3D Printing

3 D Printing

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Pitot Tube

A pitot tube is a small transparent open tube bent at right angle. The basic purpose is to measure the flow i.e. Velocity of the fluid. The point where the velocity of the fluid is zero is known as stagnation point. The pressure at that point is known as stagnation pressure.

p + 1/2 ρ v² + γ h = constant along a streamline         (1)

where

p = static pressure (relative to the moving fluid) (Pa)

ρ = density (kg/m³)

v = flow velocity (m/s)

γ = ρ g =  specific weight (N/m³)

g = acceleration of gravity (m/s²)

h = elevation height (m)

Each term of this equation has the dimension force per unit area - N/m² or in imperial units psi, lb/ft².

If pitot tube is used in a close conduit, then pressure can be measured with the help of piezometer.

Equation for ideal velocity is

V_o= (2gh)^½

^{For local velocity the equation becomes}

V_o= C(2gh)^½

Where C is pitot tube co efficient  which is less than unity.

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Duties of Lubrication Personnel

 Following are duties of Lubrication Personnel

1. Use correct lubricants in every case and as few types as possible for the plant as a whole.
2. Apply lubricants properly.
3. Apply the correct amount of lubricant.
4. Apply lubricants at proper intervals.
5. Develop schedules for items 1 to 4 for each machine, distribute or post them, and see that they are followed.
6. Train and instruct the oilers, and arrange for lubrication clinics if the number of oilers warrants. Suppliers’ sales and engineering representatives frequently can render valuable assistance in the preparation and execution of such programs.
7. Install and use lubricating devices correctly.
8. Keep lubricants clean by keeping the oil room clean and keeping lubricant containers covered.
9. Dispense lubricants through clean, properly identified equipment.
10. Practice preventive maintenance.
11. Cooperate with the maintenance and production departments on lubrication problems.
12. Collect used oils for purification for resale or reclamation if quantity warrants.
13. Keep complete consumption records.
14. Record and analyze all lubrication connected failures and breakdowns.
15. Eliminate all accident hazards connected with lubrication.
16. Keep abreast of new developments and practices in the lubricating field by periodic consultation with a qualified lubrication engineer—staff, consultant, or supplier’s representative.
17. Minimize the total cost of lubrication, remembering that the price of an improper lubricant is a small fraction of its final cost in terms of poor service.

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Planning Outages

Most companies, as part of their annual business plan, develop an outage schedule that is based on anticipated business cycle or perceived maintenance requirements. This outage schedule contains all shutdown dates for critical production systems. Unfortunately, most of these plans do not consider the impact on capacity. An effective outage schedule should be configured to minimize loss of production capacity, product quality and the potential increase in overall operating cost that can result from poorly coordinated outage schedules. Care should be taken to assure minimal, negative impact from this schedule.

Effective shutdown management depends on absolute adherence to prescribed standards that define what type of work will be done during scheduled shutdowns. These decisions cannot be made by the maintenance planner alone. To aid in the selection, planning and implementation of outage tasks, a management team is a fundamental requirement. This team should be composed of:

·          Maintenance manager(s)

·          Maintenance planner(s)

·          Production manager(s)

·          Production planner(s)

·          Operations supervisors

·          Engineering liaison

·          Contract liaison (if needed)

·          Material/storeroom representative

·          Purchasing representative.

When the nucleus of the project team is assembled, its first order of business is to clarify the project and arrive at agreement among team members about the project’s definition and scope, as well as the basic strategy for carrying it out. An orderly process can guide you through these steps. The following sequence of activities will get your project smoothly under way:

1. It is critical for the team to spend adequate time at the beginning to study, discuss, and analyze the project.

This establishes a clear understanding of what you are dealing with. It may be necessary to research how similar projects structured their approach, or what other patterns of experience can contribute to project planning.

The purpose of this activity is to be sure you are addressing the right problem or pursuing the real opportunity.

2. When you are confident that you have a firm grasp of the situation, work up a preliminary project definition.

This preliminary definition will be subject to revision as additional information and experience is acquired.

3. Now, using this project definition, state the end-results objective of the project.

4. Then, list both the imperatives and desirables to be present in the results. That is, list the outcomes that must be present for the project to be considered successful, and list the outcomes that are not essential but that would add to the project’s success.

5. Now you are ready to generate alternative strategies that might lead you to your objective. To generate these alternatives, try brainstorming with your project team.

