Dry - Wet Processing Technologies for Large Area Electronics

Dry Processing Technologies for Large Area Electronics

http://innolae.org/dry-processing-technologies/

The Dry Processing Short Course is delivered by the Centre for Process Innovation (CPI). It covers the key processing techniques required for large area electronic device manufacture, including vacuum deposition, photolithography, laser ablation and wet and dry etching. In each case the advantages, disadvantages and technological challenges of each technique will be covered, along with issues arising in scale up for manufacture.

MONDAY 20 JANUARY 2020

12:30 – 13:30 Registration
13:30 Course begins


Dry Processing (Thin Film Fabrication and Patterning)
Vacuum Deposition
Dr Andrew Cook, CPI

Physical vapour deposition
Chemical vapour deposition
Description of evaporation process
Description of sputtering process
Comparison of evaporation vs sputtering
PVD chamber design
Requirements for a process chamber
Discussion on vacuum pumps types
Discussion on power supplies
PVD process conditions
Pressure, time & power vs deposition rate & thickness
Magnetron sputtering
Metal vs reactive sputtering
Target types

Description of ALD process
ALD cycle
Temporal vs spatial ALD
Current tool types


Photolithography Processes
John McLean, CPI

Photo processes
Positive and negative resists
Lift off resists
Image reversal resists
Cured dielectrics
Hard mask process
UV-NIL
Photo tool set
Spin Coating
Alignment
Maskless photolithography
Developing photoresist
Common issue considerations
Resist adhesion
Reflectivity of the material or underlying material
The planarity of the material
Etch characteristics of the material
Resist removal method
Thermal stability of sublayers and deposited material
Exposure factors-

14:50 - 15:20 Coffee break

Laser Processing for Ablation and Patterning
John McLean, CPI

Etching Processes

Mike Clausen, CPI

Differences between wet and dry etching
Isotropic versus anisotropic
Typical wet etch chemistries
Typical wet etch problems
Plasma etch fundamentals
Selectivity, etch rate, uniformity
Steps in a plasma etch process
Typical plasma chemistries
Integration


Mike Clausen, CPI

Brief overview of the CPI integration facility
Case studies
17:00 Course ends

Dr Andrew Cook, Senior Scientist
CPI, UK
Dr Andrew Cook gained his PhD in physical organic chemistry. He has worked in the fields of polymer synthesis and industrial scale roll to roll vacuum coating technologies (primarily sputtering, thermal evaporation and atomic layer deposition). Andrew’s background is in synthetic organic and organometallic chemistry from mg to kg scale, and is very competent with all modern analytical measuring and identification techniques. Andrew has a proven publication track record and has worked across multi collaborative research & development projects funded by IUK and the European Union, most notably Fabrigen, HiBPE and R2R CIGS, which have directly investigated the scaling up of technologies to manufacturing readiness levels.



John McLean, Process Engineering Team Leader
CPI, UK
John McLean is the Process Engineering Team Leader within CPI Electronics. He started his working life in 1986 with National Semiconductor and has mainly worked within the semiconductor industry since. He has worked for a number of large companies like Siemens and Atmel as well as smaller companies in his capacity as a process engineer. For the last seven years he has been at CPI as part of the process engineering team. John has primarily been involved in photolithography and patterning, from contact aligners to deep UV scanners. John has also worked in defect engineering and metrology.



Mike Clausen, Head of Technology
CPI, UK
Mike Clausen is the Head of Technology within CPI’s Electronics unit. He is responsible for providing technical leadership, developing technologies so that they can be translated to innovative products capable of commercialization in the future. Previously, he was responsible for developing the knowledge base and technology assets for the optoelectronics sector, in addition to delivering technology programmes from concept through to innovation. Mike has 25 years experience within the electronics field working within research and development, mass production and customer service environments. He has worked for medium size British companies and major international blue chip organisations such as Fujitsu Microelectronics, NXP, Filtronic Compound Semiconductors and RFMD. His knowledge base spans operations management, process engineering and integration, technology development, yield enhancement and project management.



Wet Processing Technologies for Large Area Electronics
http://innolae.org/wet-processing-technologies-for-large-area-electronics/
The Wet Processing Short Course is delivered by Printed Electronics Ltd (PEL) and the Centre for Process Innovation (CPI). It covers the inks and printer technology required for deposition techniques including screen, inkjet and flexo/gravure printing. The short course also covers coating techniques such as doctor blade and slot die, drawdown, spin and spray coating. In each case the advantages, disadvantages and technological challenges of each technique will be covered, along with issues arising in scale up for manufacture

COURSE OUTLINE

MONDAY 20 JANUARY 2020

08:00 – 09:00 Registration

09:00 Course begins

Wet Processing (Formulation, Coating and Printing)
PEL and CPI

Materials and Formulation
Nicola Broughton, CPI

Inks
Silver, copper, carbon and other ink materials
Formulation
Rheology
Solvent-based inks
Curable inks
Ink formulation components
Mixing and scale-up
Substrates
Polymers, glass, paper, textiles and metals
Printing
Dr Neil Chilton, Printed Electronics Limited (PEL)

Inkjet
Screen print
Other print technologies such as flexography, gravure etc.
11:00 - 11:30 Coffee break

Large Area Coating Methods
Nicola Broughton & Dr Rob Valentine, CPI

Batch coating
Drawdown and dip
Spin coating
Continuous processes
Doctor blade
Spray coating
Slot die
Scale-up for continuous processes
Applications of large area coating
12:30 Course ends

Nicola Broughton, Senior Scientist
CPI, UK

Nicola is a Senior Scientist working on collaborative and commercial research projects in the field of printable electronics. With a background in cell biology, Nicola has worked as an industrial laboratory chemist developing new products and formulations for an aerosol manufacturer. At CPI Nicola has worked to develop functional ink formulations, particularly those containing nanomaterials. She also works to establish coating, printing and curing methods for a number of different applications including IoT enabled devices, wearable electronics and sensors.



Dr Rob Valentine
CPI, UK

Dr Rob Valentine graduated from University of Durham with an MChem before undertaking a PhD at the University of Edinburgh in the Synthesis and Characterisation of Novel Organic Electronic Materials. Following these postgraduate studies Rob joined CPI in 2012 where he has been ever since. During his time at CPI Rob has developed particular expertise in a range of topics including OTFT, Photovoltaics and Sensor Technologies covering areas such as material formulations, deposition techniques and device architecture.



Dr Neil Chilton, Technical Director
Printed Electronics Limited, UK

Neil has more than twenty years’ experience in the field of electronics and electronic components. After completing his BSc and PhD in Physics, his technical career took him to Japan where he worked for four years at the advanced materials research division of Nippon Steel Corporation. After returning to the UK he joined Europe’s then largest printed circuit board manufacturing company where he was later part of an MBO team and technical director. In 2006, together with co-founder Dr Steve Jones, he started Printed Electronics Limited to focus on the practical use of inkjet for manufacturing electronic interconnects, devices and systems

Short courses
Wet processing technologies for large-area electronics
Dry processing technologies for large-area electronics
Short course registration

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Engineering and Technology News India - 2019

Engineering in India - Daily  https://paper.li/e-1474708368#/

Indian 3D Printing Industry – Highlights of the Year 2019
by MANUFACTUR3D  December 28, 2019
https://manufactur3dmag.com/indian-3d-printing-industry-highlights-of-the-year-2019/


Tata Technologies’ flagship program ‘Ready Engineer’ honored with National CSR Award 2019 by Ministry of Corporate Affairs

It has an e-learning program.
http://www.punekarnews.in/tata-technologies-flagship-program-ready-engineer-honored-with-national-csr-award-2019-by-ministry-of-corporate-affairs/


Hindustan Zinc receives its first European patent

"The patent describes the process to treat Antimony-bearing by-product of Zinc-Lead smelters and convert it into a value added product, Potassium Antimony Tartarate (PAT), "

The patented process has been commercialized and is running successfully at DSC Ancillary setup since 2016
https://economictimes.indiatimes.com/industry/indl-goods/svs/steel/hindustan-zinc-receives-its-first-european-patent/articleshow/70934910.cm

Engineering and Technology News 2019

IN THE OCEAN OF IGNORANCE, STAND OUT AS THE ENLIGHTENED DROP!

Interesting message from an Engineering Site - Newsletter.

Process and Product Industrial Engineering Database

Methods Engineering and Value Engineering Database

The Engineer, UK  Manufacturing and Engineering Magazine, UK AZO Materials News

https://phys.org/chemistry-news/materials-science/   https://www.electronicsweekly.com/

Engineering & Management News  #Engineering-Twitter   The Technical Science Advocate - Pli

https://paper.li/knoltweet/1567482299#/ (Engineering and Technology News)

https://www.designnews.com/     https://manufactur3dmag.com/

Engineering and Technology Daily  (https://paper.li/RodgersBosire/1518521271#/)

Mechanical Engineering Daily (https://paper.li/e-1543228763#/)



December 2019

Engineering in Industrial Engineering - Product Industrial Engineering  - Process Industrial Engineering
__________________

__________________

Very interesting.
Climate change: UK 'has technology' for zero carbon.
With current technologies zero emission can be achieved.
https://www.bbc.com/news/uk-wales-50576028


AI enables design of spray-on coating that can generate solar energy
December 26, 2019
https://www.designnews.com/materials-assembly/ai-enables-design-spray-on-coating-can-generate-solar-energy/183899371862115

Rolls-Royce  all-electric aircraft
The zero-emissions plane to  run  with a target speed of 300+ mph (480+ kph) in late Spring 2020.
It can run up to 200 miles on single charge.
https://gulfnews.com/auto/news/rolls-royce-reveals-all-electric-aircraft-1.1576999811630

Nissan shares exciting advances in vehicle technology.
Nissan’s mission to change the way cars are integrated into society. Their ProPILOT technology can make driving less stressful. The unveiling of their Invisible-to-Visible technology.
 This future-state technology will leverage sensored infrastructure and the “Metaverse” to enhance the driver’s experience behind the wheel.

“The technology taps into the cloud and enables you to see what you couldn’t see before -What was invisible – such as parking spots, traffic jams,  – you will actually see now."
https://www.nationalcar.com/en/blog/nissan-intelligent-mobility-vehicle-technology.html



Big Database Engineering
Distributed database is an earlier name. Now Bigdata base may be more appropriate. It has to be collected from number of sensors and number of people who communicate in an unstructured way. The database has to be organized so that it will generate value through analysis carried out centrally and analysis carried out individually by the associates of the organization.
https://www.imapeg.com/the-future-of-all-technologies-is-big-data-engineering/

AI-Driven Software Engineering
Will AI replace human engineers? An analysis based on the current state of the art.
Inateresting Writeup
Omar Rabbolini
https://medium.com/swlh/ai-driven-software-engineering-669f21742e91


Redefining the Future of Engineering.
Engineering, which has always been defined by its ability to constantly innovate and evolve alongside high-tech growth, is now advancing at a faster rate than ever before thanks to the rise of powerful technologies like artificial intelligence, robotics, and IoT.
Here are a few examples of unique engineering advancements that will push the future of engineering further.
https://www.thomasnet.com/insights/redefining-the-future-of-engineering/


Product Engineering Services – A Step-by-Step Guide
DECEMBER 28, 2017 BY EINFOCHIPS PES GENERAL READING TIME: 10 MINUTES
There are different phases of product engineering from inception to the end of the lifecycle of a product. Read this blog to get a step-by-step understanding of Product Engineering Services.
Product Industrial Engineering has to be one of them.
https://www.einfochips.com/blog/a-step-by-step-guide-to-understanding-product-engineering-services/

Top manufacturing stories for 2019
Here are the top stories on manufacturing produced by Design News throughout 2019.
by: Rob Spiegel, Automation & Motion Control, Automation, December 24, 2019
https://www.designnews.com/automation-motion-control/top-manufacturing-stories-2019-workforce-matters/121515474462111

19 in 2019: Best electronic bits from the Design News vault
Check out the best curated technical content from the editors at Design News.
by: John Blyler Electronics & Test Sensors, Materials & Assembly, IoT, Gadget Freak, Design Hardware & Software December 23, 2019
https://www.designnews.com/electronics-test/19-2019-best-electronic-bits-design-news-vault/60305283062096


5 Incredible IoT Applications In Civil Engineering
The internet of things is making a major impact on the field of civil engineering, and these four examples of IoT applications in civil engineering are fascinating.
Avatar
Megan Ray Nichols
December 20, 2019
https://www.smartdatacollective.com/5-incredible-iot-applications-in-civil-engineering/

DECEMBER 19, 2019
Engineers Are Not Ending Poverty. Time for a Change?
https://www.engineeringforchange.org/news/engineers-not-ending-poverty-time-change/

Cool and super cool 3D printed projects
Here’s a look back at several cool hobbyist-level gadgets and a few super cool printed car projects.
December 19, 2019
One of the biggest content repositories for 3D printer models on the internet is Thingiverse – the site offers close to 2 million STL files. The website is operated by MakerBot Industries, the creators of the Replicator series of 3D printers. The Thingiverse community mostly share their STL files for free in varying categories and complexity.
https://www.designnews.com/3d-printing/cool-and-super-cool-3d-printed-projects/180614978762044

3D printer files to download for production on any 3D printer -  high-tech, artificial intelligence robot arm

Zhixiong via CGTrader
CGTrader is a marketplace to buy and sell 3D CAD files. The site also offers a selection of free 3D printer files to download for production on any 3D printer.
https://www.designnews.com/3d-printing/cool-and-super-cool-3d-printed-projects/180614978762044/page/0/2


Can Start/Stop Technology Save Fuel?
BY AIM · PUBLISHED DECEMBER 16, 2019
http://blog.applechevy.com/2019/12/16/can-start-stop-technology-save-fuel/

Engineering, Innovation and Technology Highlights From 2019
Posted on December 27, 2019 by Jacques VDW
http://blog.prv-engineering.co.uk/engineering-innovation-and-technology-highlights-from-2019/


Augmented Reality Changes Manufacturing. Here’s How
03 Dec 2019
https://hqsoftwarelab.com/about-us/blog/augmented-and-virtual-reality/augmented-reality-changes-manufacturing

WORKFORCE 4.0: THE HUMAN SIDE OF DIGITAL TRANSFORMATION
By Scott Jenkins, Chemical Engineering magazine | December 1, 2019
https://www.chemengonline.com/workforce-4-0-the-human-side-of-digital-transformation/?printmode=1

Winchester Publishes Article About More Inclusive Approaches in Design and Management of Emerging Technologies

Woodrow W Winchester III, Ph.D., a lecturer and the director of Engineering Management in the Mechanical and Industrial Engineering Department, wrote a defining article in the American Society for Engineering Management’s (ASEM) Fall 2019 issue of Practice Periodical – Articles for the Practicing Engineering Manager.
http://engineering.umass.edu/news/winchester-more-inclusive-approaches-design-and-management

https://medium.com/@exiledconsensus/my-fellow-engineers-it-is-time-for-the-greatest-invention-of-all-f738d8394998

Nov 22, 2019
The 5 Biggest Technology Trends Disrupting Engineering And Design In 2020
https://www.forbes.com/sites/bernardmarr/2019/11/22/the-5-biggest-technology-trends-disrupting-engineering-and-design-in-2020/#1debe3e2676a

6 monumental and revolutionary VR construction tools
Virtual reality in engineering and construction provides many great opportunities for greater efficiency and safety.
https://knowtechie.com/6-monumental-and-revolutionary-vr-construction-tools/


ASME - DFAM Course
https://resources.asme.org/dfam-solutions?_ga=2.50128294.120699207.1577523038-873367813.1576585828

ADVANCED TECHNOLOGY DIESEL ENGINES DELIVERING MAJOR CLEAN AIR AND CLIMATE BENEFITS TODAY; READY TO DELIVER EFFICIENT, CLEAN AND RENEWABLE POWER FOR FREIGHT TRANSPORT IN THE FUTURE

 Thanks to a fundamental transformation in environmental performance, the Forum further outlined how the technology achieves levels of near zero emissions, and how it will continue to be a dominant technology in the future for moving freight.
https://www.dieselforum.org/news/advanced-technology-diesel-engines-delivering-major-clean-air-and-climate-benefits-today-ready-to-deliver-efficient-clean-and-renewable-power-for-freight-transport-in-the-future

Engineers Need a New Approach to Learning
Nov 27, 2019
by Arin Ceglia
ASME’s modern course design helps engineers advance in a rapidly shifting field.

https://www.asme.org/topics-resources/content/engineers-need-a-new-approach-to-learning

Top Universities that offer Courses in 3D Printing
by MANUFACTUR3D November 7, 2019
https://manufactur3dmag.com/top-universities-that-offer-courses-in-3d-printing/

How advances in 5G and IoT will impact technology
November 29, 2019
https://www.engineersgarage.com/featured/how-advances-in-5g-and-iot-will-impact-technology/

A Kink in the Hyperloop
The dream of zipping from San Francisco to Los Angeles in 35 minutes has run into a few speed bumps.
By Benjamin Wallace
http://nymag.com/intelligencer/2016/10/the-kink-in-elon-musks-hyperloop.html

High Energy Users Opting for Combined Heat and Power
Nov 6, 2019 | Combined Heat and Power

https://www.powersystemsuk.co.uk/combined-heat-and-power/high-energy-users-opting-combined-heat-power/

September 2019

Five new technology missions to be launched to make India future-ready
Published on September 13, 2019
https://www.thehindubusinessline.com/news/science/five-new-technology-missions-to-be-launched-to-make-india-future-ready/article29408035.ece

1. Electric mobility
2. Batteries
3. Methanol economy
4. Quantum technologies
5. Digital maps

August 2019

UMD Launches Quantum Technology Center - Science to Technology
Researchers to Push Quantum Science Beyond Physics for High-Impact Innovations
By Maryland Today Staff  /  Aug 23, 2019
https://today.umd.edu/articles/umd-launches-quantum-technology-center-aab47089-8270-47ad-b15c-5b0047d9d957

Quantum computer
EP1286303A1
European Patent Office
2003-02-26: Publication of EP1286303A1
2019-09-15: Application status is Withdrawn
https://patents.google.com/patent/EP1286303A1

Bosch claims new diesel technology cuts NOx emissions
26/04/2018 in Fleet Industry News
https://www.fleetnews.co.uk/news/fleet-industry-news/2018/04/26/bosch-claims-new-diesel-technology-cuts-nox

https://robertbensh.net/new-technology-in-the-oil-and-gas-industry/

A Century of Innovation in Aerospace Materials
https://blog.geaviation.com/technology/a-century-of-innovation-where-will-the-next-100-take-us/


Engineering and Technology News - 30 July 2019


Modern Manufacturing Processes
Muammer Koc, Tugrul Özel
John Wiley & Sons, 18-Sep-2019 - Technology & Engineering - 528 pages
copy right year 2020.
https://books.google.co.in/books?id=rMOlDwAAQBAJ

Industrial Imager pinpoints compressed air leaks in minutes
30 July, 2019

Compressed air systems can lose a significant amount of air through leakage. - the average compressed air system loses 30% of its air through leaks. Locating those leaks has been a time-consuming and difficult process. Fluke says its ii900 Sonic Industrial Imager enables maintenance teams to quickly, and visually, pinpoint the location of compressed air, gas, and vacuum system leaks even during peak production periods. Leaks can be detected in a matter of minutes.
https://pwemag.co.uk/news/fullstory.php/aid/3695

A commentary on the additive manufacturing workshop for automotive 2019
https://community.plm.automation.siemens.com/t5/Digital-Transformations/The-additive-manufacturing-workshop-for-automotive/ba-p/609523

