Manufacturing 101 By Subramanian Chidamabram Metal Selection Iron

Manufacturing 101 By Subramanian Chidamabram

Metal Selection • Iron • Steel • Stainless steel • Aluminum • Copper

Material Selection • Wood • Cardboard • Foam • Plastic • 3 D printing – ABS/PLA

Corrosion • SS has a high corrosion resistance • Followed by Steel • Al only faces surface corrosion • Cast Iron corrodes with less effort

Weldability • Cast iron is difficult, but not impossible, to weld. In most cases, welding on cast iron involves repairs to castings, not joining casting to other members. The repairs may be made in the foundry where the castings are produced, or may be made to repair casting defects that are discovered after the part is machined. • The austenitic/higher chromium stainless steels, usually required in very high or very low temperatures, are generally more corrosion resistant than the lower chromium ferritic or martensitic stainlesses. Most stainless steels are considered to have goodweldability.

Weldability • Most aluminum alloys are readily weldable using TIG or MIG • 1 XXX, 4 XXX and 5 XXX are readily weldable. 3 XXX series is weldable using 4053 or 5356 as filler metal. • 6 XXX is weldable but prone to cracks • 2 XXX and 7 XXX are high aerospace grade with chemistries that make it unweldable. • I generally tend to use Al – 6061 T 6

Dissimilar metals Avoid using two dissimilar metals when you are thinking about welding the parts Welding Dissimilar metals is hard but not impossible https: //www. youtube. com/watch? v=5 Jbn. DXw-0 p. M

Machinability • Surface Roughness: How smooth is a surface? • Hardness • Usually measured in Rockwell hardness

CAD • Solidworks • Catia • Pro E

Analysis • Finite Element Analysis • Theory of Failure • Predict if a part is going to fail

Drafting • Also know as technical drawing

Tolerance

Lathe • Basics of Lathe: https: //www. youtube. com/watch? v=H 0 Ay. VUfl 8 -k • Turning : https: //www. youtube. com/watch? v=8 Es. Ax. Onz. Ems

Tool Material • Cutting Tool: https: //www. youtube. com/watch? v=J 63 d. Zsw 7 Ia 4

CNC milling machine • https: //www. youtube. com/watch? v=h. MK 7 g_Pp. Cv 8 • https: //www. youtube. com/watch? v=U 99 asu. DT 97 I&list=PLyv 4 Q 1 Jx. T_Rh 0 F v 5 lo. UN 9 ZTm 74 Vkx. Yjh. J

Drill bits

TIG Welding • Tungsten Inert gas Welding • TIG welding is very versatile • Produces the highest quality welds. • It also takes considerable practice and is least productive. • TIG uses an torch with a tungsten electrode. • Argon is used as a shielding gas to protect weld and tungsten. • Can weld both Steel and Al. • Why can it weld Al?

Interference fit • Also know as a press fit or a friction fit • Video: https: //www. youtube. com/watch? v=J 4 gp. LYo 0 vyw

Co-ordinate measuring machine (CMM) • https: //www. youtube. com/watch? v=w. Sn. Ek 1 nkk. Gs Location: Metrology Laboratory Purdue Polytechnic MGL 1208 B

Some equipment's available at the AFL Pedestal Grinder Surface Grinder

Some equipment's available at the AFL Miter Saw Circular Saw

Some equipment's available at the AFL Jig Saw Bench Top router

Back up

Basic designs • Key and • Key seat • Keyway

Knuckle joint

Universal joint

• Always wash your hands after working in a machine shop!