic University

Individual Report
Ic348- Appreciation of Manufacturing Processes

Yuen Wai Ying ,Eunice 10256712d Group K


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IC348 Appreciation of Manufacturing Processes

I. i.

Introduction Project overview and objectives The objectives of this subject are developing students, understanding on the principles and operations of common manufacturing processes, as well as the properties and application of common materials.

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Brief description of project The class was divided in to group A-K, around 10 people in 1 group. Each member is responsible to manufacture and fabricate a robotic stag beetle with different parts and gears. The robotic insect contained around 20 parts. It included cover, bush, spacers, gears and gear box plates, gear box shafts etc. Each part is produced at the different workshop and followed the tolerance and dimension indicated in engineering drawings. Ten workshops are provided to teach students the basic techniques and do the manufacturing of different parts. The workshop includes Hot Metal, Marking Out / Machining, QC/ NCM, PCM, CAM, Plastics, Rapid Prototyping, Sheet Metal, welding, surface finishing. After the workshops, we have a mentor session. The mentor session is let the mentor know more about what the jobs have done and leant by the students. If we have no questions we can dismiss earlier. In the workshops, we had learnt how to use different kinds of machines and methods that taught by instructors in the IC center. Also, we can apply the knowledge to make different parts of the product and discuss how to achieve it. During each process, we can have practical experience instead of only learn the theories or knowledge. Besides learning the skills, there are various safety instructions in different workshops. Everyone can pay head to it and protect ourselves as well as the workers. After producing different parts in the workshops, all the parts were assembled together to make a beetle. The problems encountered in the project were reported during presentation session.

IC348 Appreciation of Manufacturing Processes

II. i.

Manufacturing Processes Description of the whole project flow Week 1 Workshop title Introduction Work description 2 3 4 NCM 5 Sheet Metal 6 Welding 7 Hot Metal 8 Plastic 9 QC Marking Out / Machining Introduce the project Introduce the industrial safety instructions Form group and commit a common goal Meet the mentor Realize the project flow Introduce the principle of the machining Operate the lathe machine Holiday Learn the working principles and writing the code used in NCM Fabricate the teeth of gears by wire cutting Introduce the shearing machine, folding machine, drilling machine Fed the data from the CAD drawings into its computer and bends as specified Cut and bent the cover by shearing and folding machines Apply CNC pressing machine to press the metal into desire shape Perform gearbox plate, battery mount, gearbox cover Introduce difference welding process Exercise the electric arc welding and gas welding Introduce and taught brazing Perform brazing the cover rear Perform sand casting of legs and leg links Report the progress to the mentor Suggest the solutions of problems facing Introduce material selection Perform silicon rubber molding Fabricate the mold of the controller case and knobs Introduce the measurement techniques of optical
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IC348 Appreciation of Manufacturing Processes

projector, roughness gauge, square 10 CAM 11 12 Machining PCM 13 plastic 14 15 16 17 CAM Machining Surface finishing 18 Fitting and Assembly 19 Presentation Operate turning, drilling and boring by CNC lathe machine Fabricate the gearbox shaft, spacer Exercise the milling and lathe machines Study electroplating and anodizing of cover Report the progress to the mentor Suggest the solutions of problems facing Design the drawing on the cover Introduce injection molding and vacuum forming Study the characteristic of different plastics Fabricate leg spacer No lesson Perform CNC milling machines Exercise the milling and lathe machines Gear hobbing Perform surface polishing for parts and components Polishing the robot-leg , the link, cover Solder and wire the circuit between controller and body of robotic beetle Check inconformity parts Modify the dimension for fitting every components Undergo the performance test Take a video the Robotic Insect Overview the project Share and discuss the experiences and difficulties in the project

IC348 Appreciation of Manufacturing Processes

ii.