MAY 13, 2019
A metal sheet stamping simulation promises improved car part production
Kanazawa University  researchers came up with a novel way of reducing the twisting of metal sheets by optimizing the shape of the blank shape while also minimizing tearing and wrinkling of the metal sheet. They also simulated how much force to use to clamp the metal sheet in place in the so-called "blank holder" and how it should be varied during the punching process to achieve the best results.
https://phys.org/news/2019-05-metal-sheet-simulation-car-production.html


Handling ‘zettabytes of data’ at the edge: Dave Laurello, CEO of Stratus Technologies
By Nick Smith

Published Saturday, January 19, 2019
https://eandt.theiet.org/content/articles/2019/01/handling-zettabytes-of-data-at-the-edge-interview-with-dave-laurello-ceo-of-stratus-technologies/


2018



The many variables of manufacturing stamped components
NOVEMBER 5, 2018
https://www.thefabricator.com/article/stamping/the-many-variables-of-manufacturing-stamped-components
https://www.thefabricator.com/article/stamping/the-many-variables-of-manufacturing-stamped-components

Improvement of Productivity in Metal Stamping Process by using progressive die
by KN Asfew et al., 2017
http://article.sciencepublishinggroup.com/pdf/10.11648.j.ijimse.20170203.11.pdf

Intelligent Stamping Dies
December 18, 2015 Avinash Khare
https://productivity.imtma.in/intelligent-stamping-dies/

US Patent US20090266135A1
Method of producing sheet metal blanks having a varing thickness
Inventor Hans-Jurgen Knaup Current Assignee Benteler Automobiltechnik GmbH
2009-10-29 Publication
https://patents.google.com/patent/US20090266135

Engineering and Technology News - 30 July 2019


Updated on 28 December 2019,  3 September 2019, 1 August 2019

3D Printing of Heart

Sep 9, 2019

BIOLIFE4D Just 3D Printed A Human ‘Mini-Heart’

Using a process similar to the Tel Aviv University attempt. Chicago based BIOLIFE4D printed a mini-heart.
https://www.forbes.com/sites/jessedamiani/2019/09/09/biolife4d-just-3d-printed-a-human-mini-heart

Researchers Just 3D Printed The First-Ever Complete Heart Using Human Tissue

16 APR 2019


Scientists at Tel Aviv University have 3D printed a small rodent-sized  heart using human tissue that includes vessels, collagen, and biological molecules.  .

The technology is still many years out from developing a human working heart. The cells do not have  pumping ability. but  they can currently contract. The trial successfully engineered and printed an entire heart complete with cells, blood vessels, ventricles and chambers.  A  hydrogel from fatty tissues extracted from human test subjects was used to form bioinks used for 3D printing the heart.

The paper was published  in the journal Advanced Science.

Earlier, in 2017,   researchers at ETH Zurich created a 3D printed artificial heart. It was made using a flexible material.
https://www.sciencealert.com/researchers-have-just-3d-printed-a-mini-heart-using-human-tissue

Smart Robots

Smart Robotics Laboratory
http://wp.doc.ic.ac.uk/sleutene/


 “Dumb” Robots vs. “Smart” Robots
https://asianroboticsreview.com/home41-html

Rethinking your process chain
Robots provide an incredible opportunity to accelerate your production. With tailored robot lines, we improve quality and productivity in steel processing industries. This enhances the entire work flow, making your production more efficient and company more competitive.

https://www.kranendonk.com/

Smart Robotics: Revolution Is Motto, Efficiency Is Aim
08/30/18
https://www.roboticstomorrow.com/article/2018/08/smart-robotics-revolution-is-motto-efficiency-is-aim/12398

3D Printing of Medicines

https://m.all3dp.com/2/3d-printing-drugs-the-latest-advancements-around-the-world/

An interesting article.

Smart Transformer

Smart Transformers
Controlling the flow of electricity to stabilize the grid
DAVID H. FREEDMAN
 April 19, 2011
http://www2.technologyreview.com/news/423686/smart-transformers/




2015

https://online.electricity-today.com/doc/electricity-today/et_summer_2015_digital/2015082101/#26/

https://www.electricity-today.com/smart-grid/smart-transformers

2019
Using smart transformer s for decentralized grid control.
https://vbn.aau.dk/en/projects/heart-the-highly-efficient-and-reliable-smart-transformer-a-new-h

You are an Engineer - Do the Engineering Work

16 Oct 2019.
You Are an Engineer Be an Engineer
http://duffney.io/YoureAnEngineerBeAnEngineer

MACHINE DESIGN - Pandya & Shah - Book Information

MACHINE DESIGN
By
Dr. N. C. Pandya & Dr. C. S. Shah
Edition : 17th Edition : 2009
ISBN : 978 - 81 - 85594-92 - 7
Size : 135 mm × 210 mm
Binding : Paperback with Four color Jacket Cover
Pages : 1064 + 16


