Posted tagged ‘Tool’

Mechanical Engineering Seminar Topics List 4

September 10, 2011

1. 4 WHEEL STEERING
2. AIR_BREATHING_ROCKET_ENGINE
3. AUTOMATIC_TRANSMISSION
4. AUTOMATIC_WATER_SPRINK
5. AUTOMOTIVE_AIR_FILTRATION SYSTEM
6. CAVITATION_IN_CENTRIFUGAL PUMPS
7. “FLEXIBLE (RUBBER) FUEL TANKS
8. AIR_SUSPENSION_SYSTEM
9. SIX_STROKE_ENGINE
10. BROADBAND OVER POWER LINE
11. CAR BIKE COMBO
12. CRUISE CONTROL SYSTEM
13. EURO EMISSION NORMS-A
14. EURO EMISSION NORMS-B
15. FOUR_WHEEL_STEERING_SYSTEM
16. FUTURE OF DIESELS
17. FUTURE OF NUCLEAR ENERGY
18. GAS TURBINE ENGINE
19. GAS TURBINE ENGINE
20. GAS_TURBINE_ENGIN
21. HARD COATING ON TOOLS
22. HOVER- CRAFT
23. HYDRAULIC LAUNCH ASSIST
24. HYDRAULIC SYSTEMS FOR AIRCRAFTS
25. INTELIGENT VEHICLE
26. ION ENGINE
27. JATROPHA SEMINAR
28. MAGNETIC_LEVITATION
29. MAGNETICALLY LEVITATED TRAIN
30. MICROTURBINES
31. NANO-NEW
32. OPTICAL COMPUTER
33. PISTONLESS_PUMP_FOR_ROCKETS
34. PM-ENGINE
35. PNEUMATIC BIKE
36. ROBOT WELDING TECHNOLOGY
37. ROBOTA –A NEW GENERATION
38. SAAB
39. SAFETY SYSTEM IN MODERN AUTOMOBILES
40. SENSOTRONIC BRAKE
41. SIX SIGMA
42. SKY BUS 3
43. SMART_VEHICLES1
44. SOLAR AIR CRAFT
45. SOLAR POWER SATELLITE
46. SOLAR-CHIMNEY
47. STIRLING ENGINE
48. SUGARCANE HARVESTING
49. THERMOACOUSTIC STIRLING ENGINES
50. TURBO_INTERCOOLER
51. VIRTUAL REALITY SHOWROOM
52. VVTI
53. WIND ENERGY TURBINE
54. YOUR CAR 2020
55. CARBON NANOTUBES11
56. DTH TV
57. EDGE
58. ELEC-HYDRO-JACK
59. ENERGY FOR TOMORROW
60. FINAL WEB CASTING
61. IMAGE ANALYSIS USING METHEMATICA MORPHOLOGY
62. NIGHT VISION
63. SEZS WORLD-CLASS HUBS FOR EXPORTERS
64. TPM
65. TURBO CODES SEMINAR
66. VIDEO PROCESSING FOR DLP DISPLAY SYSTEMS
67. ELECTRIC POWER STEERING

