subject fundamentals of machinery manufacturing technology

Fundamentals of Machinery Manufacturing TechnologyClass:INS314601 Contents Chap I: Foreword Chap II: Introduction Product Chap III: Technical requirements of the product Chap IV: Metho

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Subject: Fundamentals of Machinery

Manufacturing Technology

PGS.TS Nguyễn Như Tùng

Students:BùiHồngAnh

HàDuyAnh

ĐặngPhúcAnh

Fundamentals of Machinery Manufacturing Technology

Class:INS314601

Contents

Chap I: Foreword

Chap II: Introduction Product

Chap III: Technical requirements of the product

Chap IV: Methods of fabrication

Chap V: Methods and machining steps

Chap I: Foreword

INTRODUCTION

Inordertoservetheimprovementandenhancementofthequalityof

mechanicalproducts,establishingappropriateandeffectivetechnological

processesisamatterofgreatimportance.Furthermore,toensuredesign

requirementsaremet,achievehightechnologicalstandards,andproducewidely

utilizedproducts,establishingsuitabletechnologicalprocessesshouldbegiventop

priority.Designingappropriatetechnologicalprocessesalsohelpsworkersreduce

machiningtime,increaseproductivity,andlowerproductcosts,meetingmarket

demands.Amachinecomponentmayhavemultipledifferenttechnological

processes,andthechosentechnologicalprocessinthisprojecthasbeenselectedto

bethemostrationalwhileensuringrequirementsforquality,cost,andtimeare

met.Allnumericaldataandcalculationshavebeenguidedbyinstructorsfrom

documentedsourcesandthroughexperience.However,asthismachine

manufacturingtechnologyprojectisbeingcarriedoutforthefirsttime,errorsin

calculationsanddesignscannotbeentirelyavoided.Wehopetoreceivefeedback

andadditionalknowledgefromourinstructorstoenrichourunderstandingand

knowledgefurther

Fundamentals of Machinery Manufacturing Technology

Chapter II: The shaping method

Asbtract:TheshapingmethodisFocusedoncreatingthedesiredshapefor

thepart

Principles of shaping:

 Cuttingshapingmethod:Removingexcessmaterialfromtheworkpieceto

formthedesiredproduct.Bycuttingtoolswithcuttingmeshofdefinedand

undefinedshapes.Forexample:milling,turning,planing,boring,

 Plastic  deformation  shaping  method:  Change  the  shape  and  size  of  the

workpiece  without  changing  the  nature  of  the  material  For  example:

stamping,rolling,drawing,

 Castingshapingmethod:Usingamoldtoshapetheproductfrommolten

material.Forexample:sandcasting,metalmoldcasting,

 Electrophysical  and  electrochemical  shaping  methods:  Connecting  parts

togetherbymelting.Forexample:electricarcwelding,TIGwelding,

 3D printing shaping method: Shape the product  layerby  layer from the

printedmaterial.Forexample:FGMprinting,SLAprinting,

Fundamentals of Machinery Manufacturing Technology

Chap III: Introduction Product

Theproductwearediscussingisamachine

partshowninthetechnicaldrawingyou

provided.Thismachinepartisaspur gear.Spur

gearsarethemostusedtransmissionsystems

Thistypeofgearhasthefollowing

characteristics:

 Gear shaft:Thegearshaftistheaxisof

rotationofthegear

 Teeth:Theteetharetheelementsthatprotrudefromthecylindricalsurface

ofthegearandareresponsibleformeshingwiththeteethofanothergearto

transmitmotion

 Tooth angle:Thetoothangleistheanglebetweenthetoothlineandthe

gearshaft.Spurgearshaveatoothangleof0°

 Number of teeth:Thenumberofteethisthenumberofteethonthegear.

 Module:Themoduleistheunitofmeasurementforthesizeofgearteeth.

Function and purpose:

Spurgearsareusedtotransmitrotarymotionandchangethespeedofrotation

betweenshaftsinmachines.Thistypeofgearcantransmitmotionbetween

parallel,intersecting,andperpendicularshafts.Spurgearsareusedinawide

varietyofmachinessuchas:

 Industrial machinery:Lathes,millingmachines,planers,cuttingmachines,

textilemachines,etc

 Automobiles:Gearboxes,axledrives,etc.

 Motorcycles:Gearboxes,finaldrives,etc.

Agricultural machinery:Tractors,harvesters,threshers,etc

Technical requirements of the product

Basedonthetechnicaldrawing,wecandeterminethefollowingimportanttechnical

parametersofthespurgear:

 Dimensions:

o Outsidediameter:D=100mm

o Insidediameter:d=60mm

o Facewidth:b=20mm

o Numberofteeth:z=20

o Module:m=2mm

o Toothangle:α=0°

 Material:SteelCT3

 Strength:≥600MPa

 Tolerances:

o Accuracygrade:IT7

o Outsidediametertolerance:±0.02mm

o Insidediametertolerance:±0.01mm

o Tooththicknesstolerance:±0.01mm

Chap IV: The manufacturing methods that were used

to manufacture products

Fundamentals of Machinery Manufacturing Technology

1 Determine the types of production:

-Materialscanbemadeofsteel,castiron,alloy,…butduetotechnicaland

economicfactors,weuseSKD61steelmaterial.

-Therequiredquantityis5000products.However,errorscannotbeavoided,so

ourteamproposestoincreasethenumberofproductsproducedto5,500products

2 Workpieces manufacturing method:

-Choosingtheblankmeanschoosingthemanufacturingmaterial,theblank

formingprocessdeterminestheamountofresidueandtolerancefortheblank

creationprocess.

-TheprocessofcreatingSKD61steelbilletincludesthefollowingsteps:

+Melting

+Castingandpouringintomoldstoformembryos

+Improvethedurabilityoftheworkpiecethroughforgingandheattreatment

Chapter V: Explain the steps to manufacture the

products

Operation 1: Roughing

Fundamentals of Machinery Manufacturing Technology

Operation 2: Re-Roughing

Fundamentals of Machinery Manufacturing Technology

Operation 3: Surfing Milling