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Manufacturing Science Lab
Teaching Laboratory
ME 361A: Manufacturing Technology
Overview:
Objective of this course is to give a broad understanding of conventional and non-conventional machining processes with an emphasis on the characterization techniques. This course also familiarizes students with the scientific principles governing various machining processes.
Equipments
- On Lathe- Lab VIEW Software, Three-component piezo-crystal type dynamometer make Kistler, NI DAQ Card, Microbalance, Dinolite USB Microscope, Vernier Calliper e.t.c.
- On Grinding- Lab VIEW Software, Three-component piezo-crystal type dynamometer make Kistler, NI DAQ Card, Microbalance, Dinolite USB Microscope, Portable Surface Roughness Measuring Instrument etc.
- On EDM – Electronica ZNC EDM Machine, Microbalance, Shadowgraph/ USB Microscope, Micrometer, Stopwatch, etc.
- On Hydraulic Press- USB Microscope, Load Cell, Lab VIEW Software, NI DAQ Card, Vernier Calliper, Proving Ring etc.
- On Microchannels fabrication- Microbalance, USB Microscope, Dessicator, vacuum pump, Furnace temperature upto 400 degree centigrade etc.
- On Milling- Multi-component dynamometer make Kistler, Labview software, NI DAQ Card, Dinolite USB Microscope, Vernier Calliper, Microbalance etc.
Experiments:
- To measure the cutting force, tool temperature and shear angle during orthogonal cutting (on Lathe).
- To study the effects of grinding variables on grinding forces, specific energy and surface finish.
- To study the EDM machine and determine material removal rate and tool wear rate during machining of EN8 steel.
- To draw a cup by cup drawing process and measure the drawing force on hydraulic press.
- To fabricate micro channels through micro Replication double inversion technique.
- Investigation of wear and cutting processes (Fx, Fy, Fz and Mz) near the tool age during milling and drilling by Rotating 4-Component Dynamometer (RCD) on EMCO Mill concept 250.
- To obtain the measurement of a given component using coordinate measuring machine (CMM).
- To fabricate micro channel through epilog laser fiber mark fusion engraving machine.
- To measure the axial force, with tool speed for different diameters, if the feed is constant on HMT Radial Drill Machine.
- To obtain the measurement of roundness of a given component using Out of roundness measuring machine (Mitutoyo, Japan)
- To measure the cutting force, shear angle during orthogonal cutting, cnc programming (Absolute/Incremental) and operations on flat bed Simple Turn5075 ACE Designer CNC Lathe Machine.
- To study the various features of surface roughness measuring instrument also measure the parameters of the specimen.
- To study the integrated multi process (µ-milling, µ-turning, µ -drilling, µ-EDM, µ-ECM, µ-wire cut, µ-EDG) on micromachining machine DT-110.
Processing Equipment: HMT LB-25 Centre Lathe: Specification: HMT LB-25 LATHE 500mm SWING x 2000mm BETWEEN CENTRES. 18 SPEEDS 32-1600 RPM. 52mm SPINDLE BORE WITH 3 JAW CHUCK, 4 JAW CHUCK, FACE PLATE, MULTIFIX QUICK CHANGE TOOLPOST.
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Processing Equipment: Horizontal Surface Grinding Machine Make: HMT Model: SFW1 Magnetic Chuck Size: 1000mm x 300mm Accuracy: 2 μm Table speed: 2.5, 5, 10, 15, 20, 25 (m/min) RPM: 1500
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Processing Equipment: Electronica R50# ZNC Work tank : 800 x 500 x 350 mm Work table size: X Y Z : 300 x 250 x 200 mm Programmable Z axis control, manually operated x and y axis. Accuracy: 5µ 99 programs, 50 steps per program Max. working current: 50A Gap voltage: 100-270V Max. Stock removal (cu-steel): 300(cu.mm/min) Best surface finish: 0.5µ CLA Electrode wear: 0.3-20%
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Processing Equipment: SPECIFICATION: Make : Fluid Power Type : Hydraulic Bed Size : 500 mm x 500 mm RAM Dia. : 12 mm" Capacity : 10 T
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Processing Equipment: SPECIFICATION: Model/Make: EMCO Concept Mill 250 Max Speed: 10,000RPM, Power 7KW 20 Station Tool Drum with directional logic Travel- X350mm, Y250mm, Z300mm Clamping Surface- 500x300mm PC Controlled CNC –Machining center with Interchangeable control EMCO Software Win NC SINUMERIK 810/840D machine license (32bit) Software EMCO 3D View 4th Axis- NC Dividing Head WALTER TANI 80 NEG 5th Axes- Turntable DSE25 èSpindle Speed A axis 15rpm; Spindle Speed B axis 3rpm; Size- X/Y/Z = 520/260/150; Swiveling Height =80MM; Swiveling Area of 4th Axis = Max. ±91o ESPRIT CAM Software è Powerful Spectrum Programming for 2-5 Axis Milling, 2-22 Axis Turning, 2-5 Axis Wire EDM, Multitasking Mill Turn Machining, Swiss Turn and B-Axis Machine Tools High Speed 3 and 5- Axes Machining.
