Mehmet Burak Toprakoğlu - 030070082 - 2nd Week of Project

Non-Destructive Testing: Non-destructive testing is the evaluation of engineering materials without impairing their usefullness. As with the fracture mechanics, nondestructive testing can serve to analyze an existing failure or be used to prevent future failures. The techniques of this field are:

1. X-radiography testing,
2. Ultrasonics,
3. Eddy-current testing,
4. Magnetic particle testing,
5. Liquid penetrant testing,
6. Acoustic-emission testing.

(Shackelford J.F., Introduction to materials science for engineers, 4th Edition, p. 560, 562-564)

Hot Isostatic Press (HIP): The container is made of a high-melting-point sheet metal, and the pressurizing is high-temperature inert gas or a vitreous (glasslike) fluid. Common condition for HIP are pressure as high as 100 MPa (15 ksi) - although it can be three times as high - and at a temperature 1200 ⁰C (2200 ⁰F). The main advantage of HIP is its ability to produce having almost %100 density. Consequently, it has gained wide acceptance in making high-quality parts.

The HIP process is used mainly in making superalloy components for the aircraft and aerospace industries and in military, medical and chemical applications. It also is used to close internal porosity, to improve properties in superalloy and titanium-alloy castings for the aerospace industry, and as a final densification step for tungsten-carbide cutting tools and P/M tool steels.

(Kalpakjian S., Schmid S.R.,Manufacturing engineering and technology, 5th Edition, p. 494,495)

Total Quality Management: TQM is a system that emphsizes the concept that quality must be desinged and built into a product. It is a systems approach in that both managements and employees make a concerted effort to consistently manufacture high-quality products. Defect preventation (rather than defect detection) is the major goal here.

Leadhership and teamwork in the organization are essential. They ensure that the goal of continuous improvement in manufacturing operations is imperative,be-cause they reduce product variability and they improve customer satisfaction. The TQM concept also requires us to control processes and not the parts produced, so that process variability is reduced and no defective parts are allowed to continue through the production line.

(Kalpakjian S., Schmid S.R.,Manufacturing engineering and technology, 5th Edition, p. 1113)

Transfer mechanism and transfer lines: Transfer mechanisms are used to move the workpiece from one station to another in the machine or from one machine to another to enable various operations to be performed on the part. Workpieces are transferred by methods, including rails along which parts (which usually are placed on pallets) are pushed or pulled by various mechanisms, rotary indexing tables, and overhead conveyors.

The transfer of parts from station to station usually is controlled by sensors and other devices. Tools on transfer machines easily can be changed using tool-holders with quick-change features, and the machines can be equipped with various automatic gaging and inspection systems. These systems are utilized between operations to ensure that the dimensions of a part produced in one station are within acceptable tolerances before that part is transferred to the next station. Transfer machines also are used extensively in automated assembly.

The transfer lines or flow lines in a very large system for producing cylinder heads for engine blocks consisting of a number of transfer machines. This system is capable of producing 100 cylinder heads per hour. Note the various machining operations performed: milling, drilling, reaming, boring, tapping, honing, washing and gaging.

(Kalpakjian S., Schmid S.R.,Manufacturing engineering and technology, 5th Edition, p. 1151)