6. Next, evaluate the alternative strategies you have generated. Be sure that your criteria for evaluation are realistic and reflect the end results objective.

7. Evaluation allows you to choose a course of action that will meet both your project definition and end-results objective.

Effective outage planning and management is dependent on well-defined objectives. Everyone, beginning with the planner, must have a universal understanding of the specific objectives that are to be achieved during the outage.

The fundamental requirements of good objectives include:

Specific: A good objective says exactly what you want to accomplish. The definition must be both clear and concise.

Measurable:  Being specific helps make your objective measurable.

Action-oriented: When writing objectives, use statements that have action-tense verbs and are complete sentences

Realistic:  Good objectives must be attainable yet should present a challenge.

Time-limited: Set a specific time by which to achieve the objective.

Outage planning

Effective planning is the next step in the outage management process. Like all other maintenance activities, each task included in the outage plan must be fully planned. However, the finite time frame associated with a fixed duration shutdown also requires effective scheduling to assure success.

Brainstorming

Brainstorming is a free-form process that taps into the creative potential of a group through association of ideas. Association works as a two-way current: when a group member voices an idea, this stimulates ideas from others, which in turn leads to more ideas from the one who initiated the idea.

Brainstorming procedures

·         List all ideas offered by group members.

·         Do not evaluate or judge ideas at this time.

·         Do not discuss ideas at this time except to clarify under-standing.

·         Welcome ‘blue sky’ ideas. It’s easier to eliminate ideas later.

·         Repetition is okay. Don’t waste time sorting out duplication.

·         Encourage quantity. The more ideas you generate, the greater your chance of finding a useful one.

·         Don’t be too anxious to close the process. When a plateau is reached, let things rest and then start again.

The management team will participate in the following activities:

Initial shutdown meeting

Ninety days prior to beginning shutdown, the shutdown management team should meet to determine the boundary conditions for the upcoming outage. These initial decisions will provide the basic knowledge required to begin the planning process. The outcome of this initial meeting should:

Select shutdown tasks

 Careful evaluation of work requests is essential for effective shutdown performance.

All requested tasks should not be automatically included in the outage plan. Each request must be evaluated to determine its real strategic value and real value added.

Question past shutdown practices. Each of the tasks or projects requested for the outage should be evaluated to determine whether or not it should be included in the outage.

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How Pistons are Made

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Fused Deposition Modelling

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Different Types of Welding

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Planning Outages

Most companies, as part of their annual business plan, develop an outage schedule that is based on anticipated business cycle or perceived maintenance requirements. This outage schedule contains all shut down dates for critical production systems. Unfortunately, most of these plans do not consider the impact on capacity. An effective outage schedule should be configured to minimise loss of production capacity, product quality and the potential increase in overall operating cost that can result from poorly coordinated outage schedules. Care should be taken to assure minimal, negative impact from this schedule.

Effective shut down management depends on absolute adherence to prescribed standards that define what type of work will be done during scheduled shutdowns. These decisions cannot be made by the maintenance planner alone. To aid in the selection, planning and implementation of outage tasks, a management team is a fundamental requirement. This team should be composed of:

·          Maintenance manager(s)

·          Maintenance planner(s)

·          Production manager(s)

·          Production planner(s)

·          Operations supervisors

·          Engineering liaison

·          Contract liaison (if needed)

·          Material/storeroom representative

·          Purchasing representative.

When the nucleus of the project team is assembled, its first order of business is to clarify the project and arrive at agreement among team members about the project’s definition and scope, as well as the basic strategy for carrying it out. An orderly process can guide you through these steps. The following sequence of activities will get your project smoothly under way:

1. It is critical for the team to spend adequate time at the beginning to study, discuss, and analyse the project.

This establishes a clear understanding of what you are dealing with. It may be necessary to research how similar projects structured their approach, or what other patterns of experience can contribute to project planning.

The purpose of this activity is to be sure you are addressing the right problem or pursuing the real opportunity.

2. When you are confident that you have a firm grasp of the situation, work up a preliminary project definition.

This preliminary definition will be subject to revision as additional information and experience is acquired.

3. Now, using this project definition, state the end-results objective of the project.

4. Then, list both the imperatives and desirables to be present in the results. That is, list the outcomes that must be present for the project to be considered successful, and list the outcomes that are not essential but that would add to the project’s success.

5. Now you are ready to generate alternative strategies that might lead you to your objective. To generate these alternatives, try brainstorming with your project team.

