Design and modification of bale cutting machine to improve its productivityeSAT Journals
Abstract The aim of this paper is to present the results of the successful implementation of the redesigned bale cutting machine in Falcon tyre manufacturing company. Modification of hydraulic bale cutting machine is carried out to increase the productivity of the machine, to reduce the time and stress on the workers. The system is consisting of modified shear blade, suitable blade holder, hydraulic system according to new tonnage capacity and conveyor system. Unigraphics is used to model the blade and blade holder, meshing and analysis is carried out by using hypermesh and nastran. The parts are manufactured accordingly to new design parameters, and the following are installed and the performance characteristics to be determined are time, cost and productivity for this new modified design relative to the old system. It is established from the test results taken for a period of three months, that there is reduction in the time and cost of 70-80%, and 50-60% which in directly increased the productivity of machine and making the process economical. Keywords: shear blade, blade holder, hydraulic system, conveyor system
The training report summarizes several training sessions provided by different trainers on topics related to sales, marketing, manufacturing processes, and materials. Key points from stamping training included discussing manual versus progressive dies and factors that influence machine selection. Material training covered calculating material weight and supplier selection criteria. Plating training introduced the plating line processes and pre/post treatment steps. The document also included lists of common materials and local suppliers.
This project aimed to reduce consumable costs at a department over 2 months. The team listed all consumables, recorded their monthly usage and costs, and tabulated this data. They found that the top 3 consumables - Spark Spray, Windowlene, and Silicone Spray - accounted for over 80% of total costs. Alternative cheaper products were identified and implemented, resulting in projected monthly savings of 65.8% for Spark Spray, 87.9% for Windowlene, and 71.4% for Silicone Spray.
The company lost facilities and equipment due to a tsunami, so cost reduction is needed to increase capacity. The summary recommends:
1) Introducing a website and social media to provide reliable data about product safety and better customer service, while canceling unmeasurable TV commercials.
2) Eliminating $129,520 per year in costs by canceling international calls ($12,900), reducing business trips ($46,620), and the TV commercial ($70,000).
3) Improving the seven factors of service quality to reduce long-term customer service costs.
The document summarizes a student project to redesign an inspection table at a tyre manufacturing plant from a pneumatic to a hydraulic system. It outlines the objectives to overcome operator fatigue issues and increase efficiency. It describes the existing pneumatic system problems like air leaks and noise. The proposed hydraulic system design is presented along with CAD drawings. A cost analysis shows the hydraulic system would have lower lifetime costs despite a higher initial price. Performance analysis indicates the hydraulic system allows workers to inspect more tyres per hour.
Drilling experiment
Abstract
The drilling experiment was conducted on aluminum specimen to open two holes for other parts to be connected in and welded on. The machines that were used in the experiment are the table saw, surface grinding machine and drilling machine.
Introduction
Drilling is one of the most important cutting procedures. The specimen is gripped in the desired position and the tool rotates. First a 1.15” of needed to be cut from the longer specimen. After the top and bottom of the specimen needed to be fattened using the surface grinding machine. Two holes were needed to be drilled one on the top and another or the side of the specimen. The holes must have 0.3” diameter and 0.5” depth, to be able to fit in the parts that were machined with the lathe.
Procedure
1. 1.15” was cut out of a long peace with a table saw (Figure 1).
2. The surfaces of the specimen was flatten using the surface grinding machine (Figure 2).
3. Using a 0.3” drill two 0.3” holes were drilled on the top and on the side of the specimen with 0.5” depth (Figure 3).
5. Assuring that the previous parts fit into the holes (Figure 4).
Pictures
Figrue 1 (Table saw)
Figure 2 (surface grinding machine)
Figure 3 (drilling machine)
Figure 4 (final results)
Lab report of 3D Printer “MakerBot”
Introduction
This experiment we learned about 3D printing, by using MakerBot printer. 3D printing also known as additive manufacturing. It’s a technology where a three dimensional object is created by laying down sequential layers of materials. The MakerBot Replicator will melt PLA Filament and transfer it into the plates in layers to build the object. By using CAD system then convert it to STL file, the file can be transfer to the MakerBot Replicator by USB drive, USB cable or by the network.
Procedure
First after designing the part in CAD software, then we convert the file to STL format. Most 3D printer can use STL files. Third transfer the STL file to the 3D printer software, were we could designate the size and orientation for printing. Machine setup is another step for example how to prepare it for a new job, which includes adding the materials. Next we let the machine do the printing job, some objects takes hours and some take minutes. Finally we remove the materials from the 3D printer some printer have post processing which could include bathing the printed object in acid to remove the ground.
Figure 1. Display screen of the MakerBot, show you how min left and the percentage.
Figure 2. The MakerBot software were you adjust positioning.
Discussion
In this experiment, we learned how 3D printing technology is an awesome thing, which made creating objects from different Martials. 3D printer are become cheaper every year, that will help people to create and design there object then print it easy, by only using CAD software and convert it to STL file, and that will help to print object to test it in t.
This document provides information on costing and cost calculations for manufacturing processes. It discusses the need for zero-based costing to understand cost contributions and identify cost reduction opportunities. It then outlines various cost elements like direct material, labor, expenses, and overheads. The document also provides examples of calculating costs for specific manufacturing processes like machining, drilling, milling, and forging conversion. Machine hour rates are calculated considering machine depreciation, power, labor, and other expenses. Cutting forces for sheet metal cutting are also explained.
Design and modification of bale cutting machine to improve its productivityeSAT Journals
Abstract The aim of this paper is to present the results of the successful implementation of the redesigned bale cutting machine in Falcon tyre manufacturing company. Modification of hydraulic bale cutting machine is carried out to increase the productivity of the machine, to reduce the time and stress on the workers. The system is consisting of modified shear blade, suitable blade holder, hydraulic system according to new tonnage capacity and conveyor system. Unigraphics is used to model the blade and blade holder, meshing and analysis is carried out by using hypermesh and nastran. The parts are manufactured accordingly to new design parameters, and the following are installed and the performance characteristics to be determined are time, cost and productivity for this new modified design relative to the old system. It is established from the test results taken for a period of three months, that there is reduction in the time and cost of 70-80%, and 50-60% which in directly increased the productivity of machine and making the process economical. Keywords: shear blade, blade holder, hydraulic system, conveyor system
The training report summarizes several training sessions provided by different trainers on topics related to sales, marketing, manufacturing processes, and materials. Key points from stamping training included discussing manual versus progressive dies and factors that influence machine selection. Material training covered calculating material weight and supplier selection criteria. Plating training introduced the plating line processes and pre/post treatment steps. The document also included lists of common materials and local suppliers.
This project aimed to reduce consumable costs at a department over 2 months. The team listed all consumables, recorded their monthly usage and costs, and tabulated this data. They found that the top 3 consumables - Spark Spray, Windowlene, and Silicone Spray - accounted for over 80% of total costs. Alternative cheaper products were identified and implemented, resulting in projected monthly savings of 65.8% for Spark Spray, 87.9% for Windowlene, and 71.4% for Silicone Spray.
