Premount Base - Essay Example

Title: 353682 - Premount Base Dated: March 29, 2009 Contents Serial number Subject Page number 1 Introduction 3 2 Analysis and formulation of the machining process and a plan to complete the machining of the component based on CNC machining. 4 3 The resources, such as machine, tool, fixture, and etc for the machining process/operation 6 4 The work holding strategy for the machining process/operation 8 5 The manufacturing parameters 9 6 NC program of CNC machining of the component 9 7 References 10 Introduction: A premount base in an automobile engine performs its pivotal role along with other parts like a tensioner ,a belt ,a clutch device ,a pivot shaft and the mounting surface of the engine. A reliable re installation of all these parts helps in the functioning of the vehicle without cumbersome manual alignment and realignment procedures. A tensioner has a pivot shaft which is configured in an arrangement which shape the overall structure as mounting on the engine surface. The manufacturing of the premount base along with other parts of the engine requires the designing of the product along with necessary drawings, use of machinery and other necessary tools, selection of material for the products, machining process, The designing of the premount base is regulated through the adoption of principles of the engineering and with the help of machining process for the removal of unnecessary parts through the numerical control arrangement(1). The process is completed with the utilization of advanced form the numerical machine system with the complement of digital and analog computers as for example the modern computer numerical controlled (CNC) machine tools which are helpful in the designing and machining process for the manufacturing of automobile accessories including the premount base with the required standards and demands of the customers. Coordinate systems choice: The manufacturing of Premount Base is conducted in a coordinated and will disciplined mechanism with the observance of specific measurements as are required for the final product and the work is completed with the help of Numerical Control system.The Numerical control refers to the automation of the machine tools that are functioning by abstractly programmed commands encoded in the shape of a storage medium. The first NC machines were manufactured in the 1940s and 50s, based on the existing tools that were modified and upgraded with motors that moved the controls to follow points as fed into the system on paper tape mechanism. These early machines were the servomechanisms and subsequently were rapidly augmented into the modern computer numerical controlled (CNC) machine tools that have revolutionized the design process in the manufacturing sector. The modern CNC systems is highly automated and is using Computer aided designs and Computer aided Manufacturing programs which are commonly called as CAD/CAM programs. The premount Bases are produced with the application of engineering tools and equipment along with the utilization of human and technical resources as to make the product with the economy of scale as per ISO certified standards. (2) Analysis and formulation of the machining process and a plan to complete the machining of the component based on CNC machining. The machining process for the manufacture of the premount base is processed with the help of CNC machining mechanism as through the removal of the object quickly from the bulk of the waste material and is consisting of the stages designing, manufacturing and finishing of the product with the utilization of machinery, equipment, tools and CNC machining mechanisms for the production of the product as with required standards and quality. The machining process is one of the most important material removal methods used during the manufacturing of the premount bases of the engines .The process is completed with the use of material-working processes in which power-driven machine tools such as milling, lathes, drill presses are used with a sharp cutting tool to mechanically cut the material to achieve the desired geometry of the product. Machining is a part of the manufacture of almost all metal products especially which are used in the automobiles. A person who specializes in the machining process is called a machinist and the place where the process is completed is called a machine shop(2). Three machining processes are involved in the machining process as turning, drilling and milling for the manufacturing of the premount base and are designed with the use of numerical machines and CNC with accurate input data. The data helps the machine to perform its functions as per the installed program for the desired products. These programs are in the form of software systems and are designed in accordance with the design, configuration and specification of the final product. The cutters and welding machines in the engineering departments of the manufacturing units are helpful in the conversion of the raw product into the finished form with the assistance of CNC machine tools. The use of machining process is helpful in making the product in the shape as to support the different parts of the engine in combination of the premount base. The utilization of CNC machines is extremely helpful in the production of the premount base with the specific sizes of all the parts of the engine. The machining process is helpful in the performance of all the related engineering tasks with their requisite standards and specifications for the installation and functioning of the premount bases.The application of engineering tools and machines with the adoption of latest technology like CNC will ensure the production of the premount base as per required standards. 