Question

Materials and process selection are key issues in optimal design of industrial products. Process planning for parts is determined largely by the material out of which the part is made and the part design itself. Using a practical example, discuss in detail the two different materials which could be selected to fabricate a specific part and outline the the following: • A basic process • One or more secondary processes • Operations to enhance physical properties • Finishing operation That would be executed for each of the two materials

Answer 1

Gear (Gears are Specific past selected : Material selection : one of the most common mechanical component and hence used here example) Although many metals and non- metals can be used for making gears, the two materials to choose are : 0 Grey cast Iron ③ Forged high carbon steel (Ni-CE-Mo alloys) > Basic process: Making Gear blanks This is generally done by casting (sand casting, Die casting, Investment casting, etc.)

* Secondary process Gears made by die casting require little machining but machined and hardened gear teeth are later finished for accuracy. Pre-machining is done to achieve desired dimension and the machining is done for production of teeth. → Process Forming os Operations to enhance physical properties Surface hardening is followed to achieve high hardness on the surface of teeth. This can be done by carburization or mechanical hardening *Finishing operation Generation. To get extremely low tolerance. processes? Gear sharing, lapping

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