The company lost facilities and equipment due to a tsunami, so cost reduction is needed to increase capacity. The summary recommends:
1) Introducing a website and social media to provide reliable data about product safety and better customer service, while canceling unmeasurable TV commercials.
2) Eliminating $129,520 per year in costs by canceling international calls ($12,900), reducing business trips ($46,620), and the TV commercial ($70,000).
3) Improving the seven factors of service quality to reduce long-term customer service costs.
The document summarizes a student project to redesign an inspection table at a tyre manufacturing plant from a pneumatic to a hydraulic system. It outlines the objectives to overcome operator fatigue issues and increase efficiency. It describes the existing pneumatic system problems like air leaks and noise. The proposed hydraulic system design is presented along with CAD drawings. A cost analysis shows the hydraulic system would have lower lifetime costs despite a higher initial price. Performance analysis indicates the hydraulic system allows workers to inspect more tyres per hour.
Drilling experiment
Abstract
The drilling experiment was conducted on aluminum specimen to open two holes for other parts to be connected in and welded on. The machines that were used in the experiment are the table saw, surface grinding machine and drilling machine.
Introduction
Drilling is one of the most important cutting procedures. The specimen is gripped in the desired position and the tool rotates. First a 1.15” of needed to be cut from the longer specimen. After the top and bottom of the specimen needed to be fattened using the surface grinding machine. Two holes were needed to be drilled one on the top and another or the side of the specimen. The holes must have 0.3” diameter and 0.5” depth, to be able to fit in the parts that were machined with the lathe.
Procedure
1. 1.15” was cut out of a long peace with a table saw (Figure 1).
2. The surfaces of the specimen was flatten using the surface grinding machine (Figure 2).
3. Using a 0.3” drill two 0.3” holes were drilled on the top and on the side of the specimen with 0.5” depth (Figure 3).
5. Assuring that the previous parts fit into the holes (Figure 4).
Pictures
Figrue 1 (Table saw)
Figure 2 (surface grinding machine)
Figure 3 (drilling machine)
Figure 4 (final results)
Lab report of 3D Printer “MakerBot”
Introduction
This experiment we learned about 3D printing, by using MakerBot printer. 3D printing also known as additive manufacturing. It’s a technology where a three dimensional object is created by laying down sequential layers of materials. The MakerBot Replicator will melt PLA Filament and transfer it into the plates in layers to build the object. By using CAD system then convert it to STL file, the file can be transfer to the MakerBot Replicator by USB drive, USB cable or by the network.
Procedure
First after designing the part in CAD software, then we convert the file to STL format. Most 3D printer can use STL files. Third transfer the STL file to the 3D printer software, were we could designate the size and orientation for printing. Machine setup is another step for example how to prepare it for a new job, which includes adding the materials. Next we let the machine do the printing job, some objects takes hours and some take minutes. Finally we remove the materials from the 3D printer some printer have post processing which could include bathing the printed object in acid to remove the ground.
Figure 1. Display screen of the MakerBot, show you how min left and the percentage.
Figure 2. The MakerBot software were you adjust positioning.
Discussion
In this experiment, we learned how 3D printing technology is an awesome thing, which made creating objects from different Martials. 3D printer are become cheaper every year, that will help people to create and design there object then print it easy, by only using CAD software and convert it to STL file, and that will help to print object to test it in t.
This document provides information on costing and cost calculations for manufacturing processes. It discusses the need for zero-based costing to understand cost contributions and identify cost reduction opportunities. It then outlines various cost elements like direct material, labor, expenses, and overheads. The document also provides examples of calculating costs for specific manufacturing processes like machining, drilling, milling, and forging conversion. Machine hour rates are calculated considering machine depreciation, power, labor, and other expenses. Cutting forces for sheet metal cutting are also explained.
The document describes the MainSqueeze, a kitchen appliance that sterilizes kitchen sponges between uses. It heats aluminum ribs and uses UV light to sanitize the sponge. The team describes their process for designing, prototyping, and testing the MainSqueeze, including selecting materials through 3D printing, assembling components, ensuring waterproofing through leak testing, and determining costs and pricing for consumers. They conclude by outlining next steps such as additional testing, sourcing vendors, designing electronics, achieving certifications, acquiring funding, and planning for production.
The document discusses optimizing parameters for boring operations. It aims to achieve a surface finish less than 2 micrometers and bore diameter of 70 mm. Experiments were conducted varying speed, feed rate, and depth of cut. Analysis of variance and response surface methodology were used to analyze results. The optimal parameters were found to be a speed of 1000 rpm and feed rate of 100 mm/min, predicted to achieve a surface roughness of 1.843 micrometers and bore diameter of 70.005 mm. Validation experiments confirmed the predicted results were within acceptable ranges.
This document contains details regarding a mechanical engineering examination, including questions on topics like process planning, cost estimation, machine selection, jigs and fixtures design, and manufacturing processes. It provides multiple choice and numerical questions to calculate costs, times, and parameters for various manufacturing steps like welding, turning, shaping and upsetting.
Manufacturing Cost (2.008x Lecture Slides)A. John Hart
Slides accompanying 2.008x* video module on Manufacturing Cost, Prof. John Hart, MIT, 2016.
*Fundamentals of Manufacturing Processes on edX: https://www.edx.org/course/fundamentals-manufacturing-processes-mitx-2-008x
The document provides details on 10 practice problems related to metal cutting. Problem 1 asks to calculate motor power required for machining based on given data. Problem 2 asks to estimate time required for boring based on given data. Problem 3 asks to estimate power required for drilling and compare to problem 2. Problem 4 asks to calculate offset distance and time required for milling. Problem 5 asks to determine total production time for milling 800 components.
2inches x 2ft x 8ft boards lay out f type 1.0pcf overlaptake16
1. This document is a product quotation from Mega Packaging Corporation providing pricing details for cutting EPS blocks into squared boards with grooves for customer Eric Acuña.
2. The quotation includes direct labor costs, electrical costs, material costs, amortization costs, and total cost per piece for cutting 2" x 2' x 8' EPS squared boards with grooves from 24" x 4' x 8' EPS blocks using croma and jet-cut machines.
3. The total cost per piece is calculated to be PHP 265.9222, which covers all direct costs of labor, electricity, materials, and machine amortization for the specified manufacturing process.
3D Printing vs GFRP Moulding - Time & Cost comparisonAkhil Mohan
- The document compares the time and cost of producing a custom designed product using 3D printing versus glass fiber reinforced plastic (GFRP) molding.
- It finds that 3D printing is 57% cheaper overall than GFRP molding, with significant savings in prototyping (100% savings), production (66% savings), and materials (68% savings) costs.
- 3D printing is also faster, taking 70% less time than GFRP molding, as it eliminates the need for prototyping and has a simpler production process than multi-step GFRP molding.