68. A Study Of a Displacement Amplifier
69. Optimal Design and Analysis Of Automotive Composite Drive Safety
70. 1st Types of Production
71. A case study of management…
72. A design theory based
73. A Fluid-Solid Interaction Model Of The Solid Phase Apiary in stressed silicon layers
74. A High -Torque Magneto-Theological fluid clutch
75. A Hypersonic Hybrid Vehicle
76. Abrasion Wear Characteristic Of Sand Cast
77. Abrasive water jet
78. Acoustic Emission Based Machining Tool Condition Monitoring – An Overview
79. Acoustic Emission Based Machining Tool Condition Monitoring – An Overview
80. Active Suspension System
81. Adaptive Cruise Control for Modern Automobile
82. ADVANCE IN CAR SAFETY
83. Advance systems in two wheelers
84. Advances in automobiles (Hybrid Vehicles)
85. AGV for FMS
86. Air Bearing Next Generation Bearings
87. Air birthing Angina
88. Air car
89. Air powered car
90. Air suspension system and its…
91. Alternative abrasive to diamond
92. Alternative fuel
93. Amphibious Army Surveillance Vehicle
94. Artificial Intelligence
95. Artificial Intelligence Future Around Us
96. Artificial intelligence (Modeling air fuel ratio control)
97. Artificial Intelligence in Mechanical field
98. Artificial Intelligence-Present and Future
99. Assembly of Water Cooler
100. Atomic Battery
101. Auto Drilling With Geneva
102. Automated assembly system
103. Automated Guided Vehicles
104. Automatic braking system
105. Automatic Transmission System
106. Automation and Robotics
107. Automation of Foundry for Production quality
108. Automation of Ultrasonic Testing Procedures
109. Automobile AC by Utilizing Waste Heat & Gases
110. Automobile Ac By Utilizing Waste Heat & Gases Advance
111. Automobile Air Conditioning
112. Autonomously Generative CMM Part
113. Balance Of Tool Holder
114. Ball Piston Engine
115. Bike of the future- pneumatic bike
116. Bio diesel : A Fuel for the Future
117. Bio diesel From Jatropha
118. Biogas
119. Biomass as an Alternate Fuel for Diesel Engine
120. Biomass as an Alternate Fuel for Diesel Engine
121. Business Excellence Through Quality Circles
122. Business Process Analysis By BPR
123. Business Process Re-Engineering
124. CAD & CAE in Bio-Medical Field
125. Caged ball technology
126. Carbon Nano-tubes
127. carbon nanotubes (GCO)
128. Catalytic Converters
129. Centrifugal Pump
130. Ceramic Hybrid Ball Bearing
131. Challenges In Plasma Spray Assembly Of Nano particles To Near Net Shaped Bulk Nano structures
132. Chloro-fluro carbons
133. Cleaning of metal..
134. Clutch lining testing machine
135. COAL GASIFICATION
136. Coating of Carbide Inserts
137. Combing Developments & Their Significance-Mech10
138. Combustion Control Using Optical Fiber
139. Combustion Stability in I.C. Engines
140. Common Rail Injection System
141. Comparison Of Experimental And Finite Element Results For Elastic Plastic Stress
142. Complex system development
143. Compressed Air Cars Technology
144. Computational Fluid Dynamics
145. Computer Aided Production Engineering (CAPE)
146. Computer Integrated Manufacturing-Building the Factory of Future
147. Concentrating Solar Power Energy from Mirrors
148. Concept of flying train
149. Concurrent Engineering
150. Condition Monitoring Of Bearings
151. Condition Monitoring Through Vibration Measurement
152. Consolidation Behavior Of Cu-Co-Fe Pre-Alloyed Powers
153. Constitutive Modeling of Shape Memory Alloy Using Neural Networks
154. Continuous process improvement
155. Control of Cure Distribution in Polymer Composite
156. Control of Cure Distribution in Polymer Composite Parts Made by Laminated Object Fabrication (LOF)
157. Control Systems In Automobiles
158. Convection in Porous Media
159. Cost Effective Safety Instrumented Systems
160. Crop Harvesting Machine
161. Cryogenic Automotive Propulsion Zero Emission Vehicle
162. Cryogenic Processing of Wear Control
163. Cryogenic Rocket Engine & Their Propellants
164. Cummins Diesel Fuel System
165. Design of Efficient Production
166. Design, Implementation, Utilization of FEM
167. Determination of Transmission Spectra Using Ultrasonic NDE
168. Development & Application. Of New Cutting Tool Materials
169. Development in arc welding process using robot
170. Development of an AGV Material Handling System in a Flexible Manufacturing Environment
171. Development of Coated Electrodes For Welding of HSLA Steels
172. Development of hexapod Walking Robot Mechanical Design
173. Development of high performance heat sink based on screen fin tech.
174. Development of Self Lubricating Sintered Steels for Terminological Applications
175. Development of Simple Driver-friendly Electric 4WD System
176. Development of the electrostatic clutch
177. Digital Manufacturing Using STEP-NC
