Posted tagged ‘mass production’

Air Car Is Heading For Mass Production

September 25, 2011

The Air Car is the brainchild of Guy Negre, a French inventor and former Formula One engineer. In February, Negre’s company, Motor Development International (MDI), announced a deal to manufacture the technology with Tata Motors, India’s largest commercial automaker and a major player worldwide. “It’s an innovative technology, it’s an environment-friendly technology, and a scalable technology, ” says Tata spokesperson Debasis Ray. “It can be used in cars, in commercial vehicles, and in power generation. ”


01-aircar-production-launching next year-guy negre, MDI, Motor development International

Though Negre first unveiled the technology in the early 1990s, interest has only recently grown. In addition to the Tata deal, which could put thousands of the cars on the road in India by the end of the decade, Negre has signed deals to bring the design to twelve other countries, including South Africa, Israel, and Germany. But experts say the car may never make it to US streets.

01-air-car-engine

The Air Car works similarly to electric cars, but rather than storing electrical energy in a huge, heavy battery, the vehicle converts energy into air pressure and stores it in a tank. According to MDI’s Miguel Celades, Negre’s engine uses compressed air stored at a pressure of 300 bars to pump the pistons, providing a range of around 60 miles per tank at highway speeds. An onboard air compressor can be plugged into a regular outlet at home to recharge the tank in about four hours, or an industrial compressor capable of 3,500 psi (likes those found in scuba shops) can fill it up in a few minutes for around two dollars. Celades says optional gasoline or biofuel hybrid models will heat the pressurized air, increasing the volume available for the pistons and allowing the car to drive for nearly 500 miles between air refills and about 160 miles per gallon of fuel burned.

Early media reports speculated that Tata could have an Air Car on the market by the end of 2008, but Ray says it’s likely to be a couple of years before the technology is available. Until the Indian models hit the streets, the best way to see an Air Car in action is to cross the pond and check out Negre’s prototypes in France- a trip entrepreneur J. P. Maeder says is worthwhile. “It’s not a fantasy, ” he says of the car. “It can make a real impact in how personal transportation will develop from here. ”

In 2003, Maeder formed ZevCat, a Califonia company that aims to bring the Air Car to America. So far, however, he says his plans have stalled for financial reasons: Without enough money to build and crash test prototypes, he can’t demonstrate the technology for investors who might be willing to fund more prototypes.

The car might garner more attention in the US if it makes it to market in India or elsewhere before other burgeoning technologies like plug-in hybrids or fuel-cell electric cars. If that were to happen, compressed air could become the “next big thing” for green-minded drivers, says Larry Rinek, an auto analyst with the international market-research firm Frost and Sullivan. But Rinek questions whether the car will have mass appeal. Another unknown is whether the vehicle could pass crash tests.

“This is an R and D novelty; it’s a curiosity that is nowhere near ready for primetime, ” says Rinek. “It’s unknown and untrusted, particularly here in North America” where, he says, adoption of new technology moves “very slowly. ”

Powder Metallurgy / Introduction / Process / Methods

September 16, 2011

Definition:

The Process of producing components from metallic powder parts made by powder metallurgy may contain non-metallic constituents to improve the bonding qualities and properties.

Number and variety of products made by powder metallurgy are continuously increasing:

  1. Tungsten Filaments for Lamps
  2. Contact Point relays
  3. Self lubricating bearings
  4. Cemented carbides for cutting tools etc.

02-PowderManufacturing-metallurgy-particles

 

Characters of Metal Powders:

  • Shape:

It is influenced by the way it’s made. The shape may be spherical (atomization) (Electrolysis) flat or angular (Mechanical crushing). The particle shape influences the flow characteristics of powders.

  • Particle Size (Fineness) and size distribution:

Particle Size and Distribution are important factors which controls the porosity, Compressibility and amount of shrinkage. Proper particle size and size distribution are determined by passing the powder through a standard sieves ranging from 45 to 150 micrometer mesh.

  • Flowability:

The ability of the powders to flow readily and conform to the mould cavity. The flow rate helps to determine to possible production rate.

  • Compressibility:

It’s defines as the volume of initial powder (Powder loosely filled in cavity) to the volume of compact part. Depends on particle shape & size distribution.