In conventional method of mixing the metal oxide powder and vehicle mixing is
carried out on ‘Unidirectional Stirring Machine’ The stirrer of conventional machine
rotates in one direction only which creates a particular flow pattern in the fluids hence
the particles tend to stick to the walls of container owing to the centrifugal force rather
than mixing thoroughly in mixture of paint, ultimately results into poor quality mixture
of paints there by poor quality output of paint .In order to have a homogeneous mixing
would be appropriate to have a directions of rotation of stirrer shaft which will rotate
stirrer blades in opposite directions in one cycle this will form turbulent flow pattern
there by leading to creation of irregular flow pattern and resulting into thoroughly
mixed paint mixture preparation which will create the good quality paint.
This is a mist machine, which can do evaporative cooling in an extensive range of indoor and outdoor with moist and soft fog.
The high quality evaporative cooling effect which Moisture Mist has is possible to cool not only the outdoor, but also indoor use will lower the use of air conditioner and also reduce CO2.
It is able to be operated in 100 Volt and therefore, the mobile installation will be easy.
There are lots of actual use, start from bureaucracy like Tokyo Metropolitan Bureau of Environment, Kitakyushu city, Kobe Waterworks Bureau, etc., there also Ueno Zoo, whole country’s highway, train station, department store, events, etc.
It shows the effectiveness of large space cooling better than spot cooler or electric fan.
This document discusses equipment replacement and maintenance analysis. It provides information on:
- Monitoring equipment for efficient functioning and to prevent poor product quality. Maintenance costs increase over time.
- Companies must decide whether to replace old equipment by considering maintenance and operation costs versus retaining equipment.
- Reasons for replacement include physical damage, obsolescence, and inability to meet demand. Preventative maintenance is planned to not disrupt operations while breakdown maintenance repairs equipment after failures.
- The economic life of equipment is determined by comparing maintenance costs to salvage value over years of use. Replacement is considered when annual costs exceed value from continued use.
This document summarizes a presentation about a summer internship at Jai Bharat Maruti Limited in Pantnagar, Uttarakhand. It discusses a project to increase production at the press shop by gang pressing, which involves mounting two similar dies on a single press machine. This allows the pressing operation to be performed faster, increasing productivity. Calculations show that gang pressing can reduce processing costs from Rs. 1320 to Rs. 640 for the example part described, a gusset head used in Bajaj bikes. The advantages of gang pressing are listed as cost saving, time saving, less manpower and machine requirements, and increased production rates.
This document discusses nanolubrication technology using AR9300 complex nanoceramic friction modifier particles. It describes how the particles bond at the atomic level to metal surfaces, filling in imperfections and creating a new protective layer that is 5 times harder. This reduces friction coefficients and prevents wear even under extreme pressures where oil is squeezed out. Applications include engines, transmissions, gearboxes, and other equipment. Case studies show significant savings in fuel costs and reduced maintenance needs when using the technology to treat locomotives, construction equipment, and trucks.
Design & Development of Injection Mold Using Flow Analysis and Higher End Des...paperpublications3
Abstract: In past Mold Design process was time taking as well as hectic. At first Drawing board, then 2D software’s were used after which patterns were made. But in this case the results were not considerable most of the times. Thus the design to market time increased immensely and also project cost required was on a higher side.
Due to the technological advancement the process of Mold Design has fastened and also the results are considerable. With the help of 3D software we can create Parametric Design, Which are editable. Also we can look at number of possibilities for designing a mold. Most importantly the process of Drawing Creation for Mold Design becomes very easy. In a 3D software Visualization of our design is easy possible. Thus our project aims at the awareness of developments of the new age technology of 3D CAD/Mold Wizard for Mold Design.
1. Size reduction involves breaking down large particles into smaller pieces for easier handling and processing. It is commonly used in industries like mining, cement, and food processing.
2. The main methods of size reduction are compression, impact, attrition, and cutting. An ideal crusher would have a large capacity, require little power, produce a uniform product size, and have low costs.
3. The power required for size reduction depends on factors like feed rate, particle sizes, material properties, and the specific reduction technique used according to models like Rittinger's law, Bond's law, or Kick's law. Efficiency is also important to minimize energy costs, which make up a major portion of size reduction
The document provides information on cost allocation and absorption costing for several companies. It includes:
- Calculating total cost per unit for a company using absorption and marginal costing, finding inventory value differs between the two methods.
- Analyzing production costs and profitability of different chocolate products using absorption costing, finding one product is unprofitable.
- Calculating overhead rates allocated to different cost pools and products for two companies, determining total overhead costs per unit for each product.
- Calculating overhead costs for two models using activity-based costing and drivers, finding one model is more expensive to produce.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document summarizes the development of a robust SMT process for placing 03015 components, which are only 0.3mm x 0.15mm in size. Through testing different solder pastes and stencil materials, the author developed a process using a laser-cut fine grain stainless steel stencil with an electro polish and nano coating that achieved over 80% transfer efficiency. Taguchi experiments were used to optimize print parameters. Initial tests achieved placement of 03015 components with 0 defects out of 36,000 placements. The printing process achieved a DPMO of 15. Further work is still needed to optimize the process for thinner stencils required by smartphones.
The document provides costs associated with Chippen Corporation's furniture manufacturing business, including tables. It lists various direct material, direct labor, and manufacturing overhead costs on a per table or annual basis. These costs must be classified as variable costs, fixed costs, product costs, period costs, or opportunity costs based on how they behave with respect to the number of tables produced in a year.
The document provides instructions to create a stress-strain diagram for a material sample with given data. Formulas are provided to calculate engineering strain, engineering stress, proportional limit, modulus of elasticity, ultimate strength and yield point at 0.2% offset from the load, deformation, area and original length and diameter data. A stress-strain diagram is to be plotted showing the elastic region, 2% offset lines, and values for proportional limit, modulus of elasticity, yield strength and ultimate strength identified.
The Hyatt Regency hotel walkways collapsed in 1981 due to errors in the structural engineering design. The original design had each walkway supported by a single rod, but the fabricator modified the design to use two rods for each walkway without properly communicating the changes. This placed twice the intended stress on structural nuts, causing them to deform and the walkways to collapse. The engineering company approved the redesign without thoroughly checking it, demonstrating issues with the communication and review processes between the companies involved.
The document describes the MainSqueeze, a kitchen appliance that sterilizes kitchen sponges between uses. It heats aluminum ribs and uses UV light to sanitize the sponge. The team describes their process for designing, prototyping, and testing the MainSqueeze, including selecting materials through 3D printing, assembling components, ensuring waterproofing through leak testing, and determining costs and pricing for consumers. They conclude by outlining next steps such as additional testing, sourcing vendors, designing electronics, achieving certifications, acquiring funding, and planning for production.