Table of Contents


Chapter 1 : MATERIALS OF CONSTRUCTION AND
THEIR PROPERTIES
1-1 Introduction
1-2 Choice of material
Factors Affecting the choice of a Material
1-3 Materials of construction
(a) Ferrous Metals (b) Non-ferrous Metals
1-4 Structure of materials
Structure of Metalic Materials
1-5 Mechanical properties of materials of construction
1-6 Determination of mechanical properties
1-7 Fabrication characteristics and processes of fabrication
(a) FormabilityHot working precesses, Cold working process
Power metallurgy
(b) Castability, Solidfication Rate, Shrinkage, Segregation
Gas Porosity, Hot Strenghth
(c) Machinability
(d) Weldbility, Heat and cooling, Oxidation Gas
1-8 Ferrous metals - Cast iron, wrought iron and steel
1-10 Available sizes
1-11 Accuracy
1-12 Finishing processes
1-13 Non-metallic materials
1-14 Plastics
1-15 Composite Materials
1-16 Improvements in properties of materials
Examples
Chapter 2 : DESIGN CONSIDERATlONS IN MACHINE
PARTS
2-1 Loads
2-2 Stress
2-3 Strain
2-4 Stress-Strain diagram : Modulus of elasticity
2-5 Poisson’s ratio
2-6 Modulus of rigidity
2-7 Bulk modulus
2-8 Basic requirements of machine elements
(i) Strength (iii) Wear resistance
(ii) Stiffness
2-9 Factor of safety : Selection of allowable stresses
2-10 Procedure for designing a machine element
2-11 Tensile stress
2-12 Compressive stress
2-13 Shearing stress
2-14 Bearing pressure intensity
2-15 Bending (Flexure) Effect or ribs on castings
2-16 Shear stresses in a beam
2-17 Torsion
2-18 Eccentric loading
2-19 Combined stresses : Bending combined with direct load
2-20 Offset connecting links and C shaped frames
2-21 Shear stresses combined with tensile and compressive stresses
2-22 Theories of elastic failure
2-23 Designing for impact loads
2-24 Design of members subjected to impact torsion
2-25 Stress concentration
2-26 Notch sensitivity
2-27 Effect of repeated application of a load
2-28 Fluctuating stress for ductile materials Ellipse quadrant relationship
Design to avoid fatigue failure
2-29 Cummulative damage in fatigue : (Miner’s equation)
2-30 Fatigue life determined by short-term resting
2-31 Light weight and minimum dimensions
2-32 Elastic matching
2-33 Temperature stresses
Examples
Chapter 3 : CYLINDERS, TANKS AND PIPES
3-1 Introduction
3-2 Types of vessels
3-3 Design of thin cylinders
3-4 Design of a thin spherical shell
3-5 Cylindrical shell with hemi-spherical ends Cylindrical shell
Hemispherical shell, Hemispherical shell
3-6 General theory of membrane stresses in vessels under internal
pressure
3-7 Design of pipes
3-8 Design of thick cylinders, Design of hydraulic cylinder
Other design considerations
3-9 Design equation for thick cylinders
Examples
Chapter 4 : RIVETED JOINTS
4-1 Introduction
4-2 Rivets
4-3 Rivet heads
4-4 Types of riveted joints
4-5 Caulking and fullering
4-6 Design of a riveted joint for boiler construction
Design of a boiler joint
4-7 Efficiency of a riveted joint
Design of a circumferential lap point
4-8 Joints for storage tanks
4-9 Lozenge joint
4-10 Eccentric loads on riveted connections
4-11 Rules in designing riveted joints
4-12 Advantages of welding over riveting, Circular arrangement
Rectangular arrangement , Triangular arrangement
Examples
Chapter 5 : BOLTS, NUTS AND SCREWS
5-1 Introduction
5-2 Definitions
5-3 Forms of screw threads
5-4 Advantages of square threads over V threads
5-5 Screw fastenings
(i) Through bolts
(ii) Tap bolts and cap screws
(iii) Machine screws
(iv) Set Screws
(v) Studs
5-6 Locking devices for nuts
5-7 Washers
5-8 Eye bolt
5-9 Efficiency of threads
5-10 Stresses in screw fastenings
5-11 Initial stresses
5-12 Stresses due to external forces
5-13 Stresses due to combined load
5-14 Bolts of uniform strength
5-15 Screwed boiler stays
5-16 Bolts subjected to shear
5-17 Bolts under eccentric loading
(a) When load is paralled to the bold axis
(i) Rectangular base
(ii) Circular base
(b) When load is perpendicular to the axis of the bolt
5-18 Design of a nut
5-19 Power transmitting capacity of set screws
Examples
2
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Telephone: (02692) 256237, Fax: (02692) 240089, e-mail: charotar@cphbooks.com, Website:www.cphbooks.com Back
Chapter 6 : COTTER AND KNUCKLE JOINTS
6-1 Introduction
6-2 Design of cottered joints
(a) Tension failure of the rods at diameter d
(b) Tension failure of the rod across slot
(c) Tension failure of the socket across the slot
(d) Shear failure of the cotter
(e) Shear failure of the rod end
(g) Crushing failure of the rod or the cotter
(h) Crushing failure of the socket or the cotter
6-3 Gib and cotter
6-4 Connection of a piston rod to a crosshead
6-5 Cotter foundation bolts
6-6 Introduction
6-7 Joint of suspension links
6-8 Design of a coupler or a turnbuckle
(a) Diameter of the rod
(b) Length of the screwed portion of the nut at each end
(c) Outside diameter of the coupler at the nut portion
(d) Outside diameter of the coupler at the middle
Examples
Chapter 7 : SHAFTS, KEYS AND COUPLINGS
7-1 Introduction
7-2 Materials and design stresses
7-3 Design of axles
7-4 Design of shafts on the basis of strength
(a) The maximum normal stress theory (Rankine’s theory)
(b) The maximum shear stress theory (Guest’s theory)
(c) The maximm strain theory (St. Venant’s theory)
Empirical desing of shafts
7-5 Design of shafts on the basis of rigidity
Torsional, Lateral rigidity, Critical speed
7-6 Design of hollow and non-circular shafts
7-7 Form of keys
7-8 Keys
7-9 Design of sunk keys
7-10 Effect of keyways in sunk keys
7-11 Taper pins
7-12 Feather keys and splined shafts
7-13 Force and shrink fits (Driving fits on solid shafts)
7-14 Couplings : Introduction
7-15 Sleeve couplings or muff couplings
7-16 Clamp or compression couplings
7-17 Flange couplings
7-18 Marine type of flange couplings
7-19 Flexible couplings
7-20 Bushed pin type of flexible couplings
7-21 Bibby type of flexible coupling
7-22 Leather pad type flexible coupling
7-23 Oldham’s coupling
7-24 Universal coupling
7-25 Safety couplings
7-26 Flexible shafts
Examples
Chapter 8 : SPRINGS
8-1 Introduction
8-3 Optimum design of helical springs
8-4 Helical springs of non-circular wires
8-5 Concentric helical springs
8-6 General considerations in design of compression and extension
springs
8-7 Torsion helical springs
8-8 Spiral springs (Power springs)
8-9 Leaf springs
8-10 Belleville springs
8-11 Energy-storage capacity
Examples
Chapter 9 : BEARINGS
9-1 Introduction
9-2 Bearing area
9-3 Sliding bearings : Solid journal bearings
9-4 Divided journal bearing : Plummer block
9-5 Hydrodynamic theory of lubrication
9-6 Oil grooving
9-7 Heating of bearings
9-8 Design procedure for hydrodynamic journal bearings
9-9 Bearing materials
9-10 Design of bearing caps and bolts
9-11 Foot step or pivot bearings
9-12 Collar bearings
9-13 Anti-friction bearings
9-14 Radial ball bearings
9-15 Roller bearings
9-16 Selection of ball and roller bearings
9-17 Bearing load
(a) Calculations of a bearing load in gear drives
(b) Calculations of a bearing load in belt drives
9-18 Equivalent bearing load
(a) Combined bearing load (b) Design for variable loading
9-19 Carrying capacity and life
9-20 Relationship between load and life
9-21 Requisite bearing life for different types of machines
9-22 Life or Timken bearings
9-23 Influence of high temperatures on load carrying capacity
9-24 Permissible misalignment
9-25 Friction in rolling bearings
9-26 Comparison of sleeve and rolling bearings
Examples
Chapter 10 : STRUTS AND COLUMNS
10-1 Introduction
10-2 Euler’s formula
10-3 End fixity coefficients
10-4 Radius of gyration and plane of buckling
10-5 Rankine’s formula
10-6 Tetmajer’s formula
10-7 Johnson formula
10-8 Design of push rods
10-9 Eccentrically loaded columns
Examples
Chapter 11 : POWER SCREWS
11-1 Introduction
11-2 Forms of threads
11-3 Force analysis
11-4 Design of a screw
11-5 Design of a nut
11-6 Practical design of simple lifting machines (screw jack)
11-7 Compound screw
11-8 Differential screw
11-9 Ball screws
Examples
Chapter 12 : LEVERS
12-1 Introduction
12-2 General procedure for design of levers
12-3 Hand lever
12-4 Foot lever
12-5 Cranked lever
12-6 Lever of a lever loaded safety valve
12-7 Rocker arm for Diesel engines (Straight arm)
12-8 Angular levers
12-9 Design of overhung cranks
12-10 Design of a crank pin (overhung crank)
12-11 Miscellaneous examples
Examples
3
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Telephone: (02692) 256237, Fax: (02692) 240089, e-mail: charotar@cphbooks.com, Website:www.cphbooks.com Back
Chapter 13 : BRACKETS
13-1 Brackets
13-2 Hangers
13-3 Wall boxes
13-4 Design considerations
Examples
Chapter 14 : BELTS, PULLEYS AND CHAINDRIVES
14-1 Introduction
14-2 Materials for belts
14-3 Design of belts
14-4 Design procedure for flat belts
14-5 V-belt drives
14-6 Design of V-flat drives
14-7 Pulleys : Materials and types
14-8 Cast iron pulleys
14-9 Design of cast iron pulleys
14-10 Steel pulleys
14-11 Wooden pulleys
14-12 Fast and loose pulleys
14-13 Speed cones
14-14 Short centre drive : Gravity idlers
14-15 Special tension adjusting belt drives
14-16 Chain drives : (Introduction)
14-17 Roller chains
14-18 Design of chain drives
Examples
Chapter 15 : FLYWHEELS
15-1 Introduction
15-2 Determination of mass of a flywheel for a given coefficient of
fluctuation of speed
15-3 Flywheel for punches and shears
15-4 Engine flywheels
Examples
Chapter 16 : GEARS
16-1 Introduction
16-2 General characteristics
16-3 Spur gear terminology
16-4 Gear tooth forms
16-5 Accuracy of gears
16-6 Materials
16-7 Allowable stresses
16-8 Design considerations
16-9 Strength of gear teeth : Lewis equation
16-10 Dynamic tooth load
16-11 Design for wear
16-12 Gear wheel proportions
16-14 Racks
16-15 Introduction
16-16 Proportions for helical gears
16-17 Design of helical gear teeth
(a) Design for strength (c) Design for wear
(b) Design for dynamic load
16-18 Herringbone gears
16-19 Rating of machine cut spur and helical gears
Kilowatt power for strength, Kilowatt for wear
16-20 Introduction
16-21 Definitions
16-22 Strength of bevel gear teeth
16-23 Constructional details
16-24 Bearing loads
16-25 Introduction
16-26 Worm gear nomenclature
16-27 Strength of worm gear teeth
16-28 Bearing loads on the shafts
Examples
Chapter 17 : WELDED CONNECTIONS
17-1 Introduction
17-2 Welding processes
17-3 Types of welded joints
17-4 Working stresses in welds
17-5 Strength of welds
17-6 Special cases of fillet welds
17-7 Eccentric loads on welded connections
17-8 Design procedure recommended by American Welding Society
17-9 Fillet welds under varying loads
Examples
Chapter 18 : DESIGN OF MISCELLANEOUS MACHINE
PARTS I ENGINES AND BOILERS
18-1 Design of flat plates
(a) Cicular plate subjected to a uniformly distributed load of p
 and supported on the outside periphery
(b) Rectangular plate subjected to uniformly distributed load p
 and supported on the outside periphery
(c) Circular plant subjected to a uniformly distributed load p
 and clamped on the outside edge
Project I Design of hydraulic press
Material selection, Design of a ram, Lower movable table
Upper table or Bridge piece, Packing for hydraulic ram
18-2 Design of a piston for I.C. Engines
18-3 Design of crossheads
Introduction, Wrist pin, Shoe, Guide, Crosshead bolts
Cap or keep plate
18-4 Design of connecting rods
Connecting rods and piston pins, Connectign rod type
Loads on connecting rods, Connecting rod length Connecting
rod sections, Materials, Calculations of connectingrods
18-5 Design of crankshafts
18-6 Design of a spring-loaded Hartnell governor
Introduction
(a) Spring design (c) Design of a cust steel body
(b) Design of a spindle (d) Design of a bell crand lever
18-7 Design of an eccentric, Design calculations
18-8 Compensating ring for a manhole
18-9 Design of safety valves for boilers
18-10 Design of a screw down steam stop valve
18-11 Design of cams (I.C. Engines)
18-12 Design of a valve gear for I.C. Engines
Materials, Value Design, Design of a spring, Design of a lever
or a rooker arm, Design of a push rod, Design of a camshaft
Rock arm, Fulcrum for a rocker arm, Roller end
Examples
Chapter 19 : DESIGN OF MISCELLANEOUS MACHINE
PARTS II BRAKES AND CLUTCHES
(A) Hoisting equipments
19-1 Introduction
19-2 Design of hoisting chains and drums
19-3 Design of a hoisting rope
Values of rn for various sections of curved Beams
19-6 Design of a crane hook
19-7 Introduction
19-8 Types of brakes
19-9 Design procedure for block brakes, Brake wheels, Brake shoe
Brake linings, Brake lever, Pull rods, Energy considerations in
design of brackes
19-10 Band brakes : Introduction
19-11 Design procedure for band brakes
19-12 Introduction, Friction clutches, Cone clutch
19-13 Design procedure for friction clutches
Examples
4
Charotar Publishing House Pvt. Ltd. Opposite Amul Dairy, Civil Court Road, Post Box No.65, ANAND 388 001 India
Telephone: (02692) 256237, Fax: (02692) 240089, e-mail: charotar@cphbooks.com, Website:www.cphbooks.com Back
Chapter 20 : DESIGN PROJECTS
20-1 Introduction
I Hand operated bench press
(1) Lever (6) Stand
(2) Torque rod (7) Frame
(3) Crank (8) Sliding head
(4) Toggle connecting rod (9) Adjustable head
(5) Toggle bars
Other considerations
Format for drawings
Surface finishes
Tolerances
Sketches and drawings
Reduction Gear
(1) Selection of materials
(2) Preliminary sketch
(3) Gears
(4) High speed shaft and bearings
(5) Low-speed shaft bearings
(6) Lubrication of gears and bearings
(7) Housing
(8) Hand operated bench press
(1) Air cylinder
(2) Compressed air receiver
(3) Pneumatic arbor press
(4) Bearing puller
(5) Toggle jack
(6) Bench vice
(7) Governor bell crank lever
(8) Bracket and bolts for tilting gear
(9) Power shaft
(10) Power shaft and a pulley
(11) Back gear of a lathe
(12) Two speed gear box
(13) Single stage speed reducer
(14) Speed reducer
(15) Winch
(16) Pulley block
(17) Jib crane
(18) Cam
(19) Combination punch and shear
(20) Drill press
(21) Globe valve design
(22) Selection of materials
(23) Specific shapes for sections
APPENDIX I Sl System
APPENDIX II Properties of Ferrous Materials
APPENDIX III Properties of Plastics
APPENDIX IV List of Indian Standards : “Testing of Materials”
APPENDIX V Indian Standards referred in the text
APPENDIX VI Preferred Numbers (Rounded values)
APPENDIX VII Deflection formulas for machine parts
APPENDIX VIII Metric threads
APPENDIX IX Common sizes of transmission shafts
 (Dimensions in mm)
APPENDIX X Properties of geometrical Sections
APPENDIX XI Imperial or Legal Standard Wire Gauge
APPENDIX XII Sizes of pulleys for flat and V-belts
APPENDIX XIII Width of flat cast iron and mild steel pulleys
APPENDIX XIV Service factors for belt drives
APPENDIX XV Load carrying capacity of V-belts
APPENDIX XVI Worm data
APPENDIX XVII Basic thicknesses of sheet and diameters of
 wire in millimetres