3) The resources, such as machine, tool, fixture, and etc for the machining process/operation. The three principal machining processes which are involved in the manufacturing of the premount base include turning, drilling and milling of the raw material used in the process. These processes are supplemented with other allied processes like shaping, planning, boring, sawing and broaching. The resources needed for the completion of all these types of activities are the raw materials needed for the production of the final product, tools, and machines as in the form of CNC machines. All these raw materials are processed by technical personals in a coordinated and disciplined fashion as to produce the product in systematic pattern. Turning operations are the operations that rotate the material as the primary method of moving metal against the cutting tool for a refined product. Lathes are the principal machine tool used in turning process. The milling operations are the operations in which the cutting tool rotates to bring cutting edges to bear against the product. In the milling process a rotating tool with multiple cutting edges works slowly to generate a plane or straight surface for further processing in the manufacturing process(3). There are two basic forms of milling process which are used in the whole manufacturing process for the assemblage of all the parts of the engines for the attainment of a synergetic impact .These two milling process are as under: a. Peripheral milling b. Face milling Drilling operations are the operations in which holes are produced or refined by bringing a rotating cutter with the cutting edges at the lower extremity into contact with the expected product as the premount base. Drilling operations are completed primarily in the drill presses. Burnishing is a good example of a miscellaneous operation as involved in the manufacturing of the premount base. Three fundamental and important stages in the manufacturing process for the production of the premount base are as: a. designing of the moulds, b. mould manufacturing, and c. Component manufacturing with the assistance of the tools and moulds. The machining system with the numerical configurations along with digital and analog computers are developing the modern computer numerical controlled (CNC) machine tools which have revolutionized the whole designing process for the manufacturing of products like the wheel centre for the automobiles . These machines are working as on the basis of numerical and digital data as stored in the CNC machine and with the help of engineering tools. In modern CNC systems, the end-to-end component designs are highly automated with the use of computer aided designs (CAD) and computer aided manufacturing (CAM) with the use of the required data. A set of tools which are helpful in the manufacturing process and are as under: 4) The work holding strategy for the machining process/operation: The working of the premount base is depending on the perfection in the specification of all the parts of the engine as the functioning of the major parts like a pivot shaft is configured in such a mechanism as for mounting on the engine surface. The pivot shaft's movement between a free arm stop positions at the premount stop position depends on the configuration and perfection with accuracy of the final product. Pulley is mounted for rotation on the tensioner arm and the same apparatus is also related with the positioning of a perfect premount base of the engine. The holding strategy is adopted for the functioning of the machining process which is completed with the assistance of the required tools as to help in the process along with the use of moulds for the purpose of manufacturing of the premount base. The moulds are equipped with sharp corners, return edges and fillets. Vertical Milling machine, Horizontal milling machine and Bridge type milling machines are the tools are which are used for the manufacturing of the engine products like the premount base which help in the functioning of the engine as on normal basis. CNC machines tools are needed for the quality output as to determine the size of the final product in the shape of the premount base. 5. The manufacturing parameters The Premount base are designed and manufactured with the help of modern machines along with the combination of multiple tools into a single cell with the requisite specifications. The machines are handled on the basis of CNC arrangement as guided by the CAD/CAM designs and programs. The products are characterized by the moulds as to manufacture in the shape of a central circular cross section. These insertions are arranged in the circular bores within the outer walls of the basic materials as consisting of brass or aluminum .The insertions are arranged in a position with the help of tools for making the structures in the outer surfaces of the moulds. The inner surfaces are spherical in their appearance and these surfaces are obtained with the application of CAD / CAM and CNC techniques for the finalization of the Premount base of the engines of the automobiles. 6. NC program of CNC machining of the component The Numerical control (NC) program refers to the automation of machine tools which are used with specific commands. These are abstractly encoded on a storage medium for their further usage in the manufacturing process. These early machines are supplemented with the use of analog and digital computers for the creation of modern computer numerical controlled (CNC) machine tools. These CNC tools have changed the whole designing process with the use of CAD/ CAM programming. The Machining program for making the Premount bases will be offered in the form of a number of separate segments and these segments will facilitate to the technical personals to complete their related technical works with professional commitment and confidence. There are three segments as (i) the understanding of the basic Machining Operations, (ii) advanced machining stage and its utilization for the delivery of the task in perfect manner and finally the (iii) use of basic welding operations for the completion of the whole task for the preparation of Premount bases in a satisfactory manner. A method of correcting a machining program with numerical control device during an execution of the machining program will also be utilized through the steps like a) Executing a machining program with a program check; b) Effecting single block stop mechanism at the portion in the machining program at the point where an error is discovered in the program; c) Executing the machining program in reverse order mechanism to a predetermined block shape; and finally d) Correcting the machining program. The manufacturing process needs special attention for the designing, manufacturing, and utilisation for the product for the promotion of the product in the market as per the standards of the International Standards Organization (ISO) which are helpful in getting the desired products through turning, drilling, boring and milling processes with specific designs for the manufacturing of the desired products as in the shape of Premount base of the engines. References: 1. Billington, David P. (1996). The Innovators: The Engineering Pioneers Who Made America Modern. Wiley; New Ed edition. ISBN 0-471-14026-0. 2. Lord, Charles R. (2000-08-15). Guide to Information Sources in Engineering. Libraries Unlimited. doi:10.1336/1563086999. ISBN 1-563-08699-9.  3. Groover, Mikell P. (2007). "Theory of Metal Machining". Fundamentals of Modern Manufacturing (3rd Ed). John Wiley & Sons, Inc. pp. 491–504. ISBN 0471744859 Read More