The document discusses optimizing parameters for boring operations. It aims to achieve a surface finish less than 2 micrometers and bore diameter of 70 mm. Experiments were conducted varying speed, feed rate, and depth of cut. Analysis of variance and response surface methodology were used to analyze results. The optimal parameters were found to be a speed of 1000 rpm and feed rate of 100 mm/min, predicted to achieve a surface roughness of 1.843 micrometers and bore diameter of 70.005 mm. Validation experiments confirmed the predicted results were within acceptable ranges.
This document contains details regarding a mechanical engineering examination, including questions on topics like process planning, cost estimation, machine selection, jigs and fixtures design, and manufacturing processes. It provides multiple choice and numerical questions to calculate costs, times, and parameters for various manufacturing steps like welding, turning, shaping and upsetting.
Manufacturing Cost (2.008x Lecture Slides)A. John Hart
Slides accompanying 2.008x* video module on Manufacturing Cost, Prof. John Hart, MIT, 2016.
*Fundamentals of Manufacturing Processes on edX: https://www.edx.org/course/fundamentals-manufacturing-processes-mitx-2-008x
The document provides details on 10 practice problems related to metal cutting. Problem 1 asks to calculate motor power required for machining based on given data. Problem 2 asks to estimate time required for boring based on given data. Problem 3 asks to estimate power required for drilling and compare to problem 2. Problem 4 asks to calculate offset distance and time required for milling. Problem 5 asks to determine total production time for milling 800 components.
2inches x 2ft x 8ft boards lay out f type 1.0pcf overlaptake16
1. This document is a product quotation from Mega Packaging Corporation providing pricing details for cutting EPS blocks into squared boards with grooves for customer Eric Acuña.
2. The quotation includes direct labor costs, electrical costs, material costs, amortization costs, and total cost per piece for cutting 2" x 2' x 8' EPS squared boards with grooves from 24" x 4' x 8' EPS blocks using croma and jet-cut machines.
3. The total cost per piece is calculated to be PHP 265.9222, which covers all direct costs of labor, electricity, materials, and machine amortization for the specified manufacturing process.
3D Printing vs GFRP Moulding - Time & Cost comparisonAkhil Mohan
- The document compares the time and cost of producing a custom designed product using 3D printing versus glass fiber reinforced plastic (GFRP) molding.
- It finds that 3D printing is 57% cheaper overall than GFRP molding, with significant savings in prototyping (100% savings), production (66% savings), and materials (68% savings) costs.
- 3D printing is also faster, taking 70% less time than GFRP molding, as it eliminates the need for prototyping and has a simpler production process than multi-step GFRP molding.
In conventional method of mixing the metal oxide powder and vehicle mixing is
carried out on ‘Unidirectional Stirring Machine’ The stirrer of conventional machine
rotates in one direction only which creates a particular flow pattern in the fluids hence
the particles tend to stick to the walls of container owing to the centrifugal force rather
than mixing thoroughly in mixture of paint, ultimately results into poor quality mixture
of paints there by poor quality output of paint .In order to have a homogeneous mixing
would be appropriate to have a directions of rotation of stirrer shaft which will rotate
stirrer blades in opposite directions in one cycle this will form turbulent flow pattern
there by leading to creation of irregular flow pattern and resulting into thoroughly
mixed paint mixture preparation which will create the good quality paint.
This is a mist machine, which can do evaporative cooling in an extensive range of indoor and outdoor with moist and soft fog.
The high quality evaporative cooling effect which Moisture Mist has is possible to cool not only the outdoor, but also indoor use will lower the use of air conditioner and also reduce CO2.
It is able to be operated in 100 Volt and therefore, the mobile installation will be easy.
There are lots of actual use, start from bureaucracy like Tokyo Metropolitan Bureau of Environment, Kitakyushu city, Kobe Waterworks Bureau, etc., there also Ueno Zoo, whole country’s highway, train station, department store, events, etc.
It shows the effectiveness of large space cooling better than spot cooler or electric fan.
This document discusses equipment replacement and maintenance analysis. It provides information on:
- Monitoring equipment for efficient functioning and to prevent poor product quality. Maintenance costs increase over time.
- Companies must decide whether to replace old equipment by considering maintenance and operation costs versus retaining equipment.
- Reasons for replacement include physical damage, obsolescence, and inability to meet demand. Preventative maintenance is planned to not disrupt operations while breakdown maintenance repairs equipment after failures.
- The economic life of equipment is determined by comparing maintenance costs to salvage value over years of use. Replacement is considered when annual costs exceed value from continued use.
This document summarizes a presentation about a summer internship at Jai Bharat Maruti Limited in Pantnagar, Uttarakhand. It discusses a project to increase production at the press shop by gang pressing, which involves mounting two similar dies on a single press machine. This allows the pressing operation to be performed faster, increasing productivity. Calculations show that gang pressing can reduce processing costs from Rs. 1320 to Rs. 640 for the example part described, a gusset head used in Bajaj bikes. The advantages of gang pressing are listed as cost saving, time saving, less manpower and machine requirements, and increased production rates.
This document discusses nanolubrication technology using AR9300 complex nanoceramic friction modifier particles. It describes how the particles bond at the atomic level to metal surfaces, filling in imperfections and creating a new protective layer that is 5 times harder. This reduces friction coefficients and prevents wear even under extreme pressures where oil is squeezed out. Applications include engines, transmissions, gearboxes, and other equipment. Case studies show significant savings in fuel costs and reduced maintenance needs when using the technology to treat locomotives, construction equipment, and trucks.
Design & Development of Injection Mold Using Flow Analysis and Higher End Des...paperpublications3
Abstract: In past Mold Design process was time taking as well as hectic. At first Drawing board, then 2D software’s were used after which patterns were made. But in this case the results were not considerable most of the times. Thus the design to market time increased immensely and also project cost required was on a higher side.
Due to the technological advancement the process of Mold Design has fastened and also the results are considerable. With the help of 3D software we can create Parametric Design, Which are editable. Also we can look at number of possibilities for designing a mold. Most importantly the process of Drawing Creation for Mold Design becomes very easy. In a 3D software Visualization of our design is easy possible. Thus our project aims at the awareness of developments of the new age technology of 3D CAD/Mold Wizard for Mold Design.
1. Size reduction involves breaking down large particles into smaller pieces for easier handling and processing. It is commonly used in industries like mining, cement, and food processing.
2. The main methods of size reduction are compression, impact, attrition, and cutting. An ideal crusher would have a large capacity, require little power, produce a uniform product size, and have low costs.
3. The power required for size reduction depends on factors like feed rate, particle sizes, material properties, and the specific reduction technique used according to models like Rittinger's law, Bond's law, or Kick's law. Efficiency is also important to minimize energy costs, which make up a major portion of size reduction
The document provides information on cost allocation and absorption costing for several companies. It includes:
- Calculating total cost per unit for a company using absorption and marginal costing, finding inventory value differs between the two methods.
- Analyzing production costs and profitability of different chocolate products using absorption costing, finding one product is unprofitable.
