Gökhan GÜNGÖR 514101006 (5th Week Terms)

1. Cause and effect diagram
2. Self-directed work team
3. A layered structure
4. The application enablers
5. In house Developed Software
6. Off-line programming (PLC)
7. Wire EDM
8. Side cutting angle
9. Intermittent Transfer
10. House Of Quality

5th Week Unanswered Terms

Chvorinov's rule

The total solidification time is the time required for the casting to solidify after pouring. This time is dependent on the size and shape of the casting by an empirical relationship known as Chvorinov's rule which states:

Tts=Cm(V/A)^n

Where Tts: Solidification time, min; V= volume of casting, cm3; A= surface area casting, cm2; n= an exponent usually taken to have value 2 and Cm is mold constant.

Gökhan Güngör (5th week - Unanswered Terms)

Product Structure Tree;

A diagram representing the hierarchical structure of the product. The trunk of the tree would represent the final product as assembled from the subassemblies and inventory units that are represented by level one, which comes from sub-subassemblies and inventory units that come from the second level and so on ad infinitum
(Kutz M., Mechanical Engineer's Handbook, Manufacturing and Management, 3rd Edition, P.135)

Standard Tooling;

Standard tooling is defined as that which is basically off the shelf and may be used by different users or a variety of products. Standard tooling is usually produced in quantity, and the cost is low.
(Kutz M., Mechanical Engineer's Handbook, Manufacturing and Management, 3rd Edition, P.104)

Station Time;

The total amount of work assigned to station, which consits of one or more of the work elements necessary for completion of the product.
(Kutz M., Mechanical Engineer's Handbook, Manufacturing and Management, 3rd Edition, P.156)

Buğra Cengiz 030060178

The Geneva Mechanism

The Geneva mechanism uses a continuously rotating driver to index the table through
a partial rotation.If the driven member has six slots for a sixstation dial indexing table. each turn of the driver results in 1/6 rotation of the worktable or 60°.The driver only causes motion of the table through a portion of its own rotation. For a six-slotted Geneva. 120 degree of driver rotation is used to index the table. The remaining 240 degree of driver rotation is dwell time for the table, during which the processing operation must be completed on the work unit.

Groover, Automation, Production Systems and CIM, P.571.

Zero Defect

Just in Time (JIT) requires high quality in every aspect of production. If defective parts are produccd.they cannot be used in subsequent processing or assembly stations, thus interrupting work at those stations and possibly stopping production. Such a severe penalty forces a discipline of very high quality levels (zero defects) in parts fabrication. Workers are
trained to inspect their own output to make sure it is right before it goes to the next operation. In effect.this means controlling quality during production rather than relying on in
specters to discover the defects later. The Japanese use the word Jidoka in their quality
control procedures. Roughly translated, it means "stop everything when something goes
wrong"

Groover, Automation, Production Systems and CIM, P.827

Last In First Out. (LIFO)

Last in first out method of inventory measurementassumes that the most recently purhaced items re to be the first ones sold that the remaining inventory will consist of the earliest item purchased. In other words, in which the are sold in reverse of order in which they are bought. Unlike FIFO and LIFO methods species that the cost of inventory on hand (ending inventory) is determined by working forward from the beginning inventory through purchases until suffiecient units are obained to cover the ending inventory. This is the opposite of FIFO system.

Joel J. Lerner, Theory and Problems of Princibles of Accounting I, P.194

Super Plastic Forming

Superplastic materials are thus multi-phase, which promotes pinning of
the grain boundaries during the high-temperature forming process, hence
inhibiting grain growth. Titanium and aluminium alloys have been developed
for industrial superplastic forming and it is also an accepted forming method
for producing the vanes of gas turbine engines using certain nickel-based
superalloys. With further refinement of grain size, superplasticity can be
extended to significantly higher (and hence commercially desirable) strain rates.