6. Next, evaluate the alternative strategies you have generated. Be sure that your criteria for evaluation are realistic and reflect the end results objective.

7. Evaluation allows you to choose a course of action that will meet both your project definition and end-results objective.

Effective outage planning and management is dependent on well-defined objectives. Everyone, beginning with the planner, must have a universal understanding of the specific objectives that are to be achieved during the outage.

The fundamental requirements of good objectives include:

Specific: A good objective says exactly what you want to accomplish. The definition must be both clear and concise.

Measurable:  Being specific helps make your objective measurable.

Action-oriented: When writing objectives, use statements that have action-tense verbs and are complete sentences

Realistic:  Good objectives must be attainable yet should present a challenge.

Time-limited: Set a specific time by which to achieve the objective.

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Solution Manual of Modern Manufacturing by Groover

Solution Manual : of Fundamentals of Modern Manufacturing by Groover

Click on the link below for manufacturing solution manual

http://www.4shared.com/office/xMss4XtCce/Manufacturing_Solution_manual.html

 

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Applied Thermodynamics By McConkey

Applied Thermodynamics  By McConkey

140828329-Applied-Thermodynamics-and-Engineering-by-T-D-Eastop-and-a-McConkey.pdf

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Pro Engineer Installation Steps

For Pro E installation follow the following steps

1.  Start pro/e setup
2.  Open license.dat with any  txt-editor and replace every occurance of 00-00-00-00-00-00 with your computer real HOST_D (same one shown in the bottom left corner of the Pro/e setup). Save the license.dat
3. Save that edited license.dat file , don't replace, remove or delete that file.
4.   Install proe - proe_mech -ptc_distributed_services (optional). On license-config screen select "nodelocked license" and point to edited license.dat

Next  apply a patches (if u didn't install the complete package, you will get "File not found" errors, accept or bleed)

• For pro/engineer:

Copy "proe_WF5_Win64_crk.exe" to folder <proeWildfire 5.0 progdir>\x86e_win64\obj and click "Next > OK > Next > OK > Next > OK > Next > OK > Finish > OK"

• For pro/mechanica

Copy "proe_mech_WF5_Win64_#1_crk.exe" to folder <proeWildfire 5.0 progdir>\x86e_win64\obj and click "Next > OK > Next > OK > Next > OK > Next > OK > Finish > OK"
Copy "proe_mech_WF5_Win64_#2_crk.exe" to folder <proe mech WF5 progdir>\x86e_win64\ptc and click "Start > OK"

• For ptc distributed services

Copy "ptc_distributed_services_WF5_Win64_crk.exe" to folder <ptc_distributed_services WF5 Win64 progdir>\x86e_win64\obj and click "Next > OK > Finish > OK"

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Universal Testing Machine (UTM)

A universal testing machine is used to test the tensile stress and compressive stress of materials. It is named after the fact that it can perform many standard tensile and compression tests on materials, components, and structures. It has the following units

1.        Loading unit:

           In this unit the specimen is clamped and the desired load is applied. It consist of the following components:

•         Table
•         Table cover
•         Column
•         Screw drive
•         Upper and lower cross head
•         Upper and lower jaws
•      Upper and lower clamping handles

   2.      Control unit:

             This unit controls the motion of the jaws and application of load. It consist of the following components:

·        Automatic control

·        Manual control (hydraulic pump control, jaws up & down motion)

·        Dial gauge (load range selector,zero adjustment, span for calibration)

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Yield and Ultimate strength

Definition of Yield strength:

            The yield strength or yield point of a material is defined as the stress at which a material begins to deform plastically. Prior to the yield point the material will deform elastically and will return to its original shape when the applied load is removed.

Importance:

Knowledge of yield point is vital when designing a component since it generally represents an upper limit of the load that can be applied.

Formula :

              Yield strength= yield load/area

Definition of Ultimate strength:

            Ultimate strength is the maximum stress that a material can withstand without failure or rapture. It is given by:

                               Ultimate strength = ultimate load/Area

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FIVE BASIC ELEMENTS OF MPI

SOURCE:-

Source produces the probing medium or investigating medium. In this MPI test the current is the source element.

MODIFICATION:

            The ability to change or vary the magnetic field if there is any crack or discontinuity in the specimen. Here in the MPI test the current is the modifying element.

DETECTION:   

  The material which detect that how much change occur in the magnetic field around the specimen. Here the iron magnetic particle is the detective element.

