Manufacturing Processes – 2000 words

 

Manufacturing Processes

 

Moulding and shaping

 

Ceramic Processes:

 

  • Slip casting

Slip and clay are poured into a mould. This is a traditional way of creating and forming a ceramic. The slip casting method gives a better quality, and is far superior to hydraulic casting as there is a higher concentration of ceramic powder used and less additives. When the ceramic is fired in the kiln it is sintered and bonded together at high furnace temperatures.

 

  • Ceramic shell casting

Shell casting is also used this technique uses a lot of frequent wet dipping to build up the mold shell layer. The other method of shell casting is used for aerospace as it has a higher dimensional stability.

 

  • Tape casting

If you want to use thin sheets of ceramic material, tape casting is used the technique is to add a polymer binder to add strength. This technique is used especially if you are wanting to make multilayer capacitors….A billion multilayer ceramic capacitors are created every day using this method..

 

  • Technical ceramics

Other aspects of ceramic production are technical ceramics that are created using injection molding techniques such as ‘hot wax molding’. This is the same process as the injection molding of plastic products.

 

  • Gel casting

Other techniques used are gel casting and injection molding that are used a lot in engineering ceramics. Ceramic forming techniques, Wikipedia (2008)

 

Board room presentation

I have chosen the ceramic insulator as an example to present to the board as it more or less gives the board an idea of the manufacturing process of a required ceramic product. Of course the product defines the process and each product would require different plant, and machinery requirements.

 

Cross section of a spark plug

The spark plug insulator is created from ceramic and can withstand temperatures of 650 degrees centigrade; the ceramic length determines the heat range of the plug. When the centre electrode passes through the ceramic it reduces emissions and radio noise from the tip when it’s sparking.

 

Cross section of a spark plug showing the insulator.

The actual porcelain insulator we would create is made from ceramic material that is stored in liquid form and is first poured into rubber molds. An automated process applies pressure to produce the unfired insulator blanks. The bore hole and hollow of the insulator are tightly controlled by the processing machines. Then a special 6 contour grinding machine provides the final exterior shape prior to the insulators been fired in a kiln using temperatures over 2700 degrees Fahrenheit.

 

A six contour grinding machine

Throughout the process a computer controls everything, the insulator is produced very strong, dense and also has to be resistive to moisture. The insulators can be fired again to included manufactures marks and serial numbers… Overall the process to create the ceramic insulator is more complex than I originally thought, and it explains also why the spark plug is such a tough component after going through the various processes to harden its shell and to seal it from moisture. Without the processes of extreme pressing under pressure and through the advent of electrolytic process the spark plug is manufactured into a durable and tough component that is relied upon by many people in their daily lives. To create this ceramic insulator will take various types of equipment as follows:

  • Kilns to fire the ceramic
  • Presses
  • Grinding machines

Spark Plug, Madehow.com (2008)

 

 

 

 

 

 

 

 

 

 

 

Aluminum Alloy Wheel Production Processes:

  • Die casting
  • Sand blasting
  • Over flow cutting
  • Drilling
  • Solution baths
  • Quenching
  • Lathing
  • Ageing
  • Painting
  • Baking (oven)
  • Finishing
  • Pressing
  • Balancing
  • Packing

 

Die casting process

Once I sourced the raw materials to make the wheels e.g.: the aluminum ingot I would then melt it and then use a die casting technique forming it into the wheel shape.

 

Die casting alloy wheels

There are various methods of die casting:

  • Sand Casting
  • Die Casting
  • Gravity Casting
  • High Pressure Die Casting
  • Low Pressure Die Casting
  • Vacuum Die Casting
  • Squeeze Casting or Squeeze Forming

 

I would use the low pressure die casting method as it is suited to producing products that are symmetric about an axis of rotation. In this process the crucible is filled with pressure from below see the diagram below:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The AtoZ of materials, (2008)

Sand Blasting process

Sand blasting uses clean silica and garnet sand also different shots or media:

  • Steel shot
  • Steel grit
  • Cut wire
  • Ceramic cut wire
  • Stainless Steel cut wire
  • Carbon steel shot and grit
  • Glass beads
  • Ceramic beads
  • Brown alumina
  • Walnut shell grits
  • Silicon carbide
  • Bronze alloy shots

 

I would use this shot peening machine for aluminum wheels.

I would this shot media for the peening machine:

  • Carbon
  • Stainless steel

Over flow cutting process

I would then use an overflow cutting machine to define the wheel further and create its shape properly.

Drilling process

The wheels have to be drilled and the centre hole made as well as holes for wheel studs.

Drilling machine for alloy wheels.

  • This machine can drill wheels between 13” to 20”
  • 3 position valve maker
  • 6000 rpm

The aging process

An age hardening furnace

There are two specifications for heat treatments:

  • AMS2770 Heat Treatment of Wrought Aluminium Alloy Parts
  • AMS2771 Heat Treatment of Aluminium Alloy Castings

 

I would use the AMS2771 process for the alloy wheels production.

