CNC MACHINING

General CNC Machining Process:

Computer numerical control, or CNC, machining is a computer-aided technique that can

be used in conjunction with a broad range of equipment. It requires software and programming,
usually in the G-code language, to guide a machining tool in shaping the workpiece according to
preset parameters. As opposed to manually guided methods, CNC machining is an automated
process. Some of its benefits include:

 High production cycles: Once the CNC machine has been properly coded, it usually needs
minimal maintenance or downtime, allowing for a faster production rate.
 Low manufacturing costs: Due to its turnover speed and low manual labor requirements,
CNC machining can be a cost-efficient process, particularly for high-volume production
runs.
 Uniform production: CNC machining is typically precise and yields a high level of
design consistency among its products.

Process Involve in CNC machining:

1. The product places in CNC machine for drilling screw to the wheelchair frame as shown
in a figure.

Figure : Wheelchair frame

2. The CNC machine will drill hole as pointed by the arrow in figure above.
GRINDING AND POLISHING

Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool. A
wide variety of machines are used for grinding. Polishing and buffing are finishing processes for
smoothing a workpiece's surface using an abrasive and a work wheel or a leather strop.

The purpose of the grinding step is to remove damage from cutting and to remove material
approaching the area of interest. Stainless steel that use in wheelchair frame require more
aggressive abrasives to achieve adequate material removal. Thus coarse SiC abrasives (120 or 180
grit) are recommended for stock removal requirements. Once planarity and the area of interest are
obtained a standard 240, 320, 400 and 600 grit series is recommended.

Polishing is the most important step in preparing a specimen for microstructural analysis.
It is the step which is required to completely eliminate previous damage. To remove deformation
from fine grinding and obtain a surface that is highly reflective, the specimens must be polished
before they can be examined under the microscope. Polishing is a complex activity in which factors
such as quality and suitability for the cloth, abrasive, polishing pressure, polishing speed and
duration need to be taken into account.

Process involve in grinding and polishing :

1. After the wrench has finished the machining process. The robotic arm will take the part
for grinding at the grinding machine.
2. Then the machine will grind the product on one side.
3. After one side is complete, the robotic arm will spin the product and the grinding
machine will polish the product again.
4. The process are repeated until all the surface of the product are polished.
HEAT TREATMENT

Heat treatments are used to soften the steel, to improve the machinability, to relieve
internal stresses, to impart dimensional stability, and to refine the grain size. It is a process of
heating cycles where the metal is subjected to controlled temperature changes in solid state.
Heating process can change the size and shape of grain structure and can also change the
constituents and hence the properties of steel.

Type of heat treatment used: Hardening & Tempering

 Hardening and tempering with the help of furnaces (atmospherically controlled) to achieve
the demand of a neutral, through hardened structure, consisting of tempered martensite.
 In order to reduce the internal stress and suitable of grain flow, material used for
manufacturing the adjustable wrenches should be heat treated to increase the toughness.
 Heat treatment increases toughness property of the adjustable wrench so that it may
withstand high stress during the application.
 A special high treatment ensures a particularly long service life. High strength is obtained
when the adjustable wrench is hardened. To simultaneously impart high toughness to the
adjustable wrench, it is allowed. The hardening and tempering operations are combined.

The Process in heat treatment of wheelchair frame.

1. The frame is well displayed in metal baskets enter the hardening furnace until reaching a
temperature of 850 degree centigrade.
2. The dissociated methane at the high temperature generates a gas that protect the pieces
from oxidation. The dissociated methane and the hardening phase give the metal strength
and durability.
3. The frames are then quickly dipped in an oil bath. They cool rapidly and become very
hard and resistant but not sufficiently elastic. Figure shows the oil bath machine.
 Figure : The Oil Bath Machine

4. After the thorough washing phase the frames are once again heated to 360 degree in the
tempering furnace and after a slow cooling to 180 degrees centigrade they become tough
thus resistant to shocks and stresses.

FINAL ASSEMBLY

All the part of wheelchair have been joint using screw and bolt. Hex bolts are used to join
a main frame and wheel. Figure shows the common type of fastener. While for footrest assembly
is comprised of an extension tube and a mounting assembly for mounting the extension tube to a
wheelchair frame. A support bracket extends from the extension tube.

Coupling means is provided for releasably coupling the support bracket relative to the
wheelchair frame in a first position. The coupling means includes means for enabling the support
bracket to selectively rotate to a second position beside the wheelchair frame and to a third position
beneath the wheelchair seat.
 Figure : The Common Type of Fastener.

MATERIAL OF PRODUCT

Wheelchair contain a several type of material used. Every single product has its own
material selection. It is important because it will make a good product that can withstand a
corrosion, impact and long-lasting. The microstructure of material must be tested first before
proceed the process. Table shows the material use in wheelchair.

Table : Material use in wheel chair

PART MATERIAL
Frame Mild steel, titanium and carbon fibers.
Seats Canvas, Rexene, and nylon.
Footrest/Armrest/Handle P.V.C or plastic
Wheels Metal frame , molded poly propylene
Tires Rubber with a tubing inside
Casters P.V.C. injection molded in different sizes
 Frame is a main part in wheelchair. The material use for frame is mild steel. Steels are a
large family of metals. All of them are alloys in which iron is mixed with carbon and other
elements. Steels are described as mild, medium- or high-carbon steels according to the percentage
of carbon they contain, although this is never greater than about 1.5%. Table shows a percentage
of carbon steel.

Table : A Percentage of Carbon Steel.

Type of steel Percentage of carbon

Mild steel Up to 0.25%

Medium carbon steel 0.25% to 0.45%

High carbon steel 0.45% to 1.50%

TOOLING REQUIRED

Injection Molding

The mold or die refers to the tooling used to produce plastic parts in molding. Molds are
typically constructed from hardened steel, pre-hardened steel, aluminum, and/or beryllium-copper
alloy. The choice of material to build a mold from is primarily one of economics. Steel molds
generally cost more to construct but offer a longer lifespan that will offset the higher initial cost
over a higher number of parts made before wearing out.

Pre-hardened steel molds are less wear resistant and are primarilly used for lower volume
requirements or larger components. The hardness of the pre-hardened steel measures typically 38-
45 on the Rockwell-C scale. Hardened steel molds are heat treated after machining, making them
superior in terms of wear resistance and lifespan. Typical hardness ranges between 50 and 60
Rockwell-C (HRC). However, typical moulds are constructed from hardened steel. Tool steel is
used because it is not prototype or very short production runs, otherwise, mild steel, aluminium,
nickel or epoxy would be suitable.
Direct extrusion
The tools used in direct extrusion are stem, mantle, liner and liner holder. Dies are broadly
grouped as solid (or flat) dies, which produce solid shapes, and hollow dies, which produce hollow
or semi hollow shapes. Combinations of solid, semi hollow, and/or hollow shapes may be
incorporated into a single die. A solid die may have one or more orifices or apertures through
which the softened alloy is forced (extruded). Multiple apertures in a single die produce multiple
extrusions with each stroke of the press. Solid dies are used to produce profiles that do not contain
any voids.

Hollow dies take a variety of forms. Bridge, porthole, and spider dies, for example, include
a fixed stub mandrel as an integral part of the die. Each type of hollow extrusion die serves certain
functions and carries its own advantages and disadvantages. A hollow die produces profiles with
one or more voids. The profile could be as simple as a tube with one void or as complex as a profile
with many detailed voids.