178. Direct Injection Process
179. Distribution Side Management for Urban Electric Utilities in India
180. Dry Sliding Wear Studies On Hybrid MMC’S – A Taguchi Technique
181. Effect of catalytic coating
182. Analysis Of Dimensionless Number For Heat Transfer Enhancements In Rectangular Channels
183. Effect Of Preload On Stability And Performance Of a Two-Lobe Journal Bearing
184. Effect of Pressure On Arc Welding Process
185. Effect Of Stacking Sequence On Notch Strength In Laminates
186. Efficiency In Boring
187. Electronically Controlled Air Suspension System
188. Embedded Applications Design Using Real-Time
189. Energy Engineering Bio diesel
190. Energy Saving Opportunity And Pollution Control In Furnaces
191. Engine & String less car
192. Enterprise Resource Planning
193. Environmental Friendly Refrigeration
194. Ethanol-Future Fuel For Indian Vehicles
195. Exert Quarts In Microprocessor Applications
196. Experimental Analysis of Modified Machine Tools
197. Experimental Stress Analysis For Pipes
198. External Nodes In Finite Element Analysis
199. Failure Analysis Of Lap And Wavy-Lap Composite Bonded Joints
200. Finite Element Analysis Of Robotic Arm For Optimal Work Space Determination
201. Flexible manufacturing system
202. Flying train
203. Frication Welding Of Austenitic Stainless Steel and Optimization of Weld Quality
204. Fuel cell technology
205. Gas Hydrates
206. GAS TURBINE
207. Genetic Algorithm Based Optimum Design Of Composite Drive Shaft
208. Geothermal Energy Utilization
209. Globalization
210. Grid Generation and Simulation Using CFD
211. Guided Missiles
212. H.C.C.I Engine
213. Heat pipe
214. By Forced Convection In Metal Foams
215. Heat transfer
216. HELIUM-A CRYGENICS FLUID
217. Hexapod machine tool
218. High Performance Heat Sink Based on Screen-Fin Technology
219. Hologram
220. Homogeneous combustion in IC engine
221. Human transporter
222. Hybrid engine
223. Hybrid Synergy Drive
224. Hydraulic analysis of hydrostatic bearing of primary sodium pump of a fast breeder reactor
225. HYDROFORMING
226. Hydrogen Car
227. hydrogen fuel cell
228. Hydro-Pneumatics
229. I-Mode
230. Improving service quality..
231. In view of the high commercial gains of a commercial place I
232. Independent Wheel Vehicle Suspension
233. Indian Manufacturing Scenario
234. Industrial Team Behavior and Management Tools
235. Innovation In Automobile Industries
236. Integrated web enabled information…
237. Integration of reinforced
238. Intelligent braking and vehicular..
239. JKJ
240. Job Scheduling Using Neural Network
241. Network Foe Rapid Manufacturing
242. JUST_IN_TIME
243. Kaizen culture
244. KANBAN-AN Integrated JIT System
245. Laser Beam Delivery through Optical Fiber in Laser Machining
246. Laser Machining
247. Laser Micromachining
248. Laser shot preening
249. Latest trends in steering systems
250. Level measurement of bulk solids
251. LEVEL
252. LEVEL MEASUREMENT OF BULK-SOLIDS
253. Liquefied natural gas
254. LNG vehicles
255. Logistics In A Competitive Milieu
256. Machine Vision
257. Machine phase fullerene
258. Machining of Advanced Composites with Abrasive
259. machining technology for….doc
260. Machining technology of leaf spring
261. Magne-gas-The Fuel of Future
262. Magnetic Bearing
263. Magnetic Refrigeration
264. magnetic refrigeration
265. Managerial
266. Manufacturing Of Leaf Spring
267. Master Planning for College Campus
268. MATERIAL BALANCES IN THE MISSILE
269. Materials of the Future
270. Materials of the Future
271. Mechanical seal
272. Mechanics of Composite Materials
273. Mechatronic
274. Mechatronic Strategies for Torque Control of Electric Powered Screwdrivers
275. Mechatronic Strategies for Torque Control of Electric Powered Screwdrivers
276. MECHATRONICS
277. Mechanical Properties Of MMC’S- An Experimental Investigation
278. Medical Application of Nano tech.
279. MEMS
280. Metal deposition
281. Metal Matrix composites
282. Methanol Vehicles
283. Micro air vehicle
284. Micro electro mechanical system
285. Microcellular Foam Technology
286. Micro finishing of rollers in roller bearings
287. Minimum Quantity Lubrication
288. Mission of mars
289. Modeling and Optimization on of Electron Beam Wealing Process Using ANOVA
290. Motronic engine management
291. Multifunction control system for robotic fire detection
292. Nano technology
293. Nano technology Binding experiment with Biosensor
294. Nano technology For Cancer Therapy
295. Nano technology – It’s Small, Small, Small, Small World
296. Navigation
297. Near Net Shape Fabrications Via Vacuum Plasma Spray Forming
298. Near net shape memory..
299. Negative Supercharging
300. Non Destructive Testing Of Welds
301. Nuclear fuel