3D Printing - Production Applications

2019

Additive Manufacturing is growing in Airplane manufacturing

GE, which spent nearly $1 billion to acquire two 3D printer businesses in 2016, is taking a bottom-up approach and looks at the technology as a creative medium that can help it improve the design of jet engines. Honeywell is content to buy 3D printers from third parties including GE and for now sees this technology as a tool that it can embed in its supply chain to increase efficiency. United Technologies is taking a science-heavy tack.

Honeywell has a football-field sized complex filled with 3D printing machines at its aerospace headquarters in Phoenix, Arizona.

So far, Honeywell has obtained approval for 18 parts including an engine surge duct and it expects to have an additional 14 cleared by the end of the month. All in, the company thinks it can get the FAA’s blessing to swap printers for traditional manufacturing processes on 250 aerospace parts by the end of this year. Honeywell is using 3D-printing technology as a working-capital improvement program.

GE Aviation currently has four 3D-printed discrete parts certified by the FAA, and the expected approval of its GE9X and Catalyst engines over the next two years will give it about 20 more. But looking at the numbers alone understates the scale of GE’s ambitions. Of the more than 80 additional parts in GE Aviation’s additive pipeline, roughly 90 percent are based on new designs, meaning these parts don’t currently exist in that form in the marketplace.

As for United Technologies, it pledged $75 million in 2017 to establish an additive manufacturing center near its Connecticut headquarters. It now has “a few parts” certified by U.S. and European aviation regulators and is targeting more than 100 by 2021
https://www.bloomberg.com/opinion/articles/2019-04-12/3d-printing-is-set-to-revolutionize-aviation-for-ge-honeywell

2 December 2018

http://mepca-engineering.com/december-2018/

Page 14 3DPrintUK

The Additive Advantage - Low Price - 20p

3D printing is increasingly being used to print finished products.
3DPrintUk can print products at a price as low as 20p per unit. It is not costly anymore.


26 April 2016
What is viable and what is not with 3D printed enclosures
http://www.newelectronics.co.uk/electronics-technology/what-is-viable-and-what-is-not-with-3d-printed-enclosures/118486/




9 January 2015

General Electric - Auburn, Alabama Plant - Nozzle Production by 3D Printing

First Production Application of 3D Printing by GE

When it opens in 2015, the General Electric Auburn plant will be producing fuel nozzles for the next-generation LEAP jet engine using 3D Printing.


Each engine will have nearly twenty 3D-printed fuel nozzles.The nozzles are five times more durable than the previous model. 3D printing allowed engineers to design them as one part rather than 20 individual parts, reducing the number of brazes and welds that would have been necessary using traditional methods.

http://www.gereports.com/post/91763815095/worlds-first-plant-to-print-jet-engine-nozzles-in





Updated on 22 September 2019,  2 December 2018,
First published on 9 January 2015

Tactile Telerobots and Robot Hands

https://www.shadowrobot.com/telerobots/


A robot hand was demonstrated that helps a person to feel the touch and manipulate the fingers and the grip.

Fastener Assembly - Automation

16 pages

http://www.pcb.com/linked_documents/force-torque/rs_fast_assemby_lowres.pdf

Dc Eletric Fastening
http://www.ingersollrandproducts.com/tools/fastening/dcelectric/DC%20Electric%20Fastening%20brochure.pdf


Quality Control in the Tightening of Bols
http://www.boltscience.com/pages/quality.htm

Blot Science Article List
http://www.boltscience.com/pages/info.htm?

Updated on 12 August 2019, 23 September 2014

Shell Moulding Process

Shell Moulding Process
http://thelibraryofmanufacturing.com/shell_mold_casting.html

From a Handbook
https://books.google.co.in/books?id=tMK6lummtq8C&pg=PA928#v=onepage&q&f=false

Comparison of Metal Casting Processes
http://www.engineershandbook.com/Tables/castchart.htm  Link not working


The Shell Moulding Process: A German Innovation U. Recknagel
To mark the 50th anniversary of the death of the inventor Johannes Croning
The inventor and entrepreneur
Johannes Carl Adolf Croning was born on May 22, 1886, in
Hamburg as the son of a tradesman.
http://www.ha-international.com/pdf/CroningShellMoulding.pdf

A patent for Jonannes Croning
https://patents.google.com/patent/US1966615A/en

Updated on 12 August 2019, 9 .9.2013

Engineering and Technology News July 2019

Process and Product Industrial Engineering Database

Methods Engineering and Value Engineering Database

The Engineer, UK  Manufacturing and Engineering Magazine, UK AZO Materials News

https://phys.org/chemistry-news/materials-science/   https://www.electronicsweekly.com/

Engineering & Management News


Engineering and Technology News August 2019

Safety Improvement - Tailor-Made Safety with FPGAs
July 31, 2019
FPGAs are proving to be extremely reliable and versatile embedded components when system uptime is of the highest priority.
https://www.eeweb.com/profile/mentcs/articles/tailor-made-safety-with-fpgas

Researchers Use Single-Electrode Material to Add Many Functions into a Microchip.
A noteworthy breakthrough in the mission to refine the miniature, self-powered sensors that will progress the Internet of Things. KAUST scientists have successfully combined energy-harvesting, sensing, current-rectifying, and energy-storage operations into one microchip.
https://www.azom.com/news.aspx?newsID=51792   https://discovery.kaust.edu.sa/en

Alibaba chip unit designs RISC-V core
26th July 2019
The core was developed by Alibaba’s IC unit called Pingtouge and called Xuantie 910.
Xuantie 910 is available for licensing and related code will be released on GitHub.
https://www.electronicsweekly.com/news/business/alibaba-chip-unit-designs-risc-v-core-2019-07/


Novel technique makes liquid droplets run uphill
25th July 2019
Hong Kong team moves liquid droplets at record high speed and long distance without extra power.  Mechanical engineers from the City University of Hong Kong (CityU) describe in "Nature Materials", can transport droplets of liquid against gravity and even for the first time along a vertical surface.
https://www.theengineer.co.uk/liquid-droplet-transporting-mechanism/

Versarien, UK-based advanced materials engineering group, has announced that it has secured its first graphene orders from the North American corporate research and development center of a Japanese headquartered company. The Company has placed development orders for 1kg each of Versarien's high purity graphene nano platelets ("GNP-HP") and Nanene.
https://www.graphene-info.com/versarien-receives-graphene-orders-japanese-automotive-company


July 24, 2019


Mazda Motor Corporation is streamlining automotive design on the system level through Siemen's Mentor’s “Capital,” an electrical design software suite designed to simplify the engineering of electrical systems for cars, aircraft, and other sophisticated machines.
https://saemobilus.sae.org/advanced-manufacturing/news/2019/07/mazda-drives-engineering-creativity-using-siemens%E2%80%99-model-based-generative-engineering-tools

LED for torches and worklamps
24th July 2019
Osram is aiming  Osconiq P 3030, it is build around a 1 x 1mm die that can be driven at 1.3A and comes in a specially-developed 3 x 3mm (1.63mm high) SMD epoxy package with lead-frame heat spreading and a silicone lens, at torches and work lamps with a long-life 160 lm LED.
It will have longer lifetime of 70,000h life.
https://www.electronicsweekly.com/news/products/led/660797-2019-07/

New in Metal 3D Printing: Copper
The latest material available in additive manufacturing is Copper (C18150), a chromium zirconium copper (CuCr1Zr) alloy defined by its excellent thermal and electrical conductivity. Additive C18150 was developed to fill the void in the AM market and the demand for additive copper.
https://www.stratasysdirect.com/materials/metals/new-in-metal-3d-printing-copper

LPBF ADDITIVE MANUFACTURING STEEL SUITABLE FOR HARDENING
Cetim, the French Technical Center for Mechanical Industries, has released a new steel grade for the Laser Powder Bed Fusion (LPBF) additive manufacturing.