- Calculating overhead rates allocated to different cost pools and products for two companies, determining total overhead costs per unit for each product.
- Calculating overhead costs for two models using activity-based costing and drivers, finding one model is more expensive to produce.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document summarizes the development of a robust SMT process for placing 03015 components, which are only 0.3mm x 0.15mm in size. Through testing different solder pastes and stencil materials, the author developed a process using a laser-cut fine grain stainless steel stencil with an electro polish and nano coating that achieved over 80% transfer efficiency. Taguchi experiments were used to optimize print parameters. Initial tests achieved placement of 03015 components with 0 defects out of 36,000 placements. The printing process achieved a DPMO of 15. Further work is still needed to optimize the process for thinner stencils required by smartphones.
The document provides costs associated with Chippen Corporation's furniture manufacturing business, including tables. It lists various direct material, direct labor, and manufacturing overhead costs on a per table or annual basis. These costs must be classified as variable costs, fixed costs, product costs, period costs, or opportunity costs based on how they behave with respect to the number of tables produced in a year.
The document provides instructions to create a stress-strain diagram for a material sample with given data. Formulas are provided to calculate engineering strain, engineering stress, proportional limit, modulus of elasticity, ultimate strength and yield point at 0.2% offset from the load, deformation, area and original length and diameter data. A stress-strain diagram is to be plotted showing the elastic region, 2% offset lines, and values for proportional limit, modulus of elasticity, yield strength and ultimate strength identified.
The Hyatt Regency hotel walkways collapsed in 1981 due to errors in the structural engineering design. The original design had each walkway supported by a single rod, but the fabricator modified the design to use two rods for each walkway without properly communicating the changes. This placed twice the intended stress on structural nuts, causing them to deform and the walkways to collapse. The engineering company approved the redesign without thoroughly checking it, demonstrating issues with the communication and review processes between the companies involved.
This technical report details an investigation into the fatigue characteristics of 1018 cold rolled steel. Fatigue, hardness, and tensile tests were conducted on pre-annealed samples, finding the ultimate tensile strength to be significantly higher than published values. Additional testing found the microstructure of the material to be elongated along the rolling direction due to cold working. Samples were then annealed and re-tested, showing ultimate tensile strengths within 5% of published data and a normalized microstructure. The annealing process was successful in reducing the strength of the material to expected published values by reforming the grain structure.
This document summarizes a spring analysis that was performed to determine if a spring is safe under an allowable stress level. Measurements of the spring's dimensions were taken and used to calculate values like the standard wire diameter, allowable stress, mean diameter, spring index, number of active coils, pitch, pitch angle, shear modulus, spring rate, solid length, solid force, maximum shear stress, free length, percent error in free length, and coil clearance at 50% operating length. The results found that the maximum shear stress of 121.9 ksi was below the allowable stress of 140 ksi, indicating the spring is safe for use.
The document summarizes the materials used in reusable water bottles. It discusses that reusable bottles are commonly made from HDPE or PP because they are rigid, resistant to chemicals like water, and can withstand freezing temperatures. While these plastics are popular, scientists are trying to create more environmentally friendly biodegradable options. The document suggests that biopolyethylene terephthalate (bio-PET) shows potential as a sustainable material for reusable bottles in the future.
This document provides an overview of a project to create an Excel file to calculate material properties and construct a stress-strain diagram from given data. Formulas are provided to calculate engineering strain, engineering stress, modulus of elasticity, percent reduction in area, and other material properties. The data from loading a sample is then plotted on a stress-strain diagram to determine key properties like proportional limit, yield points, ultimate strength, and breaking strength.
The document discusses redesigning a CCTV system to better meet user needs. It identifies issues with the current system such as text being difficult to move and read and the system being clunky and not portable. It outlines user personas including a soon to be college student and a 65+ individual who needs accessible printed material. Key user needs are identified as the system needing to be affordable, reliable, usable, portable, and durable. Several potential solutions are mentioned but not described in detail.
1. 0617-240-70 Manufacturing Processing II Project
Cost Reduction of a Light Switch
Plate
Executive Summary
The original price of the light switch plate is $3.99. The 40% rule is used to find out
what is costs to make the plate. To do the 40% rule by multiplying 0.40 to $3.99. By
doing the 40% rule it came out to $1.60. It takes $1.60 to manufacture a light switch
plate form this $3.99 plate. A cost reduction was done to determine a cheaper way to
manufacture the plate. The prices of the three common ways to manufacture this part
were calculated. The stamping, abrasive water jet, and laser are the manufacture
processes that were calculated. When comparing prices the proper way to
manufacture the plate is by comparing how much it cost to make it and the time to
make it. According to the calculations the stamping is the quickest and the cheapest
way to make a light switch plate. Abrasive water jet machining is the slowest way to
manufacture it. Laser is between abrasive water jet and stamping. Cost wise laser is
the most expensive to make per piece because of all the tooling/consumables
involved with laser while abrasive water jet is in between laser and stamping for cost.
Stamping is the cheapest and the fastest way to make the plate.
Author: Stephanie Ulman
For: Professor Slifka
2. 1 Stephanie Uman
Cost Reduction Project 0617-240-70
Material Selection
Carbon steel
Gauge 15: 18in x 18in (picture below of the nesting when stamping.
The plate has an antique textured antique pewter finish.
This finish will be the same for all the pieces.
Assume 8 lb = 50 lbs = 40 sheets
Figure 1 shows a sheet of the nesting when stamping.
18 in ×
1 ft
12 in
= 1.5ft
1.5ft × 15ft = 2.75 ft2
2.75ft2
× 40sheets = 90 ft2
for 40 sheets
15 parts × 40 sheets = 600 parts for 40 sheets
$50
600 pieces
= $0.08 for each light switch plate
18 in
18 in
4.5
in
2.75 In
3. 2 Stephanie Uman
Cost Reduction Project 0617-240-70
Assembly
Light Switch Plate
Table 1 shows the dimensions of the light switch plate. The thickness was assumed.
Light Switch Holes
(Assu
Table 2 shows the assumptions of the dimensions of the rectangle hole in the light
switch plate.
Table 3 shows the dimensions two circle holes. This is an assumptions of the
measurement of the holes.
Diagram 2 is a picture of the light switch plate that was used in this cost analysis. The
part number is 9TAP101.
Part Specific Tooling/Steps
Traditional process
Stamping
First place a sheet of material into the punch press die set. Then active the punch
press. When the ram returns the operator removes the finish parts from the die set
and the removes the scrape material. Then the process repeats.
Height 4.5 in
Width 2.75 in
Thickness 0.06 in
Height 1 in
Width 0.5 in
Radius 0.125 in
4. 3 Stephanie Uman
Cost Reduction Project 0617-240-70
Non-Traditional processes
Abrasive Water Jet
The operator will put the material on the abrasive water jet bed. Then the operator
pushes the start button. The machine would cut the interior holes. Then the machine
would cut the outside shapes of the light switch cover. After the machine is finished it
will go to the resting position. Then the operator will remove all the finished parts and
then the scrap. Then the operator would repeat the process.
