This document discusses the production process of propellers. It begins by describing what a propeller is and its main functions. It then outlines the different types of propellers based on the number of blades and materials used. The production process is then summarized in 3 steps: 1) the tooling is made using CNC milling to create a wax mold, 2) the lost wax process is used to create a ceramic shell around the wax mold which is then melted and replaced with molten metal, 3) the casting is finished through grinding and polishing. Finally, the suitable heat treatment process is described which involves heating the wax mold to create a pattern, dipping it in ceramic to strengthen the mold, then using high heat

1. KUMPULAN 5CASE STUDY 1: PRODUCT PROPELLER
MUHAMMAD AZRI BIN AZMAN D20111050147
NUR AINA NASIHAH BT MOHAMAD ASHRI D20111050157
NOOR HASYILA BT MOHD ISA D20112052137
SITI HAJAR BINTI YAZID D20112052142
FARIHIN BINTI MD FAUZI D20112052143

2. PROPELLER
• A propeller is a rotating fan like structure
which is used to propel the ship by using the
power generated and transmitted by the
main engine of the ship.
• The transmitted power is converted from
rotational motion to generate a thrust which
imparts momentum to the water, resulting in
a force that acts on the ship and pushes it
forward.

3. Types of Propeller
• Propellers are be classified on the basis of
several factors. The classification of different
types of propellers is shown below:
Classification by Number of Blades Attached:
Propeller blades may vary from 3 blade
propeller to 4 blade propeller and sometimes
even 5 blade propeller. However, the most
commonly used are 3 blades and 4 blade
propellers.

4. a)3 blade propeller:
- The manufacturing cost is lower than other
types.
- Are normally made up of aluminium alloy.
- Gives a good high speed performance.
- The acceleration is better than other types.
- Low speed handling is not much efficient.

5. b) 4 blade propeller:
- The manufacturing cost is higher than 3
blade propellers.
- Have better strength and durability.
- Gives a good low speed handling and
performance.
- Has a better holding power in rough seas.
- 4 blade propeller provides a better fuel
economy than all the other types.

6. c)5 blade propeller:
- Manufacturing cost is higher of all.
- Vibration is minimal from all the other
types.
- 5 blade propellers have better holding
power in rough seas.

7. TYPE OF MATERIAL
USED

8. Propellers are made of aluminum or steel and
both have their advantages and disadvantages.
Unlike other prop features, the choice of
material is really more a matter of preference.
Aluminum Steel

9. Choose Aluminum Blades For : Choose Stainless Steel Blades For:
Lower cost
Protective coating
Light weight (weighs about
1/2 as much as steel)
Satisfactory performance in
most situations
Less expensive to repair
Higher performance
Repairs closest to brand
new condition
Blade strength prevents
flexing under pressure;
blades remain in optimal
condition longer
Durability and lower
susceptibility to damage .

10. THE PRODUCTION
PROCESS OF THE
PRODUCT

11. The production process of the
propeller
Tooling
First, the propeller has to be digitalized.
Through the CNC milling a reverse of the propeller is cut
into a solid piece of aluminum, this creates the tooling.
The tooling is a hollow version of the propeller used to
inject wax into.

12. • The “Lost Wax” process
Once the tooling is completed, