Flexible Automation:
Flexible automation or programmable automation includes:
> Computer- aided design (CAD) - engineering analysis and simulation and computer- aided design and drafting(CADD)
> Computer -aided manufacturing (CAM) consisting of computer numerically controlled (CNC) machine tool, direct numerical control (DNC) machine tool, flexible manufacturing systems (FSM), automated material handlingsystem (AMH) and robotics.
> Computer -aided techniques for management consisting of management information systems (MIS), computer -aided planning (CAP), computer-aided process planning (CAPP),
These tools are used to help design products, manufacture precision products on the factory floor and assist in management of many shop floor ar plant operations. When systems for design, manufacturing and management are used together in a coordinated system, the result is computer -integrated manufacturing (CIM), a new strategy. ( Robotics Technology and Flex - Deb - page 282 )
Induction Heating: Induction heating for forging is now fairly common, particularly for repetitive forging operations. Temperature control for induction heating must be taken seriously, given the rapid heating rates possible with this system. It should be remembered that the temperature of the billet is related directly to its initial temperature and the electrical power input to the induction coil. Commonly, the induction heater is set up the use a specific wattage for a given billet size and weight,based on the billet being at ambient temperature at the outset. The controls downstream of the induction coil can detect a billet temperature outside of the required range and eject the billet from the line. the billet is allowed to cool and is fed back into the system. If the billet is still warm when it enters the coil again, the exit temperature will be higher than intended and the risk of burning is increased. In induction heating lines, optical pyrometer systems are generally used and these must be kept clean and maintained. ( Steel forging: design, production, selection, testing, and application - Edward G. Nisbett - page76 )
Investment casting: In investment casting, the ceramic slurry of a metarial such as colloidal silica ( consisting of nano-sized ceramic particles) coats a wax pattern. After the ceramic hardens(i.e., the colloidal silica dispesion gels), the wax is melted and drained from the ceramic shell, leaving behind a cavity taht is filled with molten metal. The investment casting process, also known as the lost wax process, is best suited for generating most complex shapes. Dentist and jewelers orginally used the precision investment casting process. Currently, this process is used to produce such components as turbine blades, titaniun heads of golf clubs, and parts for kneel and hip prosthesis. In another process known as the lost foam process, polystyrene beads, similar to those used to make coffee cups or packaging materials, are used to produce a foam pattern. ( Essential of materials science and engineering - Donald R. Askeland, Pradeep P. Fulay - page 274 )
Inspection and Testing: Inspection is normally used to examine whether a product conforms to the design standards specified for it. For a mechanical components, this would be probably concerned with the dimensionsi surface texture and tolerances specified for the part. Non-confirming goods result in scrap, rework and the loss of customer goodwill. The common situation that warrant inspection are :
>Incoming materials (raw materials, standard items, subcontracted parts )
>Stage inspection during manufacturing (e.g., when the parts are moved from one production section to another)
>At the completion of processing of the parts
>Before shipping the final assembled product to the customer
Whereas inspection is a regular activity in production, testing is a significant stage of work in product development to prove the capability of the product. Testing is normally associated with the functionalaspect of item, and is often directed at the final product rather than its components. Testing consist of the appraisal of the performance of the final product under actual or simulated conditions. If the product successfully passed the tests, it is deemed suitable for use. Testing ascertains the quality of performance of product. (CAD/CAM/CIM - P.Radhakrishnan - page 493 )
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