Characterised as 33CrMoV12 steel, this material is designed for parts enduring nitriding, a hardening heat treatment that diffuses nitrogen into the surface of a metal. Such nitrided parts feature mechanical properties suitable for the power transmissions sector.
https://3dprintingindustry.com/news/cetim-releases-lpbf-additive-manufacturing-steel-suitable-for-hardening-158987/


A New Coating Promises to Make Fingerprints and Grease Stains Invisible on Stainless Steel Appliances.

Researchers and chemists from the Fraunhofer Institute for Microstructure of Materials and Systems IMWS worked with experts from FEW Chemicals GmbH in Wolfen, Germany, to develop a new coating with added particles that help make it both water and oil repellent. The effectiveness of the new coating is being tested and optimized by the Fraunhofer Institute, but it expects a final recipe for the coating to be perfected by the end of 2020.
https://gizmodo.com/a-new-coating-promises-to-make-fingerprints-and-grease-1836730370

Porsche’s New Bioconcept-Car Features Natural-Fiber Composite Body Parts
Jul 23 2019
Automaker Porsche launches the new 718 Cayman GT4 Clubsport body parts made of natural-fiber composite materials developed in the Application Center for Wood Fiber Research HOFZET
https://www.azom.com/news.aspx?newsID=51758

The New Optical Defect Inspection System for Faster Defect Sourcing
Jul 18 2019
KLA Corporation (NASDAQ: KLAC) announced the 392x and 295x optical defect inspection systems and the eDR7380™ e-beam defect review system.
https://www.azom.com/news.aspx?newsID=51740

Isamill Reduces Specific Energy Requirements by up to 21.5% by Releasing New Conical Spacers
Jul 18 2019
Reducing the specific energy requirements from fine grinding by even a small amount is critical to cost savings and boosting the returns from mineral processing.
https://www.azom.com/news.aspx?newsID=51733


Beta-Gallium Oxide Shows Promise for Creating High-Power Semiconductors
Jul 23 2019
Electrical engineers at the University of Illinois (U. of I.) have added beta-gallium oxide—the field’s hottest material—to their arsenal, thus overcoming another barrier in the fabrication of high-power semiconductors.
https://www.azom.com/news.aspx?newsID=51765

New Epoxy Potting Compound with Excellent Flow Properties
UK adhesive specialists Techsil have launched a new potting compound for electronics with medium viscosity and small filler particle size: Structalit® 5894-1
https://www.azom.com/news.aspx?newsID=51778

Nano Dimension Ltd., an additive electronics provider,  has unveiled its new DragonFly Lights-Out Digital Manufacturing (LDM) printing technology, which the company presents as the industry’s only comprehensive additive manufacturing platform for round-the-clock 3D printing of electronic circuitry.
The initial deployment took place at the Munich premises of sensor and defense electronics provider Hensoldt.
https://www.memuk.org/technology/electronics/additive-electronics-provider-delivers-3d-printed-electronics-49874

BAE Systems demonstrates unmanned armed boat
By The Engineer 24th July 2019 11:55 am
An unmanned armed boat demonstrated by engineers at BAE Systems
https://www.theengineer.co.uk/bae-systems-demonstrates-unmanned-armed-boat/

Knee-powered energy-harvester keeps devices running
22nd July 2019 12:44 pm
Researchers at the Chinese University of Hong Kong have developed a knee-powered energy-harvester that generates  1.6 microwatts of power while the wearer walks without any increase in effort. The energy is enough to power devices like health monitoring equipment and GPS devices.
The article appeared in  Applied Physics Letters. The energy harvester is attached to the wearer’s knee.

Applied Physics Letters
Macro fiber composite-based energy harvester for human knee

Casting for lightweighting solutions
Quick Prototype “Make Like Production” concept (pioneered by the Warwick Manufacturing Group,  University of Warwick) in which the prototype part behaves like a production component.
2019-07-16

Grainger & Worrall has invested in computer-simulation methods for casting design, including Magma software packages for various materials. Aimed at producing right-first-time castings without extensive and time-consuming practical trials, more than 500 simulation projects have been completed—validated by x-ray, CT (computerized tomography), micro examination and tensile testing.
https://www.sae.org/news/2019/07/casting-specialist-grace--worrall

Additive Manufacturing
EOS Introduces Four New Materials for Laser Melting of Serial Products
Jul 2, 2019
EOS has developed four new metal materials for its direct metal laser sintering machines: EOS Stainless Steel CX, EOS Aluminum AlF357, EOS Titanium Ti64 Grade 5 and EOS Titanium Ti64 Grade 23. They are intended to make a wide variety of series applications possible, ranging from automotive engineering to medical technology.
https://www.spotlightmetal.com/eos-introduces-four-new-materials-for-laser-melting-of-serial-products-a-838920/


JULY 1, 2019

Porsche leveraging the benefits of organic materials in automotive manufacturing applications. The new 718 Cayman GT4 Clubsport features body parts made of natural-fiber composite materials developed in the Application Center for Wood Fiber Research HOFZET, which is part of the Fraunhofer Institute for Wood Research.
https://phys.org/news/2019-07-porsche-leveraging-benefits-materials-automotive.html


June 17, 2019
Rio Tinto unveiled  a new aluminum alloy that could reduce the weight of vehicle wheels by as much as 7%, while making them stronger 15% to 20% stronger than traditional wheels.

It has called its new product “Revolution-Al” and said it’s part of its high-strength 3xx Series Alloys.
https://www.mining.com/rio-tinto-unveils-new-aluminium-alloy-to-make-lighter-cars/

New strong, conductive, copper-alloy fasteners
June 05, 2019
Isabellenhütte is manufacturing fasteners made of their proprietary Isa-Con copper alloy materials. Isa-Con fasteners have comparable strength and conductivity to stainless steel and copper materials, respectively. Source: Isabellenhütte Gmbh

The fasteners are intended for fastener applications that need high electrical conductivity and heat resistance.
https://insights.globalspec.com/article/11993/new-strong-conductive-copper-alloy-fasteners

MAY 27, 2019

Scientists create new aluminum alloy with flexibility, strength, lightness
by National University of Science and Technology MISIS.

Tthe proposed material can be used primarily in aeronautics and automobile industry, as well as for the design of modern robotics, including copters, where reducing the weight of the drone is critical. The material can be used for the manufacture of complex parts via 3-D printing.
https://phys.org/news/2019-05-scientists-aluminum-alloy-flexibility-strength.html

Generative Design for Additive Manufacturing: The iteration generation: a new age of design
By Stuart Nathan 9th April 2019
https://www.theengineer.co.uk/iteration-generative-design/

NASA DEVELOPS NEW COPPER ALLOY FOR 3D PRINTING ROCKET COMPONENTS
MARCH 20TH 2019
https://3dprintingindustry.com/news/nasa-develops-new-copper-alloy-for-3d-printing-rocket-components-151593/

New welding process  for formerly unweldable lightweight alloy AA7075
February 13th, 2019

Developed in the 1940s, AA7075 is an aluminum alloy that's almost as strong as steel, yet it weighs just one third as much. But its pieces  couldn't be securely welded together.

Led by Prof. Xiaochun Li, a team at the UCLA Samueli School of Engineering wanted to develop welding solution for that problem. They fabricated thin rods made of 7075 infused with minuscule particles of titanium carbide. These rods were then placed between the pieces of the aluminum alloy which were about to be joined, acting as a filler. When the rods and adjacent material were subsequently melted in an arc welding process, the nanoparticles eliminated an  uneven flow issue and good welds were obtained. Nanoparticles make the elements in the liquid metal solidify together more uniformly, thus preventing phase segregation, which was happening earlier.

The resulting welded joints have a tensile strength of up to 392 megapascals – by contrast, the commonly-used 6061 aluminum alloy has a weld strength of 186 megapascals. It is believed that post-welding heat treatments could boost the strength of the 7075 welds up to 551 megapascals, which is on par with the weld strength of steel.

The alloy is already used in items such as airplane wings and fuselages but sheets of it typically have to be riveted together.
https://newatlas.com/welding-aa7075-aluminum-alloy/58449/

Researchers Develop New Aluminium Alloy Using Microscopic Diamonds
FEB. 11, 2019

A team of Russian and British scientists announced the development of a process to add nanoscale diamonds to molten aluminium, making a new aluminium alloy tailored to maritime transportation applications.
 new aluminium alloy shows promise for use in aerospace, automotive, and other industries where high strength, low density metals are needed. They say the new aluminium alloy may well replace more expensive aluminium-scandium alloys currently in use.
https://aluminiuminsider.com/researchers-develop-new-aluminium-alloy-using-microscopic-diamonds/

New Milling Cutters

M5130 shoulder milling cutter – Xtra·tec® XT – performance und reliability extend your perspective.
Maximum stability for optimum productivity and process reliability
Lower tool costs and minimal administrative effort thanks to universal usability
No additional finishing operations thanks to exact 90° angle
Tiger·tec® cutting tool materials guarantee extremely high cutting data
Excellent handling thanks to improved accessibility
High number of teeth and small indexable inserts for maximum efficiency
More information

Available:
With AC.T0602.. indexable insert | From 1st January 2019
With BC.T1605.. indexable insert | From 1st May 2019
​

placeholder
Xtra·tec® XT M5009 face milling cutter
Fullscreen
Xtra·tec® XT M5009 face milling cutter – small indexable inserts, high productivity.
High level of stability – ideal for small machining allowances and variable conditions
Maximum feeds, tool life and productivity thanks to small indexable inserts and high number of teeth
High level of process reliability due to tough double-sided indexable inserts
Very good handling thanks to easily accessible clamping screw at an angle – prevents typical installation mistakes
Highly cost-effective thanks to low cutting tool material costs
More information
https://www.walter-tools.com/en-gb/tools/innovations/milling/pages/innovations-milling-2/new-products-milling-2.aspx

ASU, Army Research Lab create new alloy with superhero-like strength

October 8, 2018
Now researchers from Arizona State University and the Army Research Laboratory have teamed and designed an alloy of copper and tantalum that can withstand extreme impact and temperature — bringing society one step closer to having real-life materials with superhero strength. Kiran Solanki, an associate professor in the Ira A. Fulton Schools of Engineering, is working on the copper and tantalum alloy, which has the potential to be used in protective equipment for the armed forces and on spacecraft for deep-space exploration.
https://asunow.asu.edu/20181008-asu-army-research-lab-create-new-alloy-superhero-strength

August 7, 2018

A new Copper Graphene (G/Cu) nanocomposite alloy has been developed recently: the addition of 3% graphene to pure copper has proven to be an alloy that significantly improves the yield strength, tensile strength, and elastic modulus if compared to pure copper. Even though the electric conductivity decreases, the resulting material is still considered highly conductive.
https://www.ennomotive.com/new-applications-graphene-copper-alloy/

July 11, 2018
Fiat Chrysler Automobiles (FCA) has created an aluminum alloy that exceeds the limitations of alloys currently used in vehicle engine cylinder heads.

