Questions tagged [manufacturing-engineering]

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Spinning a balanced load with DC motor

Enclosed within a consumer electronic, I would like to spin a small balanced load. The device will be rotated relative to gravity, but no other direct forces will be applied to the load. A coreless ...
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2 answers
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Part to "increase" the diameter of a small shaft, what is is called?

In my lab we have dressing tools for sharpening grinding wheels. The tools are diamonds mounted on a steel shank and the shank fits into a custom holder with a set screw in our machine (pictured). ...
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2 votes
3 answers
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How to manufacture parts with complex air channels inside?

I am designing a part that requires multiple air channels with an intricate structure inside. I would like to know if there is any state of the art injection molding technique or other technology that ...
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3 votes
3 answers
2k views

Work hardening?

Can some please explain why is the elastic modulus of aluminium and work hardened aluminium the same? Is it only the same for pure metals?
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General purpose automated assembly?

I've been using 3d printers for prototyping for a long time, and I'll admit it's incredibly convenient to be able to throw together a CAD model, send it to the printer, and have it ready to assemble ...
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3 votes
2 answers
1k views

Definition of the "specific material removal rate"?

I've run across a term in some grinding manufacturing research papers called the specific material removal rate. The units given for this term are [mm$^3$/mm$\cdot$s] (I don't really like this style ...
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4 votes
1 answer
60 views

Can graphene really be made in a modest lab at home?

I have seen some resources on the Internet that claim to be able to make sheets of graphene (single atom thick lattice of hex-bonding carbon) from commercial off the shelf materials and a modest lab ...
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1 vote
1 answer
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What manufacturing process is suited for production of the elastomer strip?

What manufacturing process should be adopted to manufacture a LEGO® compatible strip made by material which is rubber like?
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-1 votes
1 answer
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What is the real CO2 emission for cars? 1g/km or >100g/km?

If one searches for the different levels of CO2 emissions in cars, one can find two very different levels. For instance: 1: Here it is written that: The law requires that the new cars registered ...
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Tool fixture and holding

How do I hold a end milling tool in a rod which is smaller than the tool(smaller efers to the diameter of the rod).
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4 votes
3 answers
589 views

How to select the correct grinding wheel type for precision grinding of tool steels?

I am planning to move from conventional grinding wheels to super-abrasive grinding wheels. I am unable to decide the right type of super-abrasive wheel for my manufacturing operations (I am into knife ...
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2 votes
1 answer
330 views

Artificial Intelligence in manufacturing machines

I am a researcher on robotics and AI, and wonder if traditional manufacturing machines, such as lathe, CNC, or grind use any kind of machine learning technique or algorithm. This algos are widely used ...
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2 votes
2 answers
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Plastic Injection Moulding a Piece with Undercuts

I am a newcomer to Plastic Injection Molding and would really appreciate some advice. I have a prototype object that will be made from a type of polypropylene. I only need a maximum of 10 units ...
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Torque limiting application

I have an application in which speed of the shaft is 0.54 rpm. The input speed of the motor (induction 4 pole AC motor) is 1400 rpm. So the gear reduction is enormous. I had two helical ...
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2 answers
58 views

What type of shop could make an isetta body?

I am curious how car bodies were made back in the 1950s. Specifically the micro-car bodies like the Isetta. What techniques and tools were used back then? They seem fairly simple. Could a body for an ...
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1 answer
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Hand-pressed metal stamping - fishing spinner blades [closed]

I want to stamp my own fishing spinner blades. They look like this: http://lurepartsonline.com/Online-Store/Colorado-Blades/Premium-Finish-Colorado-Blades.html Specs are usually 1mm thick, 3x2" ...
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3 votes
2 answers
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How to attach lycra / leather to Polyurethane foam?

What would be the best solution for attaching polyurethane foam to a lycra sheet of material. I was thinking a chain or pad stitch or possibly glue, but not sure if sewing would be the best ...
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2 votes
1 answer
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Multicolor dip-painting techniques

I once saw on TV a factory dipping a product into a tank of paint and it magically emerged with a crisp pattern. (It was an Archery bow, and the pattern was army-style camouflage). Was I deceived or ...
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7 votes
2 answers
715 views

Line balancing - How far do companies go? [closed]

I understand that the concept of line balancing is such that each station takes exactly the same amount of time to process one unit. Clearly, this is an idealization and real manufacturing plants will ...
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6 votes
3 answers
1k views

How to manufacture cutting dies for metal foil?

I am making a die for cutting arbitrary shapes from thin (0.1–0.5 mm) copper foil/sheet using a manual arbour press. The product will be an oak leaf shape, approximately life-size, for use as part of ...
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4 votes
1 answer
863 views

How do I cut a crack into a polymer/plastic?