John Martin, Materials for engineering, P.55

Olcay Türkoğlu (5th week)

1 Hydraulic automation

2 Solenoid operation

3 Deceleration valve

4 Sequencing Actuators

5 Hydraulic interlocks

6 Borazon Tips

7 Rake angle

8 Obliquity angle

9 Approach angle

10 End cutting angle

Gökçe Dil 5.week

1.Product integrity
2. Elastic modulus
3.POrosity
4.Impact milling
5.Roll crushing
6.Liquid-crystal polymers
7.Vibratory ball milling
8.Plasticizer
9.Super plastic forming
10.Solvent

Burcu Atay, 140060029, 5th week

Open Mold

The distinguishing feature of this family of FRP( fiber-reinforced polymer composites) shaping processes is its use of a single positive or negative mold surface to produce laminated FRP structures. Other names for open mold processes include contact lamination and contact molding. The starting materials (resins, fibers, mats, and woven rovings) are applied to the mold in layers, builging up to the desired thickness. This is followed by curing and part removal. Common resinds are unsaturated polyesters and epoxies, using fiberglass as the reinforcement. The moldings are usually large( e.g., boat hulls). The advantage of using an open mold is that the mold costs mych less than if two matching molds wew used. The disadvantage is that only the part surface in contact with the mold surface is finished; the other side is rough. For the best possible part surface on the finished side, the mold itself must be very smooth.

There are several important open mold FRP processes. The differences are in the methods of applying the laminations to the mold, alternative curing techniques, and other variations. The family of open molf processes for shaping fiber-reinforced plastics: (1) hand lay-up, (2) spray-up, (3) automated tape – laying machines, and (4) bag molding. We treat hand lay-up as the base process and the others as modifications and refinements.

(Groover, M.P., Fundamentals of modern manufacturing: materials, processes, and systems, 4th Edition, pg.331-332)

edit:

Open sand molds suitable for casting large metal plates, especially aluminium plates for builfing facades are prepared by using a large roller bearing a model and rolling spaced guides to level a bed of moldable substance therebetween and simultaneously impressing the molding pit in the bed.

(United States Patent US3812902, Apparatus for preparing open sand molds suitable for casting large metal plates, 1974, pg.1)

Intelligent Control

Industrial robots are becoming increasingly intelligent. In this context, an intelligent robot is one that exhibits behavior that makes it seem intelligent. Some of the characteristics that make a robot appear intelligent include the capacities to interact with its environment, make decisions when things go wrong during the work cycle, communicate with humans, make computations during the motion cycle, and respond to advanced sensor inputs such as machine vision.

In addition, robots with intelligent control possess playback capability for both PTP(point-to-point) or continuous path control. These features require (1) relatively high level of computer control and (2) an advanced programming language to input the decision-making logic and other “intelligence” into memory.

(Groover, M.P., Automation, Production Systems and Computer - Integrated Manufacturing, pg.222, Pearson Education Inc,2008)

Fly Cutter

For drilling large holes in pipe or sheet metal, twist drills are not suitable because of the drill tends to dig into the work or the hole is too large to be cut by a standard-size drill. Large holes are cut in thin metal by a hole cutter. Saw- type cutters of this design can be obtained in a wide range of sizes. For very large holes in thin metal a fly cutter is used. Such a cutter consists of tool bits held in a horizontal holder that can accommodate a range of diameters. Both cutters cut in the same path but one is set slightly below the other.

(Amstead, B.H., Ostwald P.F., Begeman, M.L., Manufacturing Processes, 8th Edition, John Wiley & SOns, Inc, pg.510)

Tweak Features

Tweak features deform or alter (“tweak”) the surface of a part. For example, the draft feature adds a draft angle to a surface, or to a series of selected planar surfaces. The Radius Dome option allows a user to create a dome feature. Other Tweak features may include section dome local push ear, offset and draft offset, replace, lip, patch, toridal and spinal bends, and free form.

(Xun Xu, Integrating Advanced Computer-Aided Design, Manufacturing, and Numerical Control: Principles and Implementations, pg.152)

Gökhan Güngör (5th week)

1- Go-Not Go Gage
2- Production Structure Tree
3- Cycle Time
4- Station Time
5- Walk-through Programming (Robot control and programming)
6- Lead-through Programmin (Robot control and programming)
7- Standard Tooling
8- Special Tooling
9- TIG Welding
10-MIG Welding

Ahmet Alp Gündüz - 030060034 - 5th Week

Soldering

Soldering is a process of joining two metal pieces by means of a low temperature fusible alloy called solder applied in molten state. Solders are alloys of low melting point metals like lead, tin, cadmium and zinc. Of these tin-lead alloys are most common and are called soft-solders. A combination of 62% lead and 38% tin produces the lowest melting point and is called 60–40 solder. This corresponds to the eutectic composition of Pb–Sn series and has a fixed m.p. of 183°C. Increasing tin content produces better wetting and flow qualities. Hard solders are also available and have higher melting points. Before applying solder, the surfaces to be joined are cleaned and a flux like ammonium chloride is used. Then the solder is melted and spread upon one surface, while the other surface is applied to it under pressure. When the solder solidifies, the two pieces get joined. The process of soldering does not call for any joint preparation. A common example of soldering can be seen in joining electrical wires of P.C.B. circuits.

