Part 05 Constructional Details MANF240 Students
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Transcript of Part 05 Constructional Details MANF240 Students
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ١
SJE Part 05 Constr. Details ١
Constructional Details
SJE Part 05 Constr. Details ٢
Different manufacturing processes such as:
-machining
-casting, die-casting
-forging
-RP
Different machining processes such as:
-course m/cg: turning, boring, milling, drilling, planing, spot facing.
-fine m/cg: turning, milling, grinding, honing, polishing.
Manufacturing Processes
Items to avoid during Casting
-high stress concentrations
-shrinkage cavities
-improper feeding of liquid metal
-non-uniform cooling
-sharp corners
-abrupt cross-sectional changes
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ٢
SJE Part 05 Constr. Details ٣
Castings Improvements
-No stress concentrations at corners
-avoiding porous areas
SJE Part 05 Constr. Details ٤
Castings Improvements
-Possibility of crack formation
-Better material flow during casting
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ٣
SJE Part 05 Constr. Details ٥
Castings Improvements
tmin, mmmetal
6Cast iron
Aluminium alloys
2Copper alloys
Magnesium
Cast steel
SJE Part 05 Constr. Details ٦
Castings Improvements
Casting Tapers
Casting Fillets
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ٤
SJE Part 05 Constr. Details ٧
Casting Thickness Flow
Castings Improvements
Casting Material at Junction
SJE Part 05 Constr. Details ٨
Machining Improvements
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ٥
SJE Part 05 Constr. Details ٩
Machining Improvements
SJE Part 05 Constr. Details ١٠
Machining Improvements
Use of chamfers
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ٦
SJE Part 05 Constr. Details ١١
Machining Improvements
SJE Part 05 Constr. Details ١٢
Machining Improvements
A clearance should be left for the run-out of
the tool
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ٧
SJE Part 05 Constr. Details ١٣
Machining Improvements
Blind hole Through holes
Too many machining surfaces
SJE Part 05 Constr. Details ١٤
Machining Improvements
Drilling on inclined surfaces is not recommended
Avoid inclined surfaces at tool exit
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ٨
SJE Part 05 Constr. Details ١٥
Machining Improvements
Need for reference surfaces for clamping on machine tools
during machining
SJE Part 05 Constr. Details ١٦
Machining Improvements
Centering spigots are needed for mating parts
Centering dowels are needed for bolted covers
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ٩
SJE Part 05 Constr. Details ١٧
Machining Improvements
SJE Part 05 Constr. Details ١٨
Machining Improvements
Poor fitting if straightness is a must
Chamfers at end of shafts
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ١٠
SJE Part 05 Constr. Details ١٩
Machining Improvements
Two-surface contact should be avoided
Two-surface contact should be avoided One-surface contact
SJE Part 05 Constr. Details ٢٠
Arch of base is subjected
to heavy flexureArch of base is reinforced by
internal ribs, working in tension
Arch of base is reinforced by external
ribs, working in compressionLug under plane of loading
– most light weight construction
Bearing Block
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ١١
SJE Part 05 Constr. Details ٢١
Casted Cover
Poor rigidity
Imp
rove
d d
esig
ns
SJE Part 05 Constr. Details ٢٢
Box-shaped cover fixed to a housing by a central stud
Poor rigidity.The cover
deflects when tightened.
Draw suitable solutions.
Box-shaped Cover
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ١٢
SJE Part 05 Constr. Details ٢٣
Flanged Shaft
Poor rigidity
Cup-shaped flange.
The transition section
“a” where the flange
joins the hub, is
strengthened.
Conical flange.
SJE Part 05 Constr. Details ٢٤
Bracket with Hub
Poor rigidity
Conical Design
Cup-shaped Design
Improved Conical Design
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ١٣
SJE Part 05 Constr. Details ٢٥
Centering Techniques
Reduction in centering diameter
SJE Part 05 Constr. Details ٢٦
Fitting on Several Surfaces
Fitting on Two surfaces
Fitting on One surface
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ١٤
SJE Part 05 Constr. Details ٢٧
Fitting on Several Surfaces
Fitting on Two surfaces
Fitting on One surface
Fitting on One surface
SJE Part 05 Constr. Details ٢٨
Fitting on Several Surfaces
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ١٥
SJE Part 05 Constr. Details ٢٩
Tapering of Flanges
SJE Part 05 Constr. Details ٣٠
Seats of Flanges
Large seat, more
machining is required
Acceptable seat, less
machining is required
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ١٦
SJE Part 05 Constr. Details ٣١
Machining Improvements
SJE Part 05 Constr. Details ٣٢
Machining Improvements
MANF 240 Constructional Details 19 March, 2011
Prof. Samy J. Ebeid ١٧
SJE Part 05 Constr. Details ٣٣
Prevention of sharp corners
Machining Improvements
Minimum machining
SJE Part 05 Constr. Details ٣٤
Design Factors
1. Stiffness
2. Strength
3. Thermal properties (thermal stresses)
4. Corrosion
5. Wear
6. Friction
7. Process of manufacturing
8. Use of the component
9. Cost
10. Safety
11. Noise and vibrations
12. Appearance of component
13. Shape and compactness
14. Size
15. Surface finish
16. Tolerances
17. Lubrication
18. Life