Ideal process flow suggestion In order to suggest an ideal process flow, we need to know the procedures of work process. So that former process facilitates the later working process. Parts Adjustment Pin Bevel Gear_15_45 Bush _a Bush _b Cover Front Frame Foot Gear_b_21T Gear_b_53T Gear Sub Assembly 1 i. ii. i. ii. Gear _a _53T Gear _a _21T Bevel Gear_45_15 Gear _a _21T Procedure of working process Turning Turning Drilling Bevel Gear Milling Tapping CNC Turning CNC Turning CNC Turret Pressing CNC Press Braking Welding CNC Milling Injection Moulding Drilling Wire cutting Turning Drilling Gear Hobbing Assemble Drilling Tapping Turning DrillingGear Hobbing Anodizing Turning Wire cutting Assemble Drilling Tapping Turning Drilling Bevel Gear Milling Turning Wire cutting CNC Turret Press Folding Welding Turning Drilling Tapping Turning Drilling Tapping CNC Turret Pressing Folding Tapping CNC Turret Pressing Folding CNC Turret Pressing Folding Tapping CNC Turning Turning CNC Turning Turning Milling Drilling Tapping Assemble CNC Turret Pressing Turning Drilling Tapping CNC Milling
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Gear Sub Assembly 2

Gear Box _cover Gear Box Pin 1 Gear Box Pin 2 Gear Box Plate 1 Gear Box Plate 2 Gear Box Plate 3 Gear Box Shaft _a Gear Box Shaft _b Gear Box Shaft _c Gear Box Shaft _d Leg link Leg Linkage i. ii. Link 1 Leg _Spacer

Motor Holder

IC348 Appreciation of Manufacturing Processes

Robot _ Leg _Assembly FSpacer _a i Space _b r Space _c s

Sand casting Milling Drilling CNC Turning Turning Turning

tly, we should do QC after producing the product. Secondly, surface finishing should be the last section, as we should finish and check the dimension or the function ability before the surface finishing. Thirdly, for the robot leg, we should carry out sand casting before milling and drilling. Fourthly, the after the CNC, we need to fold, so CNC should put before sheet metal. Last but not least, PCM is also about the surface finishing, so it can be done later. The flow is therefore as follow: Hot metal-> CNC->CAM->machining->sheet metal->welding->plastic-> PCM -> QC ->surface finishing->assembly iii. Process flow comparison Basically, the process follows the ideal path, however, some point need to be specified. Originally the quality control should make after producing the parts. However, we should know QC before 2 machining section. It is because we are required to know the notation of tolerance on the engineering drawing before milling and turning, so that the dimension can be correctly made for the ease of assembly. Originally CNC and CAM can do almost all the job, the machining is for auxiliary purpose like hobbing the gear for non-vertical plane. However, machining is put before CNC and CAM, so that we know the basic principle of cutting before the learning the program in CNC and CAM. Besides ,there are three machining section , actually two should be enough .However , machining is the most time consuming part in the workshop ,as most of the part is made in machining , so we need to have more sections than required.

IC348 Appreciation of Manufacturing Processes

iv.

Component Description Leg This component is made by a casting material and without any flat surfaces for the reference in machining process. So, special fixtures are made to mount the component to machine the surfaces and to drill the holes in the Milling Machine.

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Workshops it went through a. hot metal In the hot metal workshop, we perform the die casting for the beetle legs .For the sand casting; we need to fade out the impurities of the sand. It is because the sand is used recyclable. After the filtration, prepare the sand casting mould plate. Insert the sand in the lower base plate. Fix and mix the sand into the lower plate firmly. Please ensure that there is no air bubbles between the sand. Then place the similar product of same shape of the leg on the center of the plate. Then develop the runner and gate and spur system. Next, put the sand in the upper plate after put some unmated particles between two plates. After the completion of all sets of legs, wait for the pouring of molten aluminum by the tutor. After a few minutes, the material cool down and the product formed. Lastly, direct
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IC348 Appreciation of Manufacturing Processes

flow the plate to the sand area. Beware of the sand, it is because there are some sharp flash adhesive with the product. After the extraction of the product, do some procurement of the legs such as parting off the legs and polishing the leg surfaces.

b. Machining After cutting off the runner of the casting and smooth the surface by a hand file, the component is clamped on the fixtures which mount on the milling machine Cut the surface of the three knobs stick out to 1 mm as indicated in the engineering drawings. Drill 8mm diameter holes. Turnover and reclamp the component in the fixture and the top surface is cut so that the thickness of the leg is 10mm.