Laser
The operator will put the material on the laser bed/brick. Then operator will push the
start button. Then the machine would cut all the interior holes. Then the machine will
cut the outside shape. After the machine is finished it returns to the starting position.
Then the operator would remove all the finished parts and the scrap. Then the
operator repeats the process.
Contacting Manufactures
I could not get in contact with the manufacturer so I assumed the light switch cover
was stamped. I also tried to contact the some manufactures for stamping, abrasive
water jet and laser so I could get some costs. The only person I got an email back
form Brad Copper from Klein Steel.
Capital Equipment
Strength and Weaknesses
The strength for stamping process will be the time rate it takes to make each part.
The weakest for stamping would be the tooling/consumables cost. The
tooling/consumables for stamping last a long time so it can be a benefit.
Abrasive water jet weakest point is the length of time to make a light switch cover is
really high compared to stamping and laser.
Laser is the go between for time meaning it is faster than abrasive water jet but
slower than punching. The only weakness about this method is that the
tooling/consumables cost the most out of these methods.
Equipment
HP accu-Lock
A HP accu-Lock machines ball holes and punch plates. Cutting lead times from
several weeks to days reducing waste. On the right is a picture of a HP accu-Lock
machine. This stamping machine costs $700.00.
5. 4 Stephanie Uman
Cost Reduction Project 0617-240-70
Figure 3 shows the HP accu-Lock machine which is a
stamping machine.
Mach 2B Abrasive Water Jet
The Mach 2B waterjet models have a 3 sided easy access to work piece. It has a
large diameter ball screw drive system. Also the Mach 2B waterjet models have a
unique autolube system. It also has a heavy duty material support. This machine has
the accuracy of 0.005 inch per 3 feet. The speed range for the Mach 2B waterjet
models is up to 400 rpm. An abrasive water jet machine is $49,950.00.
Figure 4 shows a
Mach 2B Waterjet model.
HIPPO Mid-Power Q-Switched Laser
This laser has a high output power for fast throughout. The high peak power
minimizes thermal damage to the parts. The thermo-beam has characteristics for a
large depth of field. The modular design allows easy field replacement of key
components. A laser machine costs $5,200.00.
6. 5 Stephanie Uman
Cost Reduction Project 0617-240-70
Figure 5 shows a HIPPO Mid-Power Q-
Switched Laser.
Process
When comparing prices the proper way to do it is by comparing how much it cost to
make it and the time to make it.
Traditional
Stamping/punching
Overhead
Assume
$50
hour
(
$50
600
+
$100
600
) = $0.25 for each light switch plate
Labor
Setup man
$50
hour
(assumed)
(Works for 2 hours assumed)
$50
hour
×
2hours
1 day
= $100
Production Worker
$18
hour
(assumed)
Assume
40 sheets
hour
=
600 pieces
hour
$118
600 𝑝𝑖𝑒𝑐𝑒𝑠
= $0.20 𝑓𝑜𝑟 𝑒𝑎𝑐ℎ 𝑝𝑖𝑒𝑐𝑒
7. 6 Stephanie Uman
Cost Reduction Project 0617-240-70
Consumables/Tooling
Assume price of die = $40,000
Assume lifespan of die = 150,000 parts
Assume maintenance cost = $1000
$40000
$150000
= $0.27
Packaging for light switch plates
Assume $0.03 each
Non-traditional
Abrasive Water Jet
Overhead
Assume
$50
hour
$50 × (30.5 hrs + 2 hrs) = $162.50 for 600pieces
$162.50
600𝑝𝑖𝑒𝑐𝑒𝑠
= $0.27 𝑓𝑜𝑟 𝑒𝑎𝑐ℎ 𝑝𝑖𝑒𝑐𝑒
Labor
Setup man
$50
hour
(assumed)
(Works for 2 hours assumed)
$50
hour
×
2hours
1 day
= $100
Production Worker
$18
hour
Perimeter
(4.5 in × 2) + (2.75 in × 2) + (1 in × 2) + (0.5 in × 2) + (π × 0.125 in × 2)
= 18.285 in
Cutting Speed
6 in
min
(between
0.6 in
min
and
18 in
min
)
18.285 in
6
in
min
= 3.05min × 600 pieces =
1830 min
60 min
= 30.5 hrs
30.5hrs × $18 =
$549
hr
for 600 pieces
(
$549
600 pieces
+
$100
600 pieces
) = $1.08 for each piece
8. 7 Stephanie Uman
Cost Reduction Project 0617-240-70
Consumables/Tooling
Abrasive
$140
1000 𝑚𝑒𝑡𝑟𝑖𝑐 𝑡𝑜𝑛𝑠
= $0.14 × 30.5 ℎ𝑟𝑠 =
$4.27
ℎ𝑜𝑢𝑟
$140
$4.27
= 32.79 hrs (the abrasive lasts 32.79hrs)
$4.27 × 30.5 ℎ𝑟𝑠 = $130.24 (this is what the abrasive costs to make 600 pieces)
Filter
$52 -assume it lasts for a month
10 in
0.45 Microns
Jewel
$14.50 - assume it lasts every 2 years
D = 004 in
Ruby
Bed/Brick
$34 (assume it lasts up to 2 years)
4 in x 6 in x 48 in
$130.24 + $52 + $14.50 + $34
600 𝑝𝑖𝑒𝑐𝑒𝑠
= $0.38 𝑝𝑒𝑟 𝑝𝑖𝑒𝑐𝑒
Water
Assume $5
Packaging for abrasive water jet will be the same.
Laser
Overhead
Assume
$50
hour
$50 × (3.7 hrs + 2 hrs) = $285 for 600pieces
$285
600𝑝𝑖𝑒𝑐𝑒𝑠
= $0.48 𝑝𝑒𝑟 𝑝𝑖𝑒𝑐𝑒
Labor
Setup man
$50
hour
(assumed)
9. 8 Stephanie Uman
Cost Reduction Project 0617-240-70
(Works for 2 hours)
$50
hour
×
2hours
1 day
= $100
Production Worker
$18
hour
(assumed)
Perimeter
(4.5 in × 2) + (2.75 in × 2) + (1 in × 2) + (0.5 in × 2) + (π × 0.125 in × 2)
= 18.285 in
Cutting Speed
50 in
min
(between
3 in
min
and
100 in
min
)
18.285 in
50
in
min
= 0.37min × 600 pieces =
222 min
60 min
= 3.7 hrs
3.7 hrs × $18 = $66.60 for 600 pieces
(
$66.60
600 𝑝𝑖𝑒𝑐𝑒𝑠
+
$100
600 𝑝𝑖𝑒𝑐𝑒𝑠
) = $0.28
Consumables/Tooling
Focus Lenses $610 (assume lasts every month)
Nozzle $6 (assume lasts every 2 weeks)
Vacuum Oil $50 (assume lasts every 2 months)
Vacuum Filter $200 (assume lasts every 4 months)
Primary Mirror $2,351 (assume lasts for a year)
Internal Bending Mirror $447 (assume lasts for a year)
Internal Polarizing Mirror $838 (assume lasts every year)
Output Coupler $2,198 (assume lasts every year)
Chiller Filter $300 (assume lasts every 2 months)
Polarizing mirror $1,860 (assume lasts every year)
Collimator Optics $829 (assume lasts every year)
External Bending Mirror $433 (assume last every year)
Adaptive Mirrors $2150 (assume last every year)
Gas
CO2 = Volume (0.42
ft32
hrs
) =
$0.25
ft3
0.042 ft3
hrs
×
$0.25
ft3
=
$0.01
hr
×
3.7 hrs
600 pieces
= $0.00006 per piece
$(610 + 6 + 50 + 200 + 2351 + 447 + 828 + 2198 + 300 + 1860 + 829 + 433 + 2150)
600 𝑝𝑖𝑒𝑐𝑒𝑠
$20.45 + $0.01 = $20.46 𝑝𝑒𝑟 𝑝𝑖𝑒𝑐𝑒
10. 9 Stephanie Uman
Cost Reduction Project 0617-240-70
Packaging for laser will be the same.