We need to cut a very thin crack into a polymer plate for a research project. The closest thing to what we are looking for is Wire EDM but since the polymer we are using is not conductive we cant use ...
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4 votes
1 answer
121 views

Why can't red flint glass be produced?

I recently went on a tour of a glass manufacturing facility who produce bottles for the prestige alcohol market. I was informed on the tour that red glass cannot be directly produced - any bottles ...
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5 votes
2 answers
2k views

What are 'inside' and 'outside' dimensions in reference to castings?

I am looking at a company-written standard for cast parts. The castings are blanks for driveshaft yokes, similar to what is pictured below. The standard defines general tolerances for the dimensions ...
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9 votes
2 answers
173 views

Material selection for weight scale

I am looking to test the FlexiForce sensor in measure force, however for accurate readings the load needs to be disturbed evenly over the sensing area. As such I am having "discs" made to cover the ...
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4 votes
1 answer
520 views

What is the accuracy of direct metal laser sintering (DMLS)?

They've printed jet engines with it that work after polishing. So how is the accuracy measured and how accurate is the DMLS process? I can't find the required info anywhere.
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4 votes
1 answer
660 views

Bend allowances when making a C-shape plate

I am trying to find the formulas for making bends in sheet metal. I understand there are formulas for bend allowances. My issue is how do I determine where to bend if I want the inside dimension to be ...
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1 answer
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Is it feasible to forge multiple, smaller parts in the same forging operation?

Let us assume you have a large forging press or drophammer, and drawings for a set of smaller parts that all need to be forged from the same material. Would it be feasible to construct a forging die ...
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0 votes
1 answer
69 views

Identification of Foundry equipment

Good day! We (undergraduates w/o prior foundry experience) inspected a foundry for its health hazards, our problem is we are not permitted to be accompanied by a laboratory assistant, so we don't have ...
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7 votes
1 answer
67 views

What is a method to detect thermal oxide layer after steel is painted?

Is there a method to test for thermal oxide on a painted steel part after the paint has cured? I'd rather the method be nondestructive but it only being destructive in the presence of thermal oxide ...
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5 votes
1 answer
166 views

Limits of Injection Molding Regarding Overhung Edges

I'm looking to redesign a seal my company currently uses. The original task was to re-source it from a lower cost supplier with the same design as is in current production. However, the supplier doesn'...
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7 votes
1 answer
614 views

How do the dimensions of a ductile iron casting change as it cools?

I am designing a pattern for a sand casting. It has only one critical dimension which is a 4" inner diameter cylinder. If I use a 4" core, will the casting shrink away from the core? In other words ...
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4 votes
3 answers
6k views

How were gears manufactured before power tools, CNC, etc

Current gear manufacturing methods for gears usually depend on power tools, or computerised machines, or something like that. However, watchmakers and clockmakers at one point in history needed to ...
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4 votes
0 answers
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Pretreatment for galvanizing primer

I currently need to paint a steel structure with galvanizing primer. The primer is an epoxy with >90% Zinc content. The TDS for the primer states that intimate contact with the substrate is needed ...
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11 votes
3 answers
467 views

Why are mass-produced metal parts machined by rotating the part against a stationary tool?

There's a TV programme called "How It's Made" which often shows automation of mass-produced machined parts. Very often, it seems that metal parts are machined (especially drilled) by rotating the part ...
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4 answers
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Designing electronic enclosures for manufacturing

I am trying to design a simple plastic electronic enclosure for a PCB and I wanted to learn how to get the enclosure as ready as possible for manufacturing. I basically wanted to understand the ...
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4 votes
2 answers
195 views

Understanding redundant pharmaceutical packaging

I ran across an interesting combination of packaging for some medicine the other day. The medicine in question was a prescription migraine medication. The exterior, cardboard package that it came in ...
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3 votes
1 answer
2k views

How to design electronics to mitigate tin whiskers?

Tin Whiskers are a major problem in the design of electronic circuits and the manufacturing of electronic hardware. What are Tin Whiskers? How can electronic products be design to mitigate the issue ...
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13 votes
3 answers
5k views

Measuring longer distances with high accuracy

I am involved right now in the fabrication of steel structures on the order of 5-50 feet long. Presently, we measure these structures with garden variety commercial tape measures. Most of the time, we ...
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3 votes
2 answers
14k views

How do I manufacture a fillet?

What are the most popular and the most efficient ways to machine a fillet on an external edge of an object? If I were to use a CNC mill, what tools can I use for it, and how would the method change ...
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6 votes
3 answers
268 views

How can the vendor be approved/disapproved based on validation test data?

The power requirement for a sub system is 5V +/- 10% @ 1A of current. A RFQ was issued and a prospect vendor was selected. A first article of inspection (FAIR) has been submitted which includes 15 ...
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