  • Apparent Density:

The Apparent density depends on particle size is defined as the ratio of volume to weight of loosely filled mixture.

  • Green strength:

It refer to strength of a compact part prior to sintering. It depends on compressibility and helps to handle the parts during the mass production.

  • Purity:

Impurities affects sintering & Compacting Oxides & Gaseous impurities can be removed from the part during sintering by the use of a reducing atmosphere.

  • Sintering ability:

It is the ability which promotes bonding of particles by the application of heat.

 

Powder Metallurgy Process steps:

 

01-powder-metallurgy-process-step by step

 

01-powder metallurgy processes-mixing-finished product

 

02-finished product 

Manufacture of Metal Powders:

Methods:

  • Mechanical pulverization:

Machining, Drilling or Grinding of metals is used to convert them to powders.

  • Machining:

It Produces coarse particles (Flack form) especially Magnesium powders.

  • Milling or Grinding:

It suitable for brittle materials.

  • Shorting:

The process of dropping molten metal through a Sieve or small orifice in to water. This produces Spherical particles or larger size. Commonly used for metals of low melting point.

03-mechanical pulverization-milling-powder

04-crushing-shredding-conveyors-powder

 

  • Atomizing:

In this molten metal is forced through a nozzle, and a stream of compressed air, stream or Inert gas is directed on it break up into five particles. Powders obtained in irregular in shapes. Atomization commonly used for aluminium, Zinc, Tin, Cadmium and other metals of low melting point.

03-atomization-powder metallurgy

 

  • Electrolytic deposition:

It’s used mainly for producing iron and copper powders. These are dense structure with low apparent density. It consists of depositing metal on cathode plate by conventional electrolysis processes. The Cathode paltes are removed and the deposited powder is scraped off. The powder is wasted, dried, screened & oversized particles are milled or ground for fineness. The powder is further subjected to heat treatment to remove the work hardening effect.

  • Chemical reduction:

It’s used for producing iron, Copper, Tungsten, Molybdenum, Nickel & Cobalt powder process consists of reducing the metal oxides by means of carbon monoxide or Hydrogen. After reduction, the powder is usually ground & Sized.

 

Forming to shape:

  1. The process of mixing the powders is called Blending.
  2. The Loose powders are formed in to shape by compacting.

METALLURGY

August 23, 2011

Definition:

The Process of producing components from metallic powder parts made by powder metallurgy may contain non-metallic constituents to improve the bonding qualities and properties.

Number and variety of products made by powder metallurgy are continuously increasing:

    1. Tungsten Filaments for Lamps
    2. Contact Point relays
    3. Self lubricating bearings
    4. Cemented carbides for cutting tools etc.

02-PowderManufacturing-metallurgy-particles

 

Characters of Metal Powders:

  • Shape:

It is influenced by the way it’s made. The shape may be spherical (atomization) (Electrolysis) flat or angular (Mechanical crushing). The particle shape influences the flow characteristics of powders.

  • Particle Size (Fineness) and size distribution:

Particle Size and Distribution are important factors which controls the porosity, Compressibility and amount of shrinkage. Proper particle size and size distribution are determined by passing the powder through a standard sieves ranging from 45 to 150 micrometer mesh.

  • Flowability:

The ability of the powders to flow readily and conform to the mould cavity. The flow rate helps to determine to possible production rate.

  • Compressibility:

It’s defines as the volume of initial powder (Powder loosely filled in cavity) to the volume of compact part. Depends on particle shape & size distribution.

  • Apparent Density:

The Apparent density depends on particle size is defined as the ratio of volume to weight of loosely filled mixture.

  • Green strength:

It refer to strength of a compact part prior to sintering. It depends on compressibility and helps to handle the parts during the mass production.

  • Purity:

Impurities affects sintering & Compacting Oxides & Gaseous impurities can be removed from the part during sintering by the use of a reducing atmosphere.

  • Sintering ability:

It is the ability which promotes bonding of particles by the application of heat.

 

Powder Metallurgy Process steps:

 

01-powder-metallurgy-process-step by step


 

01-powder metallurgy processes-mixing-finished product

 

02-finished product 

Manufacture of Metal Powders:

Methods:

  • Mechanical pulverization:

Machining, Drilling or Grinding of metals is used to convert them to powders.

