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Assignment 1 - EPP201

The document discusses sustainable manufacturing techniques for camshafts. It describes the camshaft manufacturing process and recommends several ways to improve sustainability, such as optimizing tool rake angle to reduce energy use, selecting appropriate tool materials to increase tool life, using minimum quantity lubrication or cryogenic machining to reduce environmental impacts of cutting fluids, recycling chips and cutting tools, and controlling feed rate to enhance productivity while maintaining surface finish quality. The recommendations are supported by references to manufacturing engineering textbooks.

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71 views5 pages

Assignment 1 - EPP201

The document discusses sustainable manufacturing techniques for camshafts. It describes the camshaft manufacturing process and recommends several ways to improve sustainability, such as optimizing tool rake angle to reduce energy use, selecting appropriate tool materials to increase tool life, using minimum quantity lubrication or cryogenic machining to reduce environmental impacts of cutting fluids, recycling chips and cutting tools, and controlling feed rate to enhance productivity while maintaining surface finish quality. The recommendations are supported by references to manufacturing engineering textbooks.

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shahanmhd51
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SEMESTER I – 2020/2021

SCHOOL OF AEROSPACE ENGINEERING

ASSIGNMENT - 1

EPP 201 - MANUFACTURING TECHNOLOGY I

Prepared by Muhammed Shahan Poomadath

Matric Number - 149616

Prepare for Dr. Sareh Aiman

Date: 27 October 2020


A camshaft is a shaft with one or more cams attached to it and a cam is a projection on a rotating part in
machinery, designed to make sliding contact with another part while rotating and to impart reciprocal or
variable motion to it. Cams are used to convert rotary motion into reciprocating motion. The working of valves
in an internal combustion engine is controlled by the camshaft. Due to this reason, the camshaft is also
referred to as the “brain” of the engine.

Currently, Chilled cast iron is primarily used to produce camshaft but in several of the competition engines
such as F1 engines, Nitriding steel is used.

The camshaft can be manufactured through casting or forging


where only final machining is required to achieve final size within
the required tolerance. It can also be made entirely through
removing excess material from metal billet which entirely
depends on machining.
A detailed description of the processes for mass manufacturing is Figure 1: Turning
as follows:
1. TURNING & DRILLING: The raw forging is put in this machine
and center drilling and turning on one side is done here.
2. TURNING: Here the turning of the 6 journals takes place. There
are 4 tools used for this turning – Rough, Neutral, Left, and
Right tool. Also, Grooving and Parting operation is performed
on the left side of the shaft.
3. DRILLING: This machine drills the diameter 4.5 dowel hole
which is used as a reference for further operations.
4. GRINDING JOURNALS: Here grinding and finish grinding of the 6 Figure 2: Straightening
journals takes place. Carborundum wheels are used for
grinding.
5. GRINDING ON FACE: An angular grinding wheel is used for the
face grinding operation. At this stage, inspection is done after
every 10 components using gauges.
6. DRILL DOVEL HOLE: Grinding of the Cam is done here. The
dowel hole is taken as the reference.
7. LAPPING: To give super finish in microns, lapping is done
using lapping paper on the Cams and the Oil seal area.
8. SLITTING: A slit is made in the right side of the shaft to fit in
the engine. The cutter used is a Saw cutter and pneumatic
deburring is done here.
9. AIR & WATER CLEANING: Washing Machine is used where
water and air jets are used to clean the component of dust,
oil, chips, etc. Figure 3: Grinding
10. INSPECTION: Measuring Machine is used to check for
tolerances - Runouts and Diameters of journals. The machine then declares the component as OK, NG,
or BAD