302. Nuclear Space Craft
303. Nuclei’s Next Generation
304. Ny-Tran – Alternative to V Belts
305. Optimizing centrifugal pump
306. Options & Accessories of Car
307. Packaging
308. Piston Ring
309. Pneumatic bike
310. Policies to overcome barriers to the spread of Bio energy technologies in India
311. Power Generation by Using Road Speed Breakers
312. Process steam generation…….
313. Processing and Tribo Behavior Of Nylon Clay Nano composites Under Abrasive Wear Mode
314. Product definition and Role of Aesthetics..
315. PTFE As Lubricant
316. PVD film method
317. Quality Function Deployment (QFD) for TQM
318. Quality in maintenance through TPM
319. Quality Function Deployment
320. Quasi turbine – Future Trends in automobile engine
321. Quieter fans for HVAC
322. Radiant Energy Welding Process
323. Rapid prototyping
324. Rapid Prototyping – Slicing Strategies
325. Rapid Prototyping – Slicing Strategies
326. Rapid prototyping technique based on 3d welding
327. Redesign of plant layout using travel chart technique (a case study)
328. Reduction of idle time through TPM
329. Reliability Redundancy Design-Using
330. Remote engine starting..
331. Renesis Rotary Engine
332. Renewable Energy Design Application In Water Cooler
333. Research On Modified Layers Of Material Surface For Cr Mov Cold Die
334. results of test on laser ignition in internal combustion engine
335. Return of two stroke engine
336. Reverse Engineering
337. Reverse Engineering in Mechanical parts
338. Risk Management
339. Robonaut
340. Robot-by-voice- Experiments on commanding an industrial robot using the human voice
341. Robotics
342. Robotics for Performing Surgical Operations
343. Rotary Engines
344. Safe Handling Of Hc
345. Scope of MEMS in Space
346. Scramjet
347. Scrubber tech.
348. Self Activated Single Use Switch
349. Self replicating system
350. Selling price decision support system for a job order based manufacturing unit
351. Server clustering
352. Set up for Small Scale Industry
353. SEZs World-Class Hubs For Exporters
354. Simulation of Fuel Injection System of System of A Diesel Engine
355. Six – Stroke hybrid engine final
356. Six sigma
357. Six sigma – a quality control tool in industry
358. Six sigma effective process improvement
359. Six Stroke Engine
360. Size Reduction of Window Air Conditioner
361. Size Reduction of Window Air Conditioner
362. Smart tire
363. SMED
364. Software based reengineering..
365. Soil compaction
366. Solar air conditioning
367. Solar aircraft
368. Solar Chimney Power Generation System
369. Solar Energy Conservation to Hydrogen
370. Solar Power Satellite
371. Space Craft Structure
372. Space Elevator
373. Space robotics
374. Space transportation system
375. Spring gauge
376. Sterling engine
377. Sterling engine for co-generation
378. Strategies for product
379. Studies on Phosphoric Irons for Concrete Reinforcement Applications
380. Supply Chain Management
381. Synthesis of Planar Mechanism with Variable Topology – Review
382. System Improvements through TQM
383. Technical development in car
384. Technology of 21st Century Nano Technology
385. The Challenge of Intelligent Systems
386. The Design Of Cellular Manufacturing Systems And Whole Business Simulation
387. The Effects of Precipitate Distributions on HSLA Grain Structure
388. The Gyro Machine
389. Thermal Conductivity Of Poros Material
390. Thermo-electric Refrigeration System
391. Thread Locking Device for Handling Thread at Flexible Endoscopy
392. Topic On Sng
393. Total Productive Maintenance (TPM)
394. Total Quality Management
395. TQM Implementation Learning form Indian Organizations
396. Transient Thermal Analysis of Railway
397. Tribological characteristics of cutting fluid groups
398. Tribology
399. Tribology of IC engine
400. Tribology of sealing
401. Tribometer
402. Tubeless Tyre Technology
403. Turbine Technology In Car
404. Types Of Bearing
405. Typre Pressure Monitoring System
406. Tyre Monitoring System
407. Ultrasonic Nondestructive Testing
408. Ultrasonic Phased Array For Defect Cartlization
409. Unmanned Aerial Vehicle Uavs
410. Vacuum Chuck
411. Value engineering
412. Variable Compression Ratio (VCR)
413. Variable Compression Ratio Engines
414. VCR
415. Vehicle Dynamics
416. Vehicular Emission Control
417. Vibration Analysis of Flywheel Using Finite Element Analysis
418. Virtual Manufacturing System
419. Virtual Reality Simulation
420. Vrb_Systems
421. Waste heat driven refrigeration and chilling systems.
422. Water Diesel Emulsion with High Injection Press
423. Water Diesel Emulsion with High Injection Press
424. Water as a fuel car
425. Water jet technology
426. What Is A Nuclear Reactor
427. When upgrading tool holders
428. Wind Energy Conversion System