  • Machining:

It Produces coarse particles (Flack form) especially Magnesium powders.

  • Milling or Grinding:

It suitable for brittle materials.

  • Shorting:

The process of dropping molten metal through a Sieve or small orifice in to water. This produces Spherical particles or larger size. Commonly used for metals of low melting point.

03-mechanical pulverization-milling-powder

04-crushing-shredding-conveyors-powder

 

  • Atomizing:

In this molten metal is forced through a nozzle, and a stream of compressed air, stream or Inert gas is directed on it break up into five particles. Powders obtained in irregular in shapes. Atomization commonly used for aluminium, Zinc, Tin, Cadmium and other metals of low melting point.

03-atomization-powder metallurgy

 

  • Electrolytic deposition:

It’s used mainly for producing iron and copper powders. These are dense structure with low apparent density. It consists of depositing metal on cathode plate by conventional electrolysis processes. The Cathode paltes are removed and the deposited powder is scraped off. The powder is wasted, dried, screened & oversized particles are milled or ground for fineness. The powder is further subjected to heat treatment to remove the work hardening effect.

  • Chemical reduction:

It’s used for producing iron, Copper, Tungsten, Molybdenum, Nickel & Cobalt powder process consists of reducing the metal oxides by means of carbon monoxide or Hydrogen. After reduction, the powder is usually ground & Sized.

 

Forming to shape:

    1. The process of mixing the powders is called Blending.
    2. The Loose powders are formed in to shape by compacting.

METALLURGY

August 23, 2011

Definition:

The Process of producing components from metallic powder parts made by powder metallurgy may contain non-metallic constituents to improve the bonding qualities and properties.

Number and variety of products made by powder metallurgy are continuously increasing:

    1. Tungsten Filaments for Lamps
    2. Contact Point relays
    3. Self lubricating bearings
    4. Cemented carbides for cutting tools etc.

02-PowderManufacturing-metallurgy-particles

 

Characters of Metal Powders:

  • Shape:

It is influenced by the way it’s made. The shape may be spherical (atomization) (Electrolysis) flat or angular (Mechanical crushing). The particle shape influences the flow characteristics of powders.

  • Particle Size (Fineness) and size distribution:

Particle Size and Distribution are important factors which controls the porosity, Compressibility and amount of shrinkage. Proper particle size and size distribution are determined by passing the powder through a standard sieves ranging from 45 to 150 micrometer mesh.

  • Flowability:

The ability of the powders to flow readily and conform to the mould cavity. The flow rate helps to determine to possible production rate.

  • Compressibility:

It’s defines as the volume of initial powder (Powder loosely filled in cavity) to the volume of compact part. Depends on particle shape & size distribution.

  • Apparent Density:

The Apparent density depends on particle size is defined as the ratio of volume to weight of loosely filled mixture.

  • Green strength:

It refer to strength of a compact part prior to sintering. It depends on compressibility and helps to handle the parts during the mass production.

  • Purity:

Impurities affects sintering & Compacting Oxides & Gaseous impurities can be removed from the part during sintering by the use of a reducing atmosphere.

  • Sintering ability:

It is the ability which promotes bonding of particles by the application of heat.

 

Powder Metallurgy Process steps:

 

01-powder-metallurgy-process-step by step


 

01-powder metallurgy processes-mixing-finished product

 

02-finished product 

Manufacture of Metal Powders:

Methods:

  • Mechanical pulverization:

Machining, Drilling or Grinding of metals is used to convert them to powders.

  • Machining:

It Produces coarse particles (Flack form) especially Magnesium powders.

  • Milling or Grinding:

It suitable for brittle materials.

  • Shorting:

The process of dropping molten metal through a Sieve or small orifice in to water. This produces Spherical particles or larger size. Commonly used for metals of low melting point.

03-mechanical pulverization-milling-powder

04-crushing-shredding-conveyors-powder

 

  • Atomizing:

In this molten metal is forced through a nozzle, and a stream of compressed air, stream or Inert gas is directed on it break up into five particles. Powders obtained in irregular in shapes. Atomization commonly used for aluminium, Zinc, Tin, Cadmium and other metals of low melting point.