The new alloy,  ACMZ, developed by FCA, the Oak Ridge National Laboratory and supplier Nemak, stays strong up to 300°C (572°F). This surpasses, by a wide margin, the limits of existing alloys, which begin to weaken and crack above 200°C (392°F).
https://www.engineering.com/AdvancedManufacturing/ArticleID/17231/Fiat-Chrysler-Creates-New-Aluminum-Alloy-for-Engines.aspx

JANUARY 26, 2018

New research yields super-strong aluminum alloy
Purdue University's School of Materials Engineering.
https://phys.org/news/2018-01-yields-super-strong-aluminum-alloy.html

https://www.dnaindia.com/science/report-new-research-yields-super-strong-aluminum-alloy-here-s-what-you-need-to-know-2579476

NASA-427: A New Aluminum Alloy
With Improved Impact Toughness and Mechanical Properties
https://technology.nasa.gov/patent/MFS-TOPS-8

New steel that beats the strength-ductilitiy trade-off
August 25, 2017
A Hong Kong-Beijing-Taiwan mechanical engineering team led by Dr Huang Mingxin from the University of Hong Kong (HKU) has recently developed a Super Steel (also called D&P Steel as it adopted a new deformed and partitioned (D&P) strategy) which addressed the strength-ductility trade-off. Its material cost is just one-fifth of that of the steel used in the current aerospace and defence applications.
https://www.sciencedaily.com/releases/2017/08/170825124908.htm

FACT SHEET Advanced steel applications - worldsteel
https://www.worldsteel.org/en/dam/jcr:4864507f-7f52-446b-98d6-f0ac19da8c6d/fact_Advanced+steel+applications_2016.pdf


Novelis introducing high-strength 7000-series aluminum alloys for automotive industry
18 August 2015

Novelis' Next Generation High Strength Automotive 6xxx Alloy: Advanz™ - 6HS-s650

Novelis; Next Generation 7xxx Aluminum Alloy for Automotive Applications
https://www.greencarcongress.com/2015/08/20150818-novelis.html

Scientists Invent a New Steel as Strong as Titanium
South Korean researchers have solved a longstanding problem that stopped them from creating ultra-strong, lightweight aluminum-steel alloys.
Feb 4, 2015
https://www.popularmechanics.com/technology/news/a13919/new-steel-alloy-titanium/

New Welding Process, "J-SolutionTM Zn", Suitable for Galvanized Steel in Automotive Industry ...
2013
https://www.kobelco.co.jp/english/ktr/pdf/ktr_32/016-023.pdf


March 1998
New Copper Alloys
Copper Applications in Innovative Technology
https://www.copper.org/publications/newsletters/innovations/1998/03/new_alloys.html


Engineering and Technology News August 2019


Updated on 29 July 2019

ISI Standards for Sheets, Plates and Bars - India

 The generally accepted meanings for  the terms, foil, sheet, strip and plate are as follows: 

Foil is sheet metal of varying widths having thickness not exceeding 1.6 mm. 

Strip is a metal rolled in any thickness between 1.6 mm and 10 mm and its widths vary from 100 mm to 1,550 mm. It is designated with letters ISST followed by the dimensions in mm in order of length, width and thickness. 

Sheet is a term used for metals having thickness lying between 0.4 mm to 4 mm and having a 

width varying from 1,800 mm to 4,000 mm. It is designated by letter ISSH followed by the dimensions in mm in order of length, width and thickness. 

Plates denote all widths of metals where the minimum thickness exceeds 5 mm and maximum upto 63 mm and all widths of metal and length varying from 2,200 mm to 13,500 mm. It is designated by letters ISPL followed by dimension in mm in order of length, width and thickness. 

18:1138-1958 gives sizes of metal strips, sheets, flats, plates, and bars round and square. Here the nominal sizes are given as well as the tolerances in the sizes kept in their manufacture are also specified. 

18:1731-1961 gives dimensions for steel flats, and their tolerances for structural and general engineering purposes while 18:1732-1961 gives dimensions for round and square steel bars for 

structural and general engineering purposes. 

Dimensions for steel plates, sheets and strips for structural and general engineering purposes are given in 18:1730-1961. The following 18 specifications also give the sizes of different structural 

sections made of steels for general purposes of engineering: 

18:808-1957 specification for rolled steel beams, channels and angle sections 

18 : 1173-1957 specification for rolled steel beams, channels and angle sections and for bars 

18:1250-1958 Specification for rolled steel beams, channels and angle sections, and bulb angles 

18:1863-1963 Dimensions for rolled steel bulb plates. 

All these structural steel sections are given combined in ISI standard handbook for structural engineers. 

18:6911-1972 gives dimensions of stainless steel plates, sheets and strips 

18:1079-1973 gives dimensions of hot rolled, carbon steel sheets and strip 

18:6527-1972 gives dimensions of stainless steel wire rods 

18:6528-1972 gives dimensions of stainless steel wire 

18:6529-1972 gives dimensions of stainless blooms, billets and slabs for forgings. 

18:6603-1973 gives dimensions of stainless steel bars and flats 

All sizes given in IS standards are not manufactured by companies. Only those sizes which are in large and continuous demand are made normally by them. So design engineers should refer to manufacturers' catalogues for the available sizes.

Milling Processes and Operations

7.6.5 Mullick and Bhattacharyya

Milling a slot - with a milling cutter

Milling  flat surface - with a helical tooth plain milling cutter

Millng a flat surface - with the side of a side millign cutter

Side milling with half-side milling cutter

Milling a semicircular groove
Milling a vee-groove

Straddle milling the sides of a projection with a set of half-side m milling cutters

Gang milling a complex form with a set of  milling cutters of various types

Vertical Milling Machine Operations

Milling a flat surface with an inserted  blade milling cutter

Milling a slot with an end mill

Milling two surfaces of a recess by an end mill.

2018

M5130 shoulder milling cutter – Xtra·tec® XT – performance und reliability extend your perspective.
Maximum stability for optimum productivity and process reliability
Lower tool costs and minimal administrative effort thanks to universal usability
No additional finishing operations thanks to exact 90° angle
Tiger·tec® cutting tool materials guarantee extremely high cutting data
Excellent handling thanks to improved accessibility
High number of teeth and small indexable inserts for maximum efficiency
More information

Available:
With AC.T0602.. indexable insert | From 1st January 2019
With BC.T1605.. indexable insert | From 1st May 2019
​

placeholder
Xtra·tec® XT M5009 face milling cutter
Fullscreen
Xtra·tec® XT M5009 face milling cutter – small indexable inserts, high productivity.
High level of stability – ideal for small machining allowances and variable conditions
Maximum feeds, tool life and productivity thanks to small indexable inserts and high number of teeth
High level of process reliability due to tough double-sided indexable inserts
Very good handling thanks to easily accessible clamping screw at an angle – prevents typical installation mistakes
Highly cost-effective thanks to low cutting tool material costs
https://www.walter-tools.com/en-gb/tools/innovations/milling/pages/innovations-milling-2/new-products-milling-2.aspx


2017
Writing in the February 2017 issue of the Journal of Manufacturing Science and Engineering, the Missouri S&T researchers describe an approach that can greatly improve the accuracy of five-axis machine tools used to fabricate large parts
"Five-axis machine tools are known to have 41 basic geometric errors.
The research is related to compensating for the errors to hold errors to five thousandths of an inch over 120 feet in case of aircraft body etc.
https://www.sciencedaily.com/releases/2017/01/170118103451.htm


Updated on 30 July 2019, 7 September 2018

Machine Element Materials - Fabrication Characteristics - Design for Manufacturability

Fabrication Characteristics and Processes of Fabrication - Materials Suited for Specific Fabrication Processes

The fabrication characteristics of metals are explained under the heads:  formability, castability,  machinability and weldability.

(a) Formability:

The ability of a metal to be formed is based on ductility of the metal. Ductility is based on its crystal structures. The metal that has the face centred cubic crystal structure is most ductile because the crystal has the greatest opportunity for slip in four distinct nonparallel planes and three directions of slip in each plane.

The other factors which control ductility of the material are grain size, alloying elements and softening heat treatments such as annealing and normalizing. The small grain sizes are recommended for shallow drawing of copper and relatively large grains for heavy drawing on the thicker gauges.

Hot and cold working, also have an effect on ductility. The high pressure applied in hot drawing distorts the grains which determine the ductility; cold working also results in distortion of crystals. Generally, cold worked crystals are more distorted and are usually less ductile than the hot worked crystals.

Alloying elements in a pure metal normally reduce its ductility, because if they replace the atoms of pure metal it reduces the number of slip planes as it occurs in steel, which is an alloy of carbon and iron and so steel is less ductile than iron. If the alloy finds its room in the spaces between the atoms of pure metal it offers increased resistance to slip, which happens in steel when iron carbide precipitates in slip planes when steel solidifies. By softening heat treatment such as annealing which consists of heating the metal to the re-crystallisation temperature at which at first the grains may be very small but they grow in size as long as the metal is exposed to the high temperature, when the desired size is obtained the metal is allowed to cool. During recrystallization ductility of metal is

restored because distorted crystals are reformed in re-crystallisation.