(H.N.Gupta, Manufacturing Processes 2nd Edition; Page:140)

Blow Moulding

This process has been used for making plastic bottles, toys, hollow dolls and

similar other items. The blow moulding begins with a heated tubular piece of plastic, which is called PARISON. The bottom opening of the parison gets pinch closed and sealed as the two piece mould closes. Air is then injected into the parison under pressure (0.7–10 kg/cm2) thereby forcing the plastic to acquire the shape of the mould. The mould is opened and the part formed inside the mould is removed after it has cooled sufficiently. The above process is similar to making articles of glass by blowing air into a mass of molten glass.

(H.N.Gupta, Manufacturing Processes 2nd Edition; Page:171)

Tail Stock

A tailstock is provided at the right hand end of the bed. It can slide along the guide ways provided on the bed and may be brought nearer to the headstock, if so desired. It can then

be clamped or fixed on the bed in that position. The tailstock has a spindle in the upper part of the tailstock, the axis of which coincides with the axis of the headstock spindle, both being at the same height above the bed. This spindle can be moved forwards or backwards by rotating a hand wheel. The front portion of tailstock spindle carries a ‘dead’ or ‘live’ centre. When a long work piece is held in the chuck at the headstock end, it is supported at the tailstock end by moving forward the tailstock spindle. Of course, there has to be a small conical hole in the centre of the work piece, in which the tailstock centre may be inserted to provide support. If the centre (being carried in its own bearings) rotates along with the work piece, it is called a live centre. However, if the tailstock centre remains stationary and work piece alone rotates, the centre is called ‘dead centre’ and the conical tip of centre has to be lubricated with grease to reduce the friction between the tailstock centre and the work piece.

(H.N.Gupta, Manufacturing Processes 2nd Edition; Page:93)

Metrology

Metrology or the science of measurement is a discipline that plays an important role in sustaining modern societies. It deals not only with the measurements that we make in day-to-day living, e.g. at the shop or the petrol station, but also in industry, science and technology. The technological advancement of the present-day world would not have been possible if not for the contribution made by metrologists all over the world to maintain accurate measurement systems. In the modern world metrology plays a vital role to protect the consumer and to ensure that manufactured products conform to prescribed dimensional and quality standards. In many countries the implementation of a metrological system is carried out under three distinct headings or services, namely scientific, industrial and legal metrology. Industrial metrology is mainly concerned with the measurement of length, mass, volume, temperature, pressure, voltage, current and a host of other physical and chemical parameters needed for industrial production and process control. The maintenance of accurate dimensional and other physical parameters of manufactured products to ensure that they conform to prescribed quality standards is another important function carried out by industrial metrology services. Industrial metrology thus plays a vital role in the economic and industrial development of a country. It is often said that the level of industrial development of a country can be judged by the status of its metrology.

(Basic Metrology for ISO 9000 Certification, G.M.S. de Silva; Page:7)

A. Selim PARLAKYİĞİT - 5th Week

1. Hydroforming
2. Roll Forming
3. Orbital Cold Forging
4. Oxyfuel Gas Cutting
5. New-Design Control
6. Incoming Material Control
7. Line Balancing
8. Repetitive Design
9. Work Sampling
10.Baka-Yoke

Onur OZAYDIN___5th Week

1. Manuel Part Programming

2. Computer-Assisted Part Programming

3. CAD/CAM- Assisted Part Programming

4. Manuel Data Input (MDI)

5. Limited Sequence Control (about robots)

6. Intelligent Control (about robots)

7. Metrology

8. Mechanical Gages

9. Electronic Gages

10. Ring Gages

503101307 Onur OZAYDIN

Gani Can Öz - 5th Week

1 Open Mold

2 Closed Mold

3 Expandable Mold

4 Permanent Mold

5 Mold Erosion

6 Chvorinov's Rule

7 Foundry

8 Foundrymen

9 Core

10 Riser

GANİ CAN ÖZ - 503101305