03-atomization-powder metallurgy

 

  • Electrolytic deposition:

It’s used mainly for producing iron and copper powders. These are dense structure with low apparent density. It consists of depositing metal on cathode plate by conventional electrolysis processes. The Cathode paltes are removed and the deposited powder is scraped off. The powder is wasted, dried, screened & oversized particles are milled or ground for fineness. The powder is further subjected to heat treatment to remove the work hardening effect.

  • Chemical reduction:

It’s used for producing iron, Copper, Tungsten, Molybdenum, Nickel & Cobalt powder process consists of reducing the metal oxides by means of carbon monoxide or Hydrogen. After reduction, the powder is usually ground & Sized.

 

Forming to shape:

    1. The process of mixing the powders is called Blending.
    2. The Loose powders are formed in to shape by compacting.

TERMS IN MEASUREMENT

August 23, 2011

MEASUREMENTS:

01-Imperial-Measurements-CONCEPTS OF MEASUREMENT-BASICS-OUTCOME OF A RESULT-EXAMPLES-MEASURING TAPES-LENGTH-HEIGHT

A Measurement is the outcome of an opinion formed by observers about some physical quantity.

CLASSIFICATION OF MEASUREMENTS:

  • Standards –  ( Reproduce the value of given quantity )
  • Fixed Gauges – (Check Dimensions)
  • Measuring Instruments – (Determine the measured value)

NEEDS FOR MEASUREMENT:

1. To Determine the true dimensions of a part.

2. To increase our knowledge and understanding of the world.

3. Needed for ensuring public health and human safety.

4. To convert physical parameters into meaningful numbers.

5. To test if the elements that constitute the system function as per the design.

6. For evaluating the performance of a system.

7. For studying some basic laws of nature.

8. To ensure interchangeability with a view to promoting mass production.

9. To evaluate the response of the system to particular point.

10. To check the limitations of theory in actual situations.

11. To establish the validity of design and for finding new data and new designs.

METHODS OF MEASUREMENT:

1. Direct Comparison

2. Indirect Comparison

3. Comparative Method

4. Coincidence Method

5. Fundamental Method

6. Contact Method

7. Transposition Method

8. Complementary Method

9. Deflection Method

Direct Method:

Measurements are directly obtained.

Ex:Vernier Caliper,Scales.

01-electroniccaliper-VERNIER CALIPER-DIGITAL VERNIER CALIPER-DIRECT MEASUREMENTS-ACCURATE-PRECISION MEASUREMENTS-CALIBRATED INSTRUMENTS

Indirect Method:

Obtained by measuring other quantities.

Ex:Diameter measurement by using three wires.

01-DIAMETER MEASUREMENTS-INDIRECT MEASUREMENTS-CAPACITIVE TRANSDUCER BY WHEATSTONE BRIDGE CIRCUITS

Comparative Method:

It’s compared with other known value.

Ex:Comparators.

01-comparator_stand_dial_gauge-precisional measurements-surface finish-height measurements-tolerance measurements

Coincidence Method:

Measurements coincide with certain lines and signals.

01-coincident methods-coincidence line-simplify lines-measurements lines and signals

Fundamental Method:

Measuring a quantity directly in related with the definition of that quantity.


Contact Method:

Sensor/Measuring tip touch the surface area.

Ex:Vernier Caliper.

01-proximity_sensor-distance measurements-long distance-measuring probe-sensing device

Transposition Method:


Quantity to be measured is first balanced by a known value and then balanced by an other new known value.

Ex:Determination of mass by balancing methods.

01-tool-balancing-balance methods-determination of mass-scale

Complementary Method:

01-volume-measurement-lighter-solids-volume displacement-liquid measure level-liquid displacement

The value of quantity to be measured is combined with known value of the same quantity.

Ex:Volume determination by liquid displacement.

Deflection Method:

The value to be measured is directly indicated by a deflection of pointer.

Ex:Pressure Measurement.

01-pressure measurement-pressure gauges-measurement of pressure-deflection of pointer

TERMS OF MEASUREMENT:

Precision:

The ability of the instrument to reproduce it’s readings or observation again and again for constant input signal.