The idea is to cause precipitation dispersion of the alloy solute to occur. This is called precipitation hardening; it is dependant on precise times and temperatures with water quenching used in the process.

Water quenching process.

The quenching time is dependent on the sizes of the wheel being hardened.

Bore machine and hole making process

A  HAAS drilling machine.

CNC machining use this machine for there alloy wheels and I would use a similar machine as it is very flexible and can run a lot of different designs and patterns. It is also very easy to programme and to rejig if needed. It does not stall the spindle when drilling and pushes the drill very well. It has the most horsepower of all the machines and is very fast to produce. Also the training for staff to use is very good.

Machining process

A HAAS VF3

This is a good choice of machine for creating the centres as it can do two wheels at a time.

Leak testing process

LDS 911-W wheel leak test cell

This machine can only test dry clean wheels. And requires a test after painting is done.

PRACTICAL CONSIDERATIONS FOR TESTING A WIDE RANGE OF WHEEL SIZES ON A SINGLE MACHINE (2008)

Spray painting process

There are various ways of painting the wheels:

  • Dry type painting
  • Revolving gun type painting
  • Reciprocating Paint Machine
  • Overhead Reciprocating Paint Machine
  • Robotic Index table paint machine
  • Spray booths
  • Hand held spray gun

 

 

Spray booth

 

 

VSC painting chamber

 

I would use the painting chamber as then it would be sealed and the air pumped out creating a vacuum chamber. Then electric is passed through and charged particles spray onto the alloy. This gives a better quality and chrome like appearance.

 

Testing process

 

A Makra testing machine

QUALITY CONTROL TESTING INCLUDES:

  • Impact test
  • Fatigue test
  • Radial dynamic test
  • Metallurgical Laboratory tests
  • Xray testing process

 

 

All tests have to conform to various standards such as TUV, German standards and VIA plus Japanese standards.

Dynamic fatigue testing process

Radial fatigue testing process

Impact testing process

Xray testing process

 

 

 

      Metallurgical Laboratory tests

 

 

Helium leakage testing process

 

 

Balancing process using a MAKRA TB02

I believe my selection of materials and machinery would create a professional product and that we could sell the product commercially given that I have identified the correct process of manufacture and the machinery needed for the production of the alloy wheels.

Raw materials needed:

Aluminium Alloy Ingot A356.2

Al-Sr-Sl, Kao-Wool

Magnesium 99.9%

Trichloromethane, Paint

Fly-Wire, Cruciable, Day395

Taper Bush

Dy-Cote-33, Cov-12, Cov-52

Center cap

Degasser-990, Grain-Refining Flux

Taper Nut

Laddle Dip R-20, Na Powder

Taper Bolt

A1-T1-B, Cov-66

Name Plate

Aluminium Strontium Silicon 10%

 

People needed

General Manager

1

Foreman

6

Clerk

3

Inventory Controller

2

Quality Controller

3

Tool Maker & Maintenance

3

Electric Technician

1

Casting Labor (3 shifts)

12

Heat Treatment Labor (3 shifts)

3

Cutting Labor (2 shifts)

2

Drilling Labor (2 shifts)

2

Machining Labor (2 shifts)

14

Finish Labor (2 shift)

18

Total

70

Equipment needed

Hold Furnace with Testing Machine

10

Hydraulic Die Casting Machine with Sand Blast Machine

4

Heavy Duty Precision Lathe Machine with Conveyor

2

Drilling Machine with Hydraulic Chuck

2

Solution Furnace with Blower

1

Structure Unit for Heat Treatment Equipment

1

Age Furnace with Blower

1

Shot Hanger Blast Machine

1

Automatic Turning Machine

2

Drill Vent Machine

2

Vertical Copy Lathe Machine with Chuck

2

Rear Copy Lathe Machine with Chuck

2

Leakage Testing Machine

2

Multi-Spindle Drill Machine

2

Defat Machine with Cooling System

1

Painting Booth with Compressor

1

Finish Copy Lathe Machine with Chuck

1

Oven

2

Hydraulic Press for Bush Inserting

1

Painting Booth for Clear with Pallet

1

Universal Wheel Balancing Machine

1

Dynamic Radial Fatigue Test Equipment

1

Universal Tensile Strength Test Equipment

1

Air Compressor (60HP)

1

Cantilever Drilling Machine

1

Vertical Type Universal Milling Machine

1

Band Saw

1

Inspecting Graplate

1

Cooling Tower

1

Oil Furnace

1

Impack Test Equipment

1

Dynamic Corner Fatigue Test Equipment

1

Plant layout

Tiawan Trade, (2008)

 

 

 

 

Golf clubs manufacturing process

Golf club head making processes:

  • Investment casting

The golf club head is created using a process called investment casting. This head is then hardened.