Secondary operations
After the light switch goes through the non-traditional process the light switch plates
need a secondary operation. The secondary operation needs to done to create a
curve on the part. The secondary operation method will be a stamping method.
Shaping tool assumed $700
$700
600
= 1.16 (lasts 100 years)
(Assume 2 seconds for each part)
2 𝑠𝑒𝑐
𝑝𝑖𝑒𝑐𝑒
× 600 𝑝𝑒𝑖𝑐𝑒𝑠 ×
1 𝑚𝑖𝑛
60 𝑠𝑒𝑐
×
1 ℎ𝑟
60 𝑚𝑖𝑛
= 0.3 ℎ𝑟𝑠
Abrasive Water Jet
Costs $1.84 +$1.16 = $3.00
Time 32.5 hrs + 0.3 hrs = 35.5 hrs
Laser
Costs $21.33 + $1.16 = $22.49
Time 5.7 hrs + 0.3 hrs = 6 hrs
Costs
Production Costs
Stamping Material $0.08
Overhead $0.25
Labor $0.20
Consumables/Tooling $0.27
Packaging $0.03
Total $0.83
Table 4 shows the total cost of the stamping process.
11. 10 Stephanie Uman
Cost Reduction Project 0617-240-70
Production Costs
Abrasive
water jet Material $0.08
Overhead $0.27
Labor $1.08
Consumables/Tooling $0.38
Packaging $0.03
Shaping $1.16
Total $3.00
Table 5 shows the total cost of the abrasive water jet process.
Production Costs
Laser Material $0.08
Overhead $0.48
Labor $0.28
Consumables/Tooling $20.46
Packaging $0.03
Shaping $1.16
Total $22.49
Table 6 shows the total cost of the laser process.
From the tables above stamping is the cheapest method to make a light switch plate.
It is cheaper than using the process abrasive water jet and laser. Stamping tools and
consumables are very expensive, but they last a long time. For the abrasive water jet
the tooling and consumables are in between the laser and the stamping method. The
material and the packing remain the same cost for all these processes. After the non-
traditional processes (laser and abrasive water jet) there needs to a secondary
operation in order to add a curve to the light switch plate. The labor costs vary
between these three processes. Abrasive water jet is the highest labor because it
takes the most time to make. The material and the packing remain the same cost
form all these processes. From doing all of these calculations the stamping method is
the cheapest way to make the plate.
12. 11 Stephanie Uman
Cost Reduction Project 0617-240-70
Time
Method Times
Times
with
shaping Total
Stamping 3 hrs 0 hrs 3 hrs
Abrasive
water jet 32.5 hrs 0.3 hrs 32.8 hrs
Laser 5.7 hrs 0.3 hrs 6 hrs
Table 7 shows the amount of time that it takes to make 600 light switch plates.
The material and the packing remain the same cost form all these processes
Conclusion:
In conclusion the cheapest and quickest way to make a light switch plate is stamping.
As you can see from the table below.
Stamping
Abrasive
water jet
Laser
Costs $0.83 $3.00 $22.49
Time 3 hrs 32.8 hrs 6 hrs
Table 8 shows the stamping process is the cheapest followed by abrasive water jet
and laser. Also it shows that the stamping method is the quickest way to make the
plate.
In the table above the abrasive water jet is the slowest process. The laser is faster
than the abrasive water jet but, the quickest way is stamping. Therefore, stamping
will be the quickest way to make the light switch plate. From this project the
materials, cost of the packing and the overhead remain the same. But, the total
overhead remains close to the same it can vary because of the hours of labor to
make the light switch plate. From the table above the cheapest way to make a light
switch plate is stamping and the cost is $0.83. The original price of the light switch
plate is $3.99. The 40% rule is used to find out what is costs to make the plate. The
40% rule was used and it came out to $1.60. So, the company that sells these plates
are making money off of the consumer buys the light switch plate. The company is
making $0.77 from the consumer if they manufacture it the cheapest way.
13. 12 Stephanie Uman
Cost Reduction Project 0617-240-70
References
Material
http://www.custompartnet.com/sheet-metal-gauge
Stamping Equipment
http://kalamazoometalmuncher.com/hydraulicpunchpress.htm
http://www.fabequip.com/equipment/ironworkers/metal%20muncher/metal%20munch
er%20ironworker%20gb_series.htm
http://www.barton.com/inventory.asp?CatId={DD841E1C-EDD0-4FB3-AD72-
13AF8E4A53E5}
http://www.wilsontool.com/stamping/stamp_accuLock.html
http://www.ebay.com/itm/Metal-Stamping-Machine-Press-
/350561773159?pt=LH_DefaultDomain_0&hash=item519f1c2667
Part
http://www.wallplatewarehouse.com/9tap101.html
Kohser, Ronald. Materials and Processes in Manufacturing. Eleventh Edition. 2012.
Abrasive Water Jet consumables:
http://www.alibaba.com/product-
gs/282156151/garnet_abrasive_for_waterjet_cutting.html?s=p
http://www.barton.com/inventory.asp?catid={F86AEEAF-AD12-4C84-AD02-
34BECF05E705}
http://www.barton.com/inventory.asp?CatId={3F67B516-B955-4DE9-83D3-
B4D3FFE86508}
http://www.barton.com/inventory.asp?CatId={3F67B516-B955-4DE9-83D3-
B4D3FFE86508}
http://www.ebay.com/itm/Abrasive-Waterjet-Machine-
/230670729726?pt=LH_DefaultDomain_0&hash=item35b50c01fe
Laser
http://www.alibaba.com/product-gs/505531139/Nozzle_for_laser_machine.html
http://www.lom.cc/
15. 14 Stephanie Uman
Cost Reduction Project 0617-240-70
Appendix 1
Special Retainers on Demand/Stamping
Create, modify and reuse special retainers on-site and on
demand with HP Accu-Lock® Retainer Inserts by Wilson
Tool. HP Accu-Lock simplifies the use of special retainers
by eliminating the need for complicated jigs, inspection
fixtures and specialized knowledge to machine ball holes
into the punch plate. In fact, HP Accu-Lock eliminates the
ball hole. Punches are held securely in place with a
straight-line machined hole that can easily be created in-
house.