FAILURE ANALYSIS

August 23, 2011

01-tank-failure-failure analysis-visual examination-scanning electron microscopy-metallography-materials technology


• Why ?

As the standards of our industry rise due to increasing globalization and competition, there is an ever growing need for consistency and reliability. Breakdown of any unit, system or equipment is an avoidable and costly occurrence and must be prevented or minimized. Analysis of such failures becomes a resourceful and affordable tool in addressing such unwanted occurrences.

To establish whether the cause of component failure lay on:

a) Service conditions
b) Design considerations
c) Material and its specification
d) Improper processing and assembly procedures or
e)  Combinations of these.

01-RootCause-root cause analysis cycle-problem solving steps-avoidance of recurring problems

Only the real “Root cause” can ensure the effectiveness of corrective and preventive actions and avoid recurrence of failure.

01-CauseEffect-analysis-bottom up predictive-ishikawa - fishbone diagram-prediction analysis

• Stages Of Failure Analysis

1. Understanding and assimilation of background data and selection of samples.
2. Examination and documentation of the failed part by the following

1. Visual examination of parts, location (if necessary) and relevant photographs as well.

01-visual examination-metallographic examination-appearance of the parts-calibrated metallurgical microscope equipment-image analysis-microstructure

2.  Non destructive testing by means of Radiography, Dye      penetrant, Magnetic particle testing etc.

01-NDT-non destructive testing-cold process-radiography-die penetrant techniques-magnetic particle testing
3. Mechanical Testing for various physical properties.

3. Vital specimens are selected, classified, and subjected to:

  1. Macroscopic examination and analysis. This involves examining the fracture surfaces, secondary cracks, deposits and other such elements
  2. Microscopic examination and analysis of fracture surface (by Scanning Electron Microscopy, if required).

01-scanning-electron-microscopy-vital specimens-fracture surfaces-secondary cracks-microscopic examination

4. Chemical analysis of material for conformation to specifications.

5. Chemical analysis of corrosion products, deposits, contaminants etc.

01-corrodedmetal-corrosion in metals-material technology-material science and metallurgy-iron oxidization-low affinity with oxigen-electrochemical corrosion-oxidation

6. The actual state of the failed part and the failure mode are established.

7.  Fracture mechanics study if found necessary.

01-connection_failure_analysis-comprehensive failure analysis-analysis and testing-investigation of failure-design life check-failure mechanisms-identification of causes of failure
8. A simulation of the identical working environment to determine if any external      factors have contributed to the failure

9. Conclusions are determined after compiling all evidences and analysis and       then the report is generated.
10. Follow-up recommendations are also provided.