These machines produce the Golf club heads:

TSA-124-3
Plate Type Wax Injection Machine

TSA-124-2
Hydraulic Wax Injection Machine

TSA-124-1
Twin Nozzle Vertical Wax Injection Machine

TSA-124A
Single Nozzle Wax Injection Machine

TSA-129
Automatic Hydraulic Wax Injection Machine

Lost wax casting process:

  • Injecting wax or polymer into a metal die
  • Creating a mold
  • Removing the mold from the die
  • Coating the mold with a ceramic shell
  • Heating the shell to melt and remove the wax or polymer
  • Filling the ceramic shell with molten metal

The traditional method of injecting wax into a die is good, but new ways of improving the process via ceramic molds, compressing the material into the mold by hot isostatic presses and subjecting the mold to gas pressure at higher temperatures in a suitable machine this can improve the density after cooling to 100%. I would look into this invention further to using the traditional method to see if this wasn’t a far better and cheaper process. Method of making a golf club head using a ceramic mold, (2008)

 

Golf club shaftmaking processes:

  • Tube drawing

The shaft is created using a process called tube drawing. This is then screwed to the head.

Tube drawing machine

Process 1 – Tube drawing

The shaft is created by tube drawing; a tube is pulled part way through a die. The tube is then allowed to get thinner by repeating the process to produce the taper. Each time the die is made smaller. Then if the shaft is steel it is chrome plated.

The shaft and head are connected with screws or pins then held with epoxy adhesive.

Process 2 – Graphite shaft production

If the shaft is made with graphite fiber then it is made using a process called pultrusion. This is when a bundle of graphite fibers are pulled through a circle opening in heated dies with epoxy resin forced through the opening. The fibers embed in the epoxy and are heated to form the shaft. The shaft when cooled is then cut to length; these shafts remain the same diameter along the length. The graphite shafts are bonded onto the shaft with glue.

Process 3 – Steel Fiber shaft production

Aerotech Golf LLC have created a composite shaft by adding steel to the graphite core, this adds hoop strength and increases its power.

Benefits of Steelfiber:

  • Power of graphite but as stable as steel
  • The graphite core gives good damping
  • Steel fibre cover adds stability and control
  • Good weight without thickness
  • 59 miles of steel fibre cover the shaft

The results for using Steel fiber:

  • SteelFiber Construction
    Ascending Mass Design
    Easy to hit long irons
    More controllable short irons

Process 4 – Grip molding

The end of the shaft is placed in a die and a grip is molded onto it. NAM (2008), Golf Club, (2008)

The processes for creating the golf club shafts are dependant on what type of golf club is required. I think I would use the new process 3 and create the graphite steel fiber version as I feel it is stronger and lighter and more of a modern invention. It has proven to out compete any of the other golf club versions and inconjunction with the new ceramic molding golf club head I thin it would be the best future combination.

Bunker shot, (2008)

 

 

 

 

 

Bibliography

 

Ceramic forming techniques, Wikipedia (2008) http://en.wikipedia.org/wiki/Ceramic_forming_techniques Date accessed 19.05.08

Spark Plug, Wikipedia (2008) http://en.wikipedia.org/wiki/Spark_plug Date accessed 19.05.08

Heywood, John. Internal Combustion Engine Fundamentals. McGraw-Hill, 1988.

Schwaller, Anthony. Motor Automotive Mechanics. Delmar Publishers, 1988.

Spark Plug, Madehow.com (2008) http://www.madehow.com/Volume-1/Spark-Plug.html Date accessed 20.05.09

Tiawan Trade, (2008) http://turnkey.taiwantrade.com.tw/en/Content.aspx?ID=64 Date accessed 21.05.08

NAM (2008), http://www.webcastgroup.com/client/start.asp?wid=0670202062107 Date accessed 21.05.08

Golf Club, (2008) http://www.madehow.com/Volume-4/Golf-Club.html Date accessed 21.05.08

Vulkan, (2008) www.vulkanshot.com/products/products.php Date accessed 21.05.08

The AtoZ of materials, (2008) www.azom.com/details.asp?ArticleID=1392 Date accessed 21.05.08

CEC, (2008) http://www.cec-intl.com/web/February%20IH%20Article.asp Date accessed 21.05.08

PRACTICAL CONSIDERATIONS FOR TESTING A WIDE RANGE OF WHEEL SIZES ON A SINGLE MACHINE (2008) http://www.lds-vacuum.com/whl2-tip.html Date accessed 22.05.08

Investment casting, Wikipedia (2008) http://en.wikipedia.org/wiki/Investment_casting Date accessed 22.05.08

 

Method of making a golf club head using a ceramic mold, (2008) http://www.patentstorm.us/patents/5094810/description.html Date accessed 22.05.08

Bunker shot, (2008) http://www.bunkershot.com/2008/viewstory.cfm?ID=3477 Date accessed 22.05.08