Shorter Lead Times and Less Waste Means Lower Costs.
Purchasing custom retainers for a special request is
costly and can add weeks to a job. With HP Accu-Lock, you can not only create your
own special retainers in-house but also modify and reuse existing retainers. Cutting
lead times from several weeks to a day and significantly reducing waste.
HP Accu-Lock Retainer Inserts are fully compatible with all ball lock punches,
including HP Ball Lock punches from Wilson Tool International.
16. 15 Stephanie Uman
Cost Reduction Project 0617-240-70
Appendix 2
Mach 2b Waterjet Models
Flow Performance Made Affordable
The Mach 2 Series outperforms the standard waterjet offerings in the industry
and wins in VALUE.
Excellent Work Table Accessibility on a Machine Built for the Rigors of Waterjet
Cutting
With robust mechanical design, integrated machine systems, intuitive user control,
multiple table sizes, and several configurations available, the Mach 2b Series sets
you up for success.
The core components of our Mach 2b waterjets
series - including Paser abrasive cutting system,
pump technology, and FlowMaster software - are
the very same components found on our elite Mach
3 and Mach 4 waterjet series.
With a Mach 2b you won't sacrifice performance,
structural integrity, or the overall quality of your
system. In fact, its solid steel casting construction
and precision reciprocating ball screws are components often found in other
manufacturers premium machines.
Special Features:
Core components include Flow's Paser abrasive
cutting system, pump technology, and FlowMaster
software
3-sided easy access to your workpiece
Large diameter ball screw drive system
Unique autolube system
Rigid construction for structural integrity
Roll-around control
Multiple pump configurations
Heavy duty material support
Solid steel casting construction
17. 16 Stephanie Uman
Cost Reduction Project 0617-240-70
World class Flow service available 24/7 365 days per year
Options and Accessories:
UltraPierce™ cutting system - for optimal piercing performance on stone,
glass, and laminated materials
Multiple head option, including patented Paser abrasive cutting system for
peak performance
Cuts higher precision parts with a variety of software
packages available, including FlowMaster easy to
use software
FlowNest software - with full geometric software with
scrap remenant control (small parts are
automatically nested within larger parts)
FlowShift Vectorization software - converts images,
sketches, and line drawings to vector formats in
minutes
Smart Stream technology
Interchangeable pure waterjet and abrasive
waterjet cutting head systems available to cut a wide
variety of materials
Final filtration system
Variety of pump configurations up to 60,000 psi
Professional classroom training; as well as on-site familiarization with every
machine
Widest variety of Sapphire, Ruby or Diamond orifices to match every
application
Mach 2b Models:
1005b
Work envelope: 1.0m x 0.5m (3.3ft x 1.6ft)
1313b
Work envelope: 1.30m x 1.30m (4.3ft x 4.3ft)
2031b
Work envelope: 2.00m x 3.10m (6.6ft x 10.1ft)
4020b
Work envelope: 4.00m x 2.00m (13.1ft x 6.6ft)
Specifications
Accuracy (+/-) 0.005" inch per 3' feet at 68° ± 3°F
(± 0.127 mm per 1M at 20° ± 3°C)
18. 17 Stephanie Uman
Cost Reduction Project 0617-240-70
Repeatability (+/-) 0.0025" inch at 68° ± 3°F
(0.0635 mm at 20° ± 3°C)
Speed Range Up to 400 ipm
19. 18 Stephanie Uman
Cost Reduction Project 0617-240-70
Appendix 3
HIPPO Mid-Power Q-Switched Lasers
OEM/Industrial design for 24/7 operation
Single platform for 4 output wavelengths: 1064 nm, 532 nm, 355 nm, 266 nm
High output power for fast throughput
High peak power minimizes thermal damage to your parts
Superior pulse-to-pulse stability for clean, consistent processing
TEM00 beam characteristics for large depth of field
Long life diodes mean low cost of operation and high uptime
Modular design allows easy field replacement of key components
Contact Us
Feedback
Overview
Applications
Features
Reliability
Specifications
Literature & Downloads
Highlights
The Spectra-Physics HIPPO lasers are a family of high power diode-pumped solid
state (DPSS) Q-switched lasers with available outputs of 1064, 532, 355 and 266 nm
wavelengths. They are used primarily in 24/7 industrial applications such as solar cell
manufacturing, LED scribing and other microelectronics applications.
The HIPPO Q-switched laser is among the most popular industrial DPSS lasers
available. It has a strong track record and large installed base around the world. Our
diodes last double the industry average. The laser’s modular design allows easy field
replacement of key components including diodes and fibers, laser output window,
and the harmonic module without costly tool realignment. Rugged and proven, the
HIPPO is the tool of choice in applications where uptime is critical.
Model Wavelength
Peak
Power
Average
Power
Pulse
Width
Repetition Rate
(nominal)
HIPPO 1064-17
DPSS Laser
1064 nm
~22.7
kW
>17 W
<15 ns at
50 kHz
50 kHz
HIPPO 1064-27
DPSS Laser
1064 nm ~9 kW >27 W
<30 ns at
100 kHz
100 kHz
HIPPO 532-11
DPSS Laser
532 nm
~16.9
kW
>11 W
<13 ns at
90 kHz
50 kHz
HIPPO 532-15
DPSS Laser
532 nm ~6 kW >15 W
<25 ns at
100 kHz
100 kHz
20. 19 Stephanie Uman
Cost Reduction Project 0617-240-70
Model Wavelength
Peak
Power
Average
Power
Pulse
Width
Repetition Rate
(nominal)
HIPPO 355-5
DPSS Laser
355 nm ~8.3 kW >5 W
<12 ns at
50 kHz
50 kHz
HIPPO Prime 266-
2 DPSS Laser
266 nm ~3.3 kW >2 W
<12 ns at
50 kHz
50 kHz
Excellent Performance
HIPPO Q-switched lasers are characterized by extremely short pulse width (as low
as <11 ns). High peak power and short pulse widths minimize undesirable thermal
damage, such as heat affected zones, recast material, kerfs, and micro-cracking of
the substrate.
All HIPPO Q-switched lasers have excellent beam quality, which ensure a large
depth of field and guarantee consistent and reliable scribing results over a wider
range of material flatness, thickness, and surface variations.
HIPPO lasers have stable power, low pulse-to-pulse energy variation, and stable
beam pointing over a wide range of operating conditions, including time, temperature,
and pulse repetition rate.