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Characterization Equipment: Coordinate Measuring Machine Model: - Spectra 5.6.4. CNC Scale Regulation = 0.5 μm Machine accuracy = (± 2.5 + L/250) μm; (L: Standard length in mm) Angular accuracy = 1” (One second) Granite flatness = 2 micron per meter square Granite grade = zero grade Probing system = MS2DI M/c version = CNC version M/c working volume = X = 500 mm; Y = 600 mm; Z = 400 mm Controller name = Renishaw UCC (Universal CMM Controller) lite-2 (U.K.)
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Processing Equipment: Epilog FiberMark Fusion Size (W x D x H): 52.5" x 33.5" x 40.75" (1334 x 851 x 1035 mm) Engraving Area: 32" x 20" (812 x 508 mm) Focal Length (F-Theta Lens): 5" (127 mm) Maximum Material Thickness: 11.25" (285 mm) Laser Wattage 20, 30, or 50 watts Laser Type: Solid State Pulsed Ytterbium Fiber Laser (air cooled) Mode of Operation: Pulsed 20-80 kHZ.
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Processing Equipment: Hindustan Radial Drill Machine Specification: Make : HMT Model : RM61 Spindle Capacity : 60 mm Arm Length : 1200mm RPM : 40,56, 80, 112, 150, 220, 300, 440, 580, 850, 1160, 1700
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Characterization Equipment: Mitutoyo RA-116 Round Test Specification: • Measuring and analysis software package ROUNDPAK running under Windows operating system • Air-bearing turntable for high precision, wear-free rotation • Accepts workpieces up to ø17.32" (440mm) diameter • Turntable loading 20 kgf maximum • Measurable diameter ø11.02" (280mm) • Measuring range ±1000μm • Measuring height for outside/inside diameters: 11.02" (280mm) maximum • Measuring depth inside 3.94" (100mm) maximum (with standard stylus) • Traverse of R axis 6.5" (165mm) • Large centering range ±.12" (±3mm) • Large levelling range ±1°
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Processing Equipment: ACE MAKE FLAT BED CNC LATHE MACHINE MODEL SIMPLE TURN 5075 WITH FANUC Oi MATE –TD CONTROL Specification: Swing Over Bed: Ø500 Swing Over the cross slide: Ø220 Maximum Turning Length : 650mm Distance between Centers: 750mm Spindle speed: 0-4000rpm Spindle Motor Power: 11/7.5KW LINEAR TOOLING X Axis: 300mm Z Axis: 700mm Tailstock Quill Travel 180mm Quill Taper: MT-5
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Characterization Equipment: Surface Roughness Measuring Instrument Specification: Model SJ–301, Make: Mitutoyo Measuring range Z-axis 350 μm X-axis 12.5 mm Drive Unit Measuring: 0.25 mm/s; 0.5 mm/s Speed Returning: 1.0 mm/s Standard Probe (178-395) Measuring Method Induction method Stylus Diamond Tip: Radius 2 μm Measuring Force 0.75 mN Parameters: Ra, Rq, Rz Cut-off-Length: 0.08 mm, 0.25 mm, 0.8 mm, 2.5 mm, 8 mm Sampling Length: x 1, x 3, x 5, x L
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Processing Equipment: Mikrotools DT-110 Specification: Work Table: 440 X 320 X & Y Axis Travel: 350 X 270 Z Axis Travel : 320+300 Max weight of the work piece: 350 kg Work tank: 800 X 480mm Connected load: 2 KVA Max matching current: 20 amp. Machine Footprint: 950 X 770 X 1950 Accuracy: 0.1 μm (100nm).
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Characterization Equipment: Dino-Lite Premier USB Microscope Specification: Model: AM7013MZT4 Dino-Lite Premier Interface: USB2.0 Resolution: 5Megapixel Magnification Range: 20x-250x Sensor: Color CMOS Save Formats: Image: BMP, GIF, PNG, MNG, TIF, TGA, PCX, WBMP, JP2, JPC, JPG, PGX, RAS, PNM DinoXcope: PNG, JPEG Movie: WMV, FLV, SWF DinoXcope: MOV Polarizer and Measurement Function
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Characterization Equipment: 3-Component Dynamometer Specification: Dynamometer with handy size. Built-in charge amplifier with 4 measuring ranges switchable. Simple operation with control unit Type 5233A1. Type 9257BA External control unit for range selection and reset/operate. Signal output with 3 x BNC neg. and D-Sub 37-pin. Type: piezo-crystal Forces: Fx, Fy and Fz with four miniature Range: Fx and Fy 500N to 5KN Fz: 1KN to 10KN
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Characterization Equipment: Rotating 4-Component Dynamometer (RCD) Specification: Make: KISTLER Dynamometer Type 9123C The dynamometer consists of a four component sensor fitted under high preload between a baseplate and top plate. The four components are measured practically without displacement.