INDICATION:-

            The element which indicate the position of the crack in the specimen. The magnetic field pattern or signals is the indicating element.

INTERPRETATION:-

            The observer which sees the signals or pattern of magnetic field which give the results of the test is called interpreter.

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Magnetic Particle Testing Inspection

Magnetic particle testing is accomplished by inducing a magnetic field in a ferromagnetic material and then dusting the surface with iron particles. The surface will produce magnetic poles and distort the magnetic field in such a way that the iron particles are attracted and concentrated making defects on the surface of the material visible.

How to perform the test:

First put the specimen into the A.C current carrying coil and then take the specimen into the beaker. And pour some kerosene oil into the beaker and put some iron powder in it. The magnetic field produce by A.C current around the specimen. If there is any crack present in the specimen then there will be greater concentration of iron particle s around the crack or defect present in the specimen. If there is no crack then the iron particles will arrange themselves throughout the specimen.

TYPES:-

            There are two types of magnetic particle inspection test.

•  CONTINUOUS:- wet method.
•   RESIDUAL:- dry method. 

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Non Destructive Test

Nondestructive testing (NDT) use test methods to examine an object, material or system without impairing its future usefulness. Non-destructive testing is often required to verify the quality of a product or a system. Various types of commonly performed NDT are

1.       Eddy Currents inspection

2.       Magnetic Particle Inspection (MPI or MT)

3.       Radiography

4.       Ultrasonics

5.       X-ray Technique

6.       Penetrant Test

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Evaporator ( In a refrigeration System)

Function of evaporator:

·         In a refrigeration system, an evaporator is a device which enables a volatile liquid to vaporize for the purpose of removing heat from a refrigerated space or product.

·         It is one of the main components in a refrigeration system.

·         A refrigerant before entering the evaporator is usually a mixture of liquid and vapor due to its expansion through the expansion valve, and enter the evaporator at low temperature and pressure.

·         The liquid refrigerant vaporizes inside the evaporator to absorb heat from the object to be cooled.

·         In many cases the vapor in a superheated state is sucked into the compressor to prevent the liquid slugging.

Main Types of Evaporator:

•            Bare tube coil evaporator
•            Plate surface evaporator
•            Finned tube type evaporator

 Bare tube coil evaporator:

·         Bare tube refers the tube whose inner and outer surfaces are both smooth.

·         Bare-tube evaporators are also called prime-surface evaporators.

·         Bare-tube coils are available in a number of sizes, shapes and designs

·         Spiral bare-tube coils are often employed for liquid chilling.

·         Large ceiling-hung bare-pipe coils employing natural convection air circulation are sometimes used in frozen storage rooms and in storage coolers where the circulation of large quantities of low velocity air is desirable.

·         They are also used as either “dry” or “spray coils,” in conjunction with centrifugal blowers to provide high-velocity chilled air for blast-cooling or freezing operations.

·         The bare-tube evaporator is generally operated dry-expansion.

Bare tube coil evaporator

 

 Plate surface evaporator:

·         There are several types of plate-surface evaporators.

·         Some are construction of two flat sheets as metal so embossed and welded together as to provide a path for refrigerant flow between them.

·         This type of plate-surface evaporators has the advantages of easy cleaning and low cost in manufacturing.

·         It can be readily formed into the various shapes required to serve as structural components, for example, the walls of a household refrigerator or reach-in cooler, when it is constructed in a boxlike shape.

·         The plate construction offers some secondary heat transfer surface, but is also useful for cooling flat packaged products that contact the surface.

Plate surface evaporator

 

 Finned tube type evaporator:

·         As the name suggested, finned tube evaporators have the fins installed on the bare tube to enhance the heat transfer from the air to the refrigerant in the tube.

·         The fins here act as a secondary heat exchange surface to improve the evaporator efficiency from increasing overall evaporator surface area.

·         Finned evaporators are used extensively in residential and commercial refrigeration and air conditioning applications.

·         In order for them to be effective, there must be good thermal contact between the evaporator fins and the tubing surface.

·         This can be accomplished by several ways.

·         One method is to solder the fin directly to the tubing.

·         Another method is to slip the fin over the tubing and expand the tubing by pressure or some such means so that the fin locks onto the tubing surface.

·         A variation of the latter method is to flare the fin hole slightly to allow the fin to slip over the tube.

·         After the fin is installed, the flare is straightened and the fin is securely locked to the tube.

Finned tube type evaporator

 

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