c. Surface Finishing Surface Finishing consist of treatment and pre-treatment. First we conduct the physical pretreatment, which is filing and grinding. Files are used to make the surface smooth and de-burr as the surface might be very rough. We can use sandpaper to make the surface smoother. Afterwards, we carry out sand blasting. This process can roughen the surface uniformly as decorative surface. Moreover, it can remove metal flash and de-burr. Then, we polish the leg. This process can make the part brighter and more reflective. Secondly, we carry out the chemical pre-treatment, which is solvent cleaning and ultrasonic clean. Solvent clean can remove heavy soil, oil and grease effectively, while ultrasonic clean can remove aforesaid substance where at the tiny gap or corner of the part. It can remove unseen substance such as dust. Thirdly, it is the finishing process; Plating and anodizing are similar process while the chemical solution (electrolyte) is different. Stannous pyrophosphate, cobalt sulfate and brighter is used for the plating whereas sulphuric acid is used for anodizing in
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IC348 Appreciation of Manufacturing Processes

this training. III. i. Material Properties Change of material I would like to change the material of bevel gear from aluminum to stainless steel. As the bevel gear is directly connected to the motor, and the diameter of the gear is rather small, so that each teeth is enduring a large force. Aluminum a soft metal , it is easily deformed with such force applying to the aluminum teeth .So ,by changing the material to stainless steel it give us a lower Youngs modulus , the teeth is less easily wore out and less easily deformed .The robot can work for a longer period of time.

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Change of manufacturing process I would like to change use CNC instead of traditional machining. Since the programming is not difficult, the program of this part only consists of several lines. However, the product can be produced mush faster than traditional machining .Large batch can be produce in a short time. Besides, the spacer is rather thin, it is hard one slight deviation of the dimension will give large percentage error. By using CNC, it the thickness is easily determined, this enhance the product quality.

IC348 Appreciation of Manufacturing Processes

IV. i.

Conclusions Objectives achievement and satisfaction of the project Appreciation of manufacturing process (IC348) provided an opportunity for me to learn industrial knowledge. I did not have any industrial practical experience before attending this training. It is a good chance for me to gain more related knowledge through the project. I may not be proficient in some of the workshops, but I am eager to learn and more as much as possible to prepare myself as an engineer. Fortunately, I think I have achieved the primary goal and have gained the experience to operate different machines, together with the experience in working in different kinds of manufacturing processes.

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Observations from the whole project I observed that hand on practice and theories are both very important. Theories are not always suitable for practical real situation and I have learnt to think carefully before action. Theories are for reference only and I have to make decision depends on the real situation. For example, in surface finishing though we applied the calculated current density for tin-cobalt coating, part of the surface is burnt .Later on; the current we applied is less than the theoretical one. Take the Numerical Control Turning Machine as an example, the cutting speed calculated by the formula based on the theory was not suitable. The speed calculated
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IC348 Appreciation of Manufacturing Processes

was too fast to turn the material and hence easily reduce the life span of the cutting tool. In fact, it is used to deciding the turning speed according to personal experience. I also observe that safety issue is very important .In the first day of IC, I have been shown what happen to the girl who did not tie up long hair while using center lathe. V. i. Delights and comments Briefly describe the most impressive process/workshop and difficulties encountered and the way you solved it The most impressive workshop is PCM .It is amazing to know that PCM can produce sophisticated products. I personally like the calendar very much, the dragon is very vivid. Besides, it is a special experience for me to go into the dark room to put the film into the machine and get the photo tool in the neighboring room. The problem is mainly attributed to the assembly part, during the sub-assembly, the one of our group mate assemble 2 parts in wrong direction. As the 2 parts are assemble by the clamp, it is almost impossible to pull them apart .We almost need to redo the 2 components again. Luckily, we asked Mr. Sin, He helped us to use the clamp to push it in opposite way. The 2 parts separate finally. ii. Recommendation of improvement of the training QC work shop can be arranged as early as possible, as we have to reproduce some components due to misinterpretation of the specification. For example, QC can be arranged after the introduction. Leg link can have a simpler design, as leg link is produced by sandcasting, sandcasting is best for prototyping; Most of our leg links are deformed. More notes and better website design. When I try to find out the data of our project, I find out that the smw and mmu is not directly linked in the IC homepage. I think add back those links can facilitate students.

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IC348 Appreciation of Manufacturing Processes

iii.

Overall opinion of the training such as the value, workload, interest, arrangement, or staff IC348 gives me a brief overview of the manufacturing process. Nowadays 3D printing is a heated topic, with such technology it is able to print guns, or even print house to live in. I hope that the IC center will incorporate it in IC 348 in the future. The workload of IC is not heavy as the task is assigned by the IC staff, and we do not need to revise or do any home work. The staff is helpful and talkative; they teach me quite a number of skills in tackling the technical difficulties. To conclude, I found this training was very useful which can be well equipped me as an engineer for the future career. I am looking forward to having similar training in the future.

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