1. Maintaining energy efficiency is an absolute must to conserve energy and thereby ensure an overall
sustainable process. One way for attaining this is to take an optimal rake angle while cutting process because ;
(a) as the rake angle decreases or the friction at the tool-chip interface (rake face) increases, the shear angle
decreases and the chip becomes thicker[1]; (b) thicker chips mean more energy dissipation because the shear
strain is higher[2] and (c) because work done during cutting is converted into heat, the temperature rise is also
higher which may also lead to tool wear[3].
2. Tool life or sustainable use of the tool can be ensured by opting for a cutting speed which is neither too
slow nor too fast to maintain a positive value for the exponent ‘n’ on which tool life depends [4].
3. Even when taking an optimal cutting speed, the highest possible speed should be considered to ensure that
majority of the heat produced is taken away by the chip which reduces machining time and temperature rise
in the cutting tool[5].
4. Selecting the appropriate tool material also affects the energy consumption and cutting tool life. In the case
of the camshaft in which chilled cast iron is mostly used as a material, a ceramic-based cutting tool would be
the best since it can be operated at the higher cutting speed[6] and temperature[7]. Selecting coated ceramic
tools to overcome some of the shortcomings of normal ceramics would also help to reduce the required
machining time[8]. Recycling or reusing of the machining tool can be achieved through reconditioning them.
Cutting tools can be reconditioned by resharpening them, using tool and cutter grinders with special fixtures.
Reconditioning of coated tools can also be done by recoating them, usually in special facilities for these
purposes.

5. Use of cutting fluids pose a severe concern due to their severe environment detrimental effects. Other than
this, they also reduce the air quality in machining plants and pose a health hazard for the machine operator.
To alleviate this problem, the practices of near-dry machining (NDM) or minimum quantity lubrication (MQL)
should be followed. Subsequently, cutting fluids could also be replaced using cryogenic gases such as nitrogen
or carbon dioxide used as a coolant. With small-diameter nozzles and at a temperature of -200°C, liquid
nitrogen is injected into the cutting zone. Because of the reduction in temperature, tool hardness is
maintained, and tool life is enhanced, thus allowing higher cutting speeds. Furthermore, the nitrogen simply
evaporates and therefore has no adverse environmental impact[9]. Recycling cutting fluid is also a viable option
that considers an eco-friendly approach in machining.

6. Machining time directly affects power consumption and in some ways, the tool life mainly depends on feed
rate and cutting speed. A higher feed rate indicates a higher material removal rate (MRR) as MRR is directly
proportional to the feed rate[10]. So, productivity can be enhanced by using a higher feed rate thereby
reducing the required machining time. However, increasing the feed rate should be controlled to not affect
the surface finish. In conclusion, the highest possible feed which ensures efficient machining should be
selected[11].
7. Production of chips during machining can be considered as a waste of useful resources and as an
environmental hazard that needs to be disposed of. Recycling the chips produced by collecting them
effectively to produce new useful items or even a new workpiece by the method of chemical and physical
treatment can be considered to develop an overall green/sustainable machining process.
Note: All the below mentioned references are from “Manufacturing Engineering and
Technology;6th Edition; Serope Kalpakjian, Stephen Schmid”
[1]: Refer equation 21.3, section 21.2, chapter 21, Fundamentals of Machining.
[2]: Refer equation 21.2, section 21.2, chapter 21, Fundamentals of Machining.
[3]: Refer table 21.1, section 21.2, chapter 21, Fundamentals of Machining.
[4]: Refer figure 21.17, section 21.5, chapter 21, Fundamentals of Machining.
[5]: Refer figure 21.14, section 21.4, chapter 21, Fundamentals of Machining.
[6]: Refer figure 21.17, section 21.5, chapter 21, Fundamentals of Machining.
[7]: Refer figure 22.1, section 22.1, chapter 22, Cutting-tool Materials, and Cutting Fluids.
[8]: Refer figure 22.6, section 22.5, chapter 22, Cutting-tool Materials, and Cutting Fluids.
[9]: Refer section 22.12.1, chapter 22, Cutting-tool Materials, and Cutting Fluids.
[10]: Refer equation 23.1b, section 23.2, chapter 23, Machining Processes: Turning and Hole
Making.
[11]: Refer table 23.4, section 23.2, chapter 23, Machining Processes: Turning and Hole
Making.

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