Making Bearing Housing - Case Study Example

Title: 353684 - Bearing Housing Dated: March 27, 2009. (1) Analysis and formulation of the machining process and a plan to complete the machining of the component based on CNC machining. Bearing Housing is deigned and manufactured for supporting a bearing in such an arrangement that the bearing is arranged in the form of a seat called as bearing seat. A bearing house poses the qualities like a rigid, strong, inexpensive and lightweight bearing housing as to accommodate the bearing in ease and comfort as per technical specifications of both the bearing and bearing housing. To meet all these requirements, the housing is shaped in the form of a tube with a central rectangular cross section to accommodate the structure within it as the bearing. The axis of the bearing is mounted in the housing region as an extended body mainly as perpendicular to two housing walls which are facing each other and the bearing is finally enclosed by the housing framework in a compact form so as to perform its functions in a perfect manner. In such an arrangement when bearing is arranged in the housing unit, the bearing axis mainly extends towards the two walls which help in performing the functions to the bearing in the bearing house(1). Coordinate systems choice, Justification of the proposed version. The manufacturing of the bearing housing and the bearing involve the stages like designing of the moulds for the synthesis of the bearing housing, designing of the whole structure, purchase of the required materials as an input, the processing of the materials as through the designed system for the manufacturing process, cutting, welding and re arrangements of all the segments so as to achieve a desired product. The manufacturing process for the manufacture of bearing housing is completed with the help of the computer aided designs and computer aided machines with the use of numerical control mechanism. The numerical control arrangement is the automation of machine tools that are used for the manufacturing of the products by abstractly designed program commands in an encoded arrangement within a storage medium. The numerical control as in encoded arrangement is different from that of the manually controlled arrangements with the help of levers operated by the human factor. 2) The resources, such as machine, tool, fixture, and etc for the machining process/operation The rapidly growing machining system with digital and analog computers are creating the modern computer numerical controlled (CNC) machine tools which have revolutionized the designing process for the manufacturing of products like bearing housing. A CNC panel used for the handling of numerical process is shown. In the modern CNC systems, a complete design structure is highly automated with the use of computer aided design and computer aided machines programs which are also called as CAD/CAM programs which produce a computer file that is explained to acquire the command needed to operate a perpendicular machine with hundred percent accuracy so as to achieve maximum results with the use of commands required to operate the machine(2). The resulting machine is then loaded into a CNC machine for the production of the desired product. A number of tools are required to complete the process like drills, saws, lathes, wood rooters, milling machines, sheet metal works, hot –wire foam cutters, water jet cutters surface grinders and cylindrical grinders. These tools are helpful in the designing, manufacturing, finishing and fitting processes for the bearings and bearing housing. There are three fundamental stages of the manufacturing process as (a) the designing of the moulds, (b) mould manufacturing and (c) the component manufacturing with the assistance of the tools and moulds . Some of these instruments are shown below: 3) The work holding strategy for the machining process/operation; The work holding strategy is adopted for the machining process which is completed with the help of the necessary tools as to aid in the machining process especially with the use of moulds and specific dyes for the purpose of manufacturing bearing and bearing housing. The moulds are used in the manufacturing of the bearing housing as equipped with return edges, sharp corners and fillets. Different kinds of milling machines tools used for the manufacturing of the bearings and the bearing housing like, Vertical Milling machine, Horizontal milling machine and Bridge type milling machine which help in the manufacturing process (3).The equipment are essential for the quality output with specific requirements as to determine the size of the final product as the bearings and the bearing housing especially with the CNC machines. For the manufacturing of bearing and bearing housing the plasma cutting technique is used to cut the metals and the steel with the use of plasma torch. This process is completed with the help of an inert gas which is blown up at high speed out of the nozzle and through the process an electrical arc is formed for cutting the surface .The plasma provides the required temperature for the cutting the metal and through the process the product is synthesized with specific configurations. 4) The manufacturing parameters The bearing and the bearing housing are designed and manufactured with specific parameters with the aid of modern machines along with the combination of multiple tools into a single cell. The machines are handled on the basis of CNC arrangement as guided by the CAD designs. The bearing seats are characterized by the moulds as to manufacture in an insertion as in the shape of a tube with a central circular cross section. These insertions are arranged in the circular bores within the housing walls which are mainly perpendicular to the bearing axis. The insertions kept in a position by snap rings for the arrangement of making the recesses in the outer surfaces for making contacts between the bearing housing and the external perpendicular walls. The inner surfaces are spherical in their appearance and these surfaces are obtained with the use of CAD / CAM and CNC techniques. 5. NC program of CNC machining of the component Numerical control (NC) program refers to the automation of machine tools that are used by the program commands which have abstractly been encoded on a storage medium. These early machines have rapidly been augmented with the use of analog and digital computers for the creation of modern computer numerical controlled (CNC) machine tools that have revolutionized the whole design process with the use of CAD/ CAM programming. These programs produces computer files that is interoperated to extract the required commands for making the operations of the machines as reality with the loaded CNC machines and production strategies for the bearings and bearing housing. The CNC techniques are helpful in getting the desired products with specific designs and structures as to help in the engineering process for the manufacturing of the desired products. The manufacturing process needs special attention of all the stakeholders for the designing, manufacturing, and utilisation and after sales services for the product as to promote the product in the market with specific technical details as per requirements of the bearings and the bearing housing.  The Machining program for making the bearing housing will be offered in the form of three separate segments and the same will facilitate to complete their related technical works with professional commitment and confidence. These three segments include the understanding of the basic Machine Operations, advanced machining stage and its utilization for the delivery of the task in perfect manner and finally the use of basic welding operations for the completion of the whole task in a satisfactory manner. A method of correcting a machining program with numerical control device during an execution of the machining program will be utilized through the steps like a) Executing a created machining program with a program check; b) Effecting single block stop 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 to a predetermined block shape; and d) Correcting the machining program, if required, and then executing same. The bearing manufacturers are making bearings in such an arrangement as to standardize the tolerances set forth by the Anti Friction Bearing Manufacturers Association (AFBMA) and by the International Standards Organization (ISO). These types of the products as proper fits can only be achieved by selecting and utilization of the proper tolerances for the shaft. References: 1. Valerie J Gawron (2000), Human Performance Measures Handbook Lawrence Erlbaum Associates - A useful summary of human performance measures. 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. Serope Kalpakjian, Steven R. Schmid: Chapter 24 of Manufacturing Engineering and Technology, 5th Edition, Prentice Hall, ISBN 0-13-148965-8 Read More