Rotating 4-component dynamometer for measuring of cutting forces and torques on the rotating tool spindle. Transmission of measured data by telemetry hence without wear. Speed 1/min max. 10 000 Range 1 FSO Fx, Fy kN –5 ... 5 –3 ... 3 Fz kN –20 ... 20 Mz Nm –200 ... 200 Range 2 FSO (switchable) Fx, Fy N –500 ... 500 Fz kN –2 ... 2 Mz Nm –20 ... 20 Sensitivity (Range 1) Fx, Fy mV/N ≈ 2 Fz mV/N ≈ 0,5 Mz mV/Nm ≈ 50 Forces: Fx, Fy, Fz and Mz
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Characterization Equipment: Column Load Cell Specification: Make: IPA Model: FC074H0 Type: Stain gauge based Capacity: 70Ton Gauge Resistance: 350 ohms nominal Exitation voltage: 10v DC Sensitivity: 1.5mV/V Safe overload: 150% of rated load. Resolution: 50Kg
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Characterization Equipment: Microbalance
Specification: Make: CITIZEN Model: CY204 Capacity x Resolution (g): 220 g x 0.0001 g Repeatability: 0.0001 g Linearity: 0.0002 g Response Time: 2 - 3 seconds Units: g, mg, ct, GN, mo, oz, dwt Platform Dimensions: 3.5" diameter Sensor Type: Electromagnetic Force Compensation
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Characterization Equipment: Proving Ring Specification: Make: HEICO Model: PR-302 Capacity: 5KN Dial Gauge: ASAHI Calibrated in: Compression
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Characterization Equipment:
Fluke Ti400 Infrared Camera
Specification: Make: FLUKE USA Model: TI-400 Temperature measurement range : -20 °C to +1200 °C Temperature measurement accuracy: ± 2 °C Image capture frequency: 9 Hz refresh rate or 60 Hz refresh rate depending upon model variation Detector type: Focal Plane Array, uncooled microbolometer, 320 x 240 pixels Thermal sensitivity (NETD): ≤ 0.05 °C at 30 °C target temp (50 mK) Total pixels: 76800 Minimum focus distance: 15cm
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Characterization Equipment:Anton Paar Physica MCR301
Specification:
Technical Data
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Unit
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MCR 302
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Bearing
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Air
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EC motor
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Yes
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Maximum torque
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mNm
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200
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Min. torque, rotation
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nNm
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1
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Min. torque, oscillation
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nNm
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0.5
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Angular deflection (set value)
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µrad
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0.05 to ∞
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Min. angular velocity
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rad/s
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10-9
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Max. angular velocity
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rad/s
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314
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Max. speed
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1/min
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3000
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Min. angular frequency
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rad/s
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10-7
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Max. angular frequency
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rad/s
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628
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Normal force range
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N
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0.005-50
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Normal force resolution
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mN
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0.5
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Max. temperature range
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°C
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-150 to +1000
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Characterization Equipment:
Nikon eclipse LV100 Industrial Microscope Specification: Model name: ECLIPSE LV100D Magnification: 5x0.15, 10x0.30, 20x0.45, 50x0.80, 100x0.90 (LO plan fluor) Optical system: CFI60 optical system Illumination: Lamp ratings: 12 VDC, 50 W halogen lamp Specified lamp: LV-HL50W 12V 50W halogen lamp Specified lamp house: LV-LH50PC Focusing mechanism: Stroke: 30 mm Coarse focus knob: 14 mm/revolution Fine focus knob: 0.1 mm/revolution Eyepiece: 10x, field number: 22, 25 Operating environment: Temp: 0°C to +40°C Relative humidity: 85% RH max. Altitude: 2000 m max. Pollution degree: Degree 2 |
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Relevant Information (if any): Faculty: Dr. J. Ramkumar (Lab Coordinator) Staff: Mr. Sanjeev Kumar Verma, Mr. Atul Kumar Gangwar Contact Person: Mr. Sanjeev Kumar Verma Location: NL-1-115A Manufacturing Science Lab., ME, IIT Kanpur Phone: 0512-259-7923 Email:
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