Accuracy:

Closeness/conformity to the true value of the quantity under measurement.

01-Accuracy-Precision-uncertainity analysis-systematic errors-reproducibility errors

Error:

The difference between true value and measured value is known as measurement error.

Error = Vt – Vm

Reliability:

It is defined as the probability that a given system will perform it’s function adequately for it’s specified period of lifetime under specified operating conditions.

01-reliability-analysis-life time analysis-life time warranty

TERMS IN MEASUREMENT

August 23, 2011

MEASUREMENTS:

01-Imperial-Measurements-CONCEPTS OF MEASUREMENT-BASICS-OUTCOME OF A RESULT-EXAMPLES-MEASURING TAPES-LENGTH-HEIGHT

A Measurement is the outcome of an opinion formed by observers about some physical quantity.

CLASSIFICATION OF MEASUREMENTS:

  • Standards –  ( Reproduce the value of given quantity )
  • Fixed Gauges – (Check Dimensions)
  • Measuring Instruments – (Determine the measured value)

NEEDS FOR MEASUREMENT:

1. To Determine the true dimensions of a part.

2. To increase our knowledge and understanding of the world.

3. Needed for ensuring public health and human safety.

4. To convert physical parameters into meaningful numbers.

5. To test if the elements that constitute the system function as per the design.

6. For evaluating the performance of a system.

7. For studying some basic laws of nature.

8. To ensure interchangeability with a view to promoting mass production.

9. To evaluate the response of the system to particular point.

10. To check the limitations of theory in actual situations.

11. To establish the validity of design and for finding new data and new designs.

METHODS OF MEASUREMENT:

1. Direct Comparison

2. Indirect Comparison

3. Comparative Method

4. Coincidence Method

5. Fundamental Method

6. Contact Method

7. Transposition Method

8. Complementary Method

9. Deflection Method

Direct Method:

Measurements are directly obtained.

Ex:Vernier Caliper,Scales.

01-electroniccaliper-VERNIER CALIPER-DIGITAL VERNIER CALIPER-DIRECT MEASUREMENTS-ACCURATE-PRECISION MEASUREMENTS-CALIBRATED INSTRUMENTS

Indirect Method:

Obtained by measuring other quantities.

Ex:Diameter measurement by using three wires.

01-DIAMETER MEASUREMENTS-INDIRECT MEASUREMENTS-CAPACITIVE TRANSDUCER BY WHEATSTONE BRIDGE CIRCUITS

Comparative Method:

It’s compared with other known value.

Ex:Comparators.

01-comparator_stand_dial_gauge-precisional measurements-surface finish-height measurements-tolerance measurements

Coincidence Method:

Measurements coincide with certain lines and signals.

01-coincident methods-coincidence line-simplify lines-measurements lines and signals

Fundamental Method:

Measuring a quantity directly in related with the definition of that quantity.


Contact Method:

Sensor/Measuring tip touch the surface area.

Ex:Vernier Caliper.

01-proximity_sensor-distance measurements-long distance-measuring probe-sensing device

Transposition Method:


Quantity to be measured is first balanced by a known value and then balanced by an other new known value.

Ex:Determination of mass by balancing methods.

01-tool-balancing-balance methods-determination of mass-scale

Complementary Method:

01-volume-measurement-lighter-solids-volume displacement-liquid measure level-liquid displacement

The value of quantity to be measured is combined with known value of the same quantity.

Ex:Volume determination by liquid displacement.

Deflection Method:

The value to be measured is directly indicated by a deflection of pointer.

Ex:Pressure Measurement.

01-pressure measurement-pressure gauges-measurement of pressure-deflection of pointer

TERMS OF MEASUREMENT:

Precision:

The ability of the instrument to reproduce it’s readings or observation again and again for constant input signal.

Accuracy:

Closeness/conformity to the true value of the quantity under measurement.

01-Accuracy-Precision-uncertainity analysis-systematic errors-reproducibility errors

Error:

The difference between true value and measured value is known as measurement error.

Error = Vt – Vm

Reliability:

It is defined as the probability that a given system will perform it’s function adequately for it’s specified period of lifetime under specified operating conditions.

01-reliability-analysis-life time analysis-life time warranty