The processes using the property of formability of metal are under two major categories: (i) Hot working and (ii) Cold working.

Hot working processes:

Rolling, forging, extrusion and hot pressing are hot working processes. In hot working the metal is heated sufficiently to make it plastic and easily worked. The temperature of the heated metal or alloy should be above the re-crystallisation temperature. This temperature is different for different metals.

Hot rolling is used to create a bar of material of particular shape and dimensions. The principal rolled steel sections arc plates, angles, tees, channels and joists; round, hexagonal and square bars for forging and machining operations; sheets, rails, etc. All of them are available in many different sizes and in different materials. The materials most available in the hot rolled bar sizes are steel, aluminium and copper alloys. Tubes may be manufactured by hot rolling of strips or plates; the product may be butt welded or lap welded.

Forging is the hot working of metals by hammers, presses or forging machines. For small work forging is carried out with hand hammers but for large work hammers and forging machines are used. Forging alters the internal structure of metals which results in increased strength and ductility. Compared with castings, forgings have greater strength for the same weight. Forging should be

carried out within proper temperature range. If the temperature is too high the metal will be weak and brittle. If the temperature is too low, there will be internal stresses which may lead to distortion or cracking.

Many small parts are drop forged. In drop forging, solid lump with little or no previous treatment by hand is squeezed between dies to the shape required with one or more blows from a drop hammer. The component can be made to dimensions and with a good surface so that machining may be unnecessary. The limitations of this process are that the number of parts should be great (production volume has to be high) and complicated shapes cannot be produced as they can not be removed from dies.

Extrusion is a process where a heated blank is caused to flow through a restricted orifice under great pressure. Very complicated shapes may be produced by the extrusion process. The process is restricted to materials of low melting points such as brass, aluminium and certain alloys of tin, lead and other soft metals.

Hot pressing consists of forming metal to shape in a very rigid type of power press. A hot piece of metal is pressed and extruded in suitable dies into a smoothly finished piece to accurate dimensions. Automobile valves are formed by this process. 

Cold working processes:

In cold working is the forming of a metal is done usually at room temperature. In some cases, higher  temperatures are used but always, the temperature is lower than re-crystallisation temperature of the material. Cold working may vary from a simple bend to great deformation produced by deep pressing and tube drawing. The result of cold work is to increase hardness and tensile strength but to decrease ductility and shock resistance. Cold worked parts have a bright new finish, are more accurate and require less machining. Where cold work is considerable, the part may be annealed at some intermediate stage or stages of work. In cold working the surface of a material is very important as scale may be worked into the finished article with serious results. Some of cold working processes are drawing, heading, spinning, stamping, etc.

Drawing is a process by which the cross section of a metal is diminished by pulling it through an accurately formed hole in a drawing die. The operation is performed cold and only simpler forms can be produced without excessive resistance and tearing.

Heading is a cold working process in which the metal is gathered or upset . This  operation is commonly used to make screw and rivet heads. The blank is usually a piece of wire of suitable length and cross section; one end is cold forged in dies to form the desired shape of the head. Annealing may be required after cold heading.

Spinning is the operation of working sheet material around a rotating form into a circular shape. Pressure is applied to the sheet by means of a blunt nosed tool which presses it against the former. This is an economical method of forming parts if the quantities are small.

Stamping is the term used to describe punch press operations such as blanking, coining, forming and shallow drawing.

Powder metallurgy :

It is the art of making small components by heat treatment of compressed metallic powders, sometimes with inclusion of non-metallic material.

The powdered metals in desired proportions are compressed in moulds under a very high pressure varying from 700 to 14,000 kg/sq cm depending on the metal. The compacted part is heated at a temperature which is less than melting point of the major ingredient. T'he disadvantages of this method are (i) low strength of the component (ii) higher cost of material and (iii) the limited range of materials which can be used.

Filaments of refractory metals such as tungsten, self lubricating bearings, tungsten carbide tips for cutting tools and iron alloys for permanent magnets are examples of articles made from powdered metal. By this process small components can be made out of some metals whose melting point is too high to allow use of die casting.

(b) Castability:

Castability of a metal is judged to a large extent on the following factors: solidification rate, shrinkage, segregation, gas porosity, and hot strength.

Solidification Rate:

The ease at which a metal will continue (o flow after it has been poured in the mold depends on its analysis and pouring temperature. Some metals such as grey iron are very fluid and can be poured into thin sections of complex castings.

Shrinkage :

Shrinkage refers to the reduction in volume of a metal when it goes from a molten to a solid state. For steel, the amount of contraction amounts to about 6.9 to 7.4% by volume, or 2 cm per metre; grey  iron contracts half as much. This shrinkage factor has to be taken into account by the pattern maker and designer, not only to allow for the proper finished .size, but also to sec that undue strains will not be encountered during shrinkage due to the mould design. Various elements can be added to the alloy to control fluidity and shrinkage as discussed later in this chapter.

Segregation :

As the metal starts to solidify tiny crystal structures resembling pine trees and referred to as dendrites start to form at the mold edges. As they form, they tend to exclude alloying elements. Subsequent crystals that form are progressively richer in alloy content as the metal solidifies. Thus the surface of the casting is not of the same quality as that in the centre. This is overcome in part at least by subsequent heat treatment, or very slow cooling.

Gas Porosity:

Some metals in the molten state have a high affinity for oxygen and nitrogen. These gases become trapped as the metal solidifies creating voids or pinholes.

Hot Strength:

Metals are very low in strength right after solidification. This is especially true of the non-ferrous metals. Precautions must b(‘ taken at the lime of casting to avoid stress concentration that causes flaws and hot tears to develop as the metal solidifies .

Casting is the oldest form of metal shaping and is still the basic engineering process since most metals are melted and cast from ores. Castings are made of iron, steel, various brasses and bronzes, aluminium and its alloys and the various white metal alloys.

Patterns may be made of wood or metal and with its help the sand mould is formed in which molten metal is poured. The mould is dried before the metal is poured. Metal in cooling solidifies to the form outlined in the mould.

In die casting process the mould is usually made of steel and molten metal is poured or forced under pressure into the mould. This method is used for mass production only.

Non-ferrous alloys arc sometimes cast centrifugally. Molten metal is poured into a rapidly rotating cylindrical mould and is held against the mould by centrifugal force so that core is not required. On cooling the casting is complete. Such castings are generally denser and more homogeneous than ordinary sand castings. This process is limited to simple shapes and to fairly large quantities.

The following precautions should be observed in design of castings :

(i) All sections should be designed as far as possible with a uniform thickness.

(ii) All walls should be sufficiently thick to allow the molten metal to flow freely into all corners.

(iii) Adjoining sections should be designed with generous fillets or radii.

(iv) Parts should be designed so that patterns may be drawn readily from the moulds.

(v) A complicated part should be designed in two or more castings. These castings are assembled by fasteners.

(vi) Where the section uniformity is not possible, light sections should be blended into heavy sections.

Thickness of casting determined by calculations is often too small to permit production of good castings. Minimum values of the thicknesses for various castings are prescribed.


Material                                 Minimum thickness in mm


Grey cast iron                                    6

Malleable cast iron                           6

Steel casting                                     6

Brass                                                3

Bronze                                             3

Aluminium                                      3

(c) Machinability :

Machinability is the ease with which metal can be removed in operations such as turning, drilling, reaming, etc. Ease of metal removal requires that the forces acting against the cutting tools should be relatively low and the chips will be broken up, a good finish should result and the tools should last a reasonable period of time before it has to be replaced or resharpened. Machinability is also expressed as a machinability rating for each material. 

This rating is given for most ferrous metals using steels 13S25  in the cold drawn conditions as the basis of 100% machinability. This value involves turning at a cutting speed of 54.9 surface metre per minute for feeds upto 0.1778 mm per revolution and depths cut upto 6.35 mm using appropriate cutting fluid with high speed steel T70W18Cr4V1 tools. Machinability of other metals will be judged with respect to this basis.

This property plays a predominant role in deciding the selection of material for components manufactured using  machining on automatic machine for mass production. By adding alloying materials like sulphur and lead in steel its machinability can be increased, however, some reduction in tensile strength in takes place.

(d) Weldability:

It may be said that all metals are weldable by one process or another. However, the real criterion in deciding on the weldability of a metal is weld quality and the ease with which it can be obtained.

In deciding on weldability of a metal, the characteristics commonly considered are the heating and cooling effects on the metal, oxidation, and gas vaporization and solubility.

Heat and Cooling:

The effect of heat in determining the weldability of a material is related to the change in microstructure that results. For example, steels are sometimes considered weldable or not weldable on the basis of the hardness of the weld. The deposited weld metal may pick up carbon or other alloys and impurities from the parent metal that make it hard and brittle so that cracks result upon cooling.

The opposite effect may also be considered. A metal may have a certain hardness temper that will be changed by the heat of the weld. Although both of these conditions can be corrected by added precautions and heat treatment, they add to the cost and hinder the simplicity of the weld.

Hot shortness, a characteristic which is indicated by lack of strength at high temperature, may result in weld failures during cooling of certain metals.

Oxidation :

Oxidation of the base metal, particularly at elevated temperatures, is an important factor in rating weldability of a metal. Metals that oxidize rapidly, such as aluminium, interfere with the welding process. The oxide has a higher melting point than the base metal, thus preventing the metal from flowing. It also may become entrapped in the weld metal, resulting in porosity, reduced strength, and brittleness

Gas:

Large volumes of troublesome gases may be formed in the welding of some metals. These gases may become trapped in the weld because certain elements vaporize at temperatures below those needed for welding. Not only will this cause porosity, but some of the beneficial effects of these elements are lost.