MANUAL CHARGING CONTROL

August 23, 2011

01-wind up battery-crank up battery-battery storage technology-hand powered spinning re-charger battery

The Wind up battery is the endless independent source of power. It is the only tool you will need to charge your mobile phone batteries, notebook batteries, GPS or any other modern gadget which is in this information-packed world essential life companion. The use of wind up battery charger is easy and being that it is totally portable and independent power supply, it is a valuable part of accessory of every trekker’s, backpacker’s, traveler’s adventures journey. It is also an essential back up power supply for any critical emergency events when there is no power supply available nearby.


How does it work?

01-wind up battery- operation-working-twisting clockwise or anticlockwise makes charging

The wind up battery mechanism uses internal generator, which is usually hand-powered by spinning the handle on the device. The hand motion, in which AC alternator is driven by a crank converts human mechanical energy and generates the electrical power, by spinning magnets past a coil of wire, which is stored in battery. To charge the device, utilizing the wind up mechanism the hand crank needs to be pulled out of the folded position, and spun in clockwise/counterclockwise direction. After some time of cranking, when the device is charged the handle is folded into position and the device is available to use.

There are also foot powered wind up battery devices, which generate power and self charge by human energy through step action. These are able to jump-start a boat or automobile battery, and power a wide array of instruments and accessories and present a valuable and versatile tool for power supply.

The Devices using wind up mechanism

There are several devices on market which utilize the wind up mechanism. It can be used as a wind up battery charger, wind up flashlight, wind up radio, wind up clock, mp3 player, or a larger electricity supply unit. Usually there are hand cranks folded into the devices, which can be pulled out when needed. The wind up devices are a great way to promote environmentally clean green energy source as the power is derived through windup mechanism which efficiently harvests the human energy and converts it to electricity.

If you are an environmentally conscious consumer who likes to travel and have a power charger available for his electric devices and an emergency power supply then the wind up battery is the device to look for.

01-exploded view of wind up battery-wind up mechanism

FINISHING OPERATIONS

August 23, 2011

Sizing:

Repressing the sintered component in a die to meet required tolerances.

06-measurement-sizing-tolerance-measurement

02-Sizing-Sintering-Height gauge

Coining:

Repressing the sintered component in a die to increase the density and to give additional strength.

03-coldforge-coining

Infiltration:

Filling the pores of sintered product with molten metal to improve the physical properties.

Impregnation:

Filling of Oil, Grease or other Lubricants in a Sintered components such as Porous Heating

Machining:


Removing excess material by using cutting tool to imparts specific features such as Threads, Grooves, Undercuts etc, which are not practicable in powder metallurgy process.

04-thread cutting-powder metallurgy

Heat Treatment:

Process of Heating & Cooling at a desired rate to improve Grain Structure, Strength & Hardness.

05-heattreatment-metals-hardening

Plating:

Used for obtaining Resistance to Corrosion or better appearance.

05-electro plating-methods-examples

05-electro plating-application-examples

Powder metallurgy is used in the following industries:

  • Automotive (Brake pads, Gear parts, Connecting rods, Planetary carriers, Sintered Engine Bearings);

07-composite gears-automobile-parts

  • Aerospace (Light weight Aluminum base structural materials, High temperature Composite materials);

07-Aeroplane-boeing-powder-metallurgy-applications

07-composite-parts-Aerospace

  • Cutting tools (Hard metals, Diamond containing materials);

07-milling-cutters-tooling

  • Medicine (Dental implants, Surgical instruments);

07-medical-applications-powder metallurgy

  • Abrasives (Grinding and Polishing wheels and Discs);
  • Electrical, Electronic and Computer parts (Permanent magnets, Electrical contacts).

 

07-electronics-computer parts

FINISHING OPERATIONS

August 23, 2011

Sizing:

Repressing the sintered component in a die to meet required tolerances.

06-measurement-sizing-tolerance-measurement

02-Sizing-Sintering-Height gauge

Coining:

Repressing the sintered component in a die to increase the density and to give additional strength.

03-coldforge-coining

Infiltration:

Filling the pores of sintered product with molten metal to improve the physical properties.

Impregnation:

Filling of Oil, Grease or other Lubricants in a Sintered components such as Porous Heating

Machining:


Removing excess material by using cutting tool to imparts specific features such as Threads, Grooves, Undercuts etc, which are not practicable in powder metallurgy process.

04-thread cutting-powder metallurgy

Heat Treatment:

Process of Heating & Cooling at a desired rate to improve Grain Structure, Strength & Hardness.

05-heattreatment-metals-hardening

Plating:

Used for obtaining Resistance to Corrosion or better appearance.

05-electro plating-methods-examples

05-electro plating-application-examples

Powder metallurgy is used in the following industries:

  • Automotive (Brake pads, Gear parts, Connecting rods, Planetary carriers, Sintered Engine Bearings);

07-composite gears-automobile-parts

  • Aerospace (Light weight Aluminum base structural materials, High temperature Composite materials);

07-Aeroplane-boeing-powder-metallurgy-applications

07-composite-parts-Aerospace

  • Cutting tools (Hard metals, Diamond containing materials);

07-milling-cutters-tooling

  • Medicine (Dental implants, Surgical instruments);

07-medical-applications-powder metallurgy

  • Abrasives (Grinding and Polishing wheels and Discs);
  • Electrical, Electronic and Computer parts (Permanent magnets, Electrical contacts).

 

07-electronics-computer parts

PRESSURE FORMING

August 22, 2011

01-pressure forming-products-intricate contours-tight radii-


Material & Description

ABS

Good general purpose material, very tough yet very hard and rigid, good impact and electrical. Available in gauges from .040 to .475 with several extruded textures. Comes opaque and can be matched in custom colors.

ABS/PC

A blend or alloy of ABS and polycarbonate that thermoforms well, weathers well, good color retention, very hard, excellent impact.

ABS/PVC

Flame retardant, tough.

Acrylic

Outstanding weather resistance, excellent optics and electrical properties, poor impact, high gloss and deep luster. Available in standard gauges from .080 to over 1″. Available in clear, transparent and opaque colors.

Acrylic, cell cast

Excellent optics and hot strength, more expensive. Acrylic, continuous and extrusion cast.
Large volume use and best price, good optics.

Acrylic film

3 or 6 mil film for laminating, decorating, and weathering of extruded ABS.

DR Acrylic

Modified acrylic with higher impact properties.

Acrylic/PVC

A blend of acrylic and PVC that is a tough, chemical-resistant material that weathers well and is flame resistant. Available in custom colors.

HDPE (high-density polyethylene)

Crystalline, very tough materials, good weather resistance with UV inhibitors, resistant to many chemicals. Available in standard gauges from .040 to .500. Available in opaque custom colors. Tough and stiff. Good low temperature. Economical.

HMWPE (high molecular weight)

Excellent environmental stress crack properties, thermoforms well, good low temperature.

HIPS (high impact polystyrene)

Good general-purpose material, rigid. Available in clear but usually opaque custom colors from .030 to .350, low cost.

PVC (vinyl)

Good general-purpose material, good abrasion and chemical resistance. Available in clear but usually opaque custom colors from .030 to .125.

Expanded PVC

Stiff, light, flat, thermoformable. Available in stock colors and gauges, generally 3 and 6 mm but others also available.

PETG

Clear, higher impact than acrylic, easy to form. Available in gauges from .030 to .500.

01-pressure forming-blow forming-Thermoform-Console-automobile parts

Pressure Forming:

Pressure Forming is the method used to produce injection mold quality, high definition plastic component parts, housings and containers without the huge expense of tooling. It involves positive pressure to force the heated plastic into the mold cavity. This is called pressure thermoforming or blow forming

Pressure Forming Working Operation:

01-pressure forming-20-150 psi pressure-temperature controlled mold cavity

The highly versatile pressure forming process utilizes air pressure, from 20 to 150 psi, to force the heated sheet into a temperature controlled mold cavity. Vent holes are provided in the mold to exhaust the trapped air. The final part features sharp definition of intricate contours and tight radii. Textures and accurate details are built right into the tooling. Low-cost, highly aesthetic plastic parts of varying sizes are possible due to the application of air pressure, as well as more sophisticated process controls that better monitor tool and sheet temperatures while controlling material shrinkage during forming.

01-pressure forming-products-intricate contours-tight radii-

Types Of Molding operation:

  • Positive Mold
  • Negative Mold

01-pressure forming process-positive molds-cost advantages-pressure forming over thermo forming

Negative molds  have concave cavities. A positive mold has a convex shape.

Pressure Forming over Thermo Forming:

The basic advantage of Pressure Forming over Thermo forming is the cost advantage for small production items. The mould cost for thermo forming is considerably higher in comparison to pressure forming thus for a lower quantity precision job the best suitable method used is pressure forming.

Application:

Pressure forming is used to create in a wide array of plastic products used for packaging of food trays, blisters, covers, internal parts, housings equipment, bezels, bases, and spare parts for use in business machines, electronics, computers and peripherals, bio-medical applications, and instruments.

Features:

Pressure forming achieves features beyond the capabilities of vacuum forming including louvers, ribs, recessed areas, crisp details and logos.

Pressure forming is ideal for small to medium sized production runs that do not justify the high cost of injection molding dies. Additionally, because the aluminum tooling used in pressure forming has an unlimited lifecycle, due to the non-abrasive process versus injection, it saves a great deal of money over many years of continued use. Pressure form tooling usually costs less than 10% the cost of an injection tool. There is also a significant time savings (sometimes 25%) in tooling lead time. Sheet gauges .020″ – .500″ are capable of being pressure formed.

METALLURGY INTERVIEW

August 22, 2011

01-interview-interview questions-placement paper-interview questions and answers-interview tips-company or firm - interview skills-interview preparation

  • What is the composition of Grey cast iron Grade 20?

Carbon      : 3.10 – 3.25%         Silicon : 1.75-1.95%    Manganese : 0.50 – 0.7%Sulphur : 0.05 – 0.07%       Phosporous : 0.04 – 0.07%

  • What is the composition of Cast iron Grade 35?

Carbon=2.90-3.10%Manganese=0.60-1.00%Silicon=1.50-1.90%Sulphur=0.10%

Phosphorus=0.15%  Chromium=0.30%        Molybdenum=0.30%   Cupper=0.25%

  • What are the super alloys?

Super alloys is an alloy that exhibits excellent mechanical strength and creep resistance at high temperatures, having good surface finish.

  • Why the Super alloys used for land-based turbines?

Super alloys are the top most alloys used for their excellent strength and corrosion resistance as well as oxidation resistance. No other alloys can compete with these grade.

  • What kinds of NDT methods are available?

1.Visual Inspection

2.Microscopy inspection

3.Radiography Test

4.Dye Penetrate technique

5.Ultrasonic testing

6.Magnetic Particle inspection

7.Eddy Current technology

8.Acoustic Emission

9. Thermograph

10.Replica Metallographic

  • What is Stress Corrosion cracking?

Stress corrosion cracking (SCC) is a process involving the initiation of cracks and their propagation, possibly up to complete failure of a component, due to the combined action of tensile mechanical loading and a corrosive medium.

  • What is meant by D2 Material used for Die tooling?

 

D2 – High Carbon Cold Work Tool Steel

D2 is a high Carbon, high Chromium, Molybdenum, Vanadium, Air hardening alloy tool steel which offers good wear resistance, high surface hardness, through hardening properties, dimensional stability and high resistance to tempering effect. D2 tool steel is also suitable for vacuum hardening.

Typical Composition

C.-1.50%

Si.-0.30%

Cr. -12.00%

Mo. -0.80%

V. -0.90%

  • What is Vacuum Induction Melting?

As the name suggests, the process involves melting of a metal under vacuum conditions. Electromagnetic induction is used as the energy source for melting the metal.

Induction melting works by inducing electrical eddy currents in the metal. The source is the induction coil which carries an alternating current. The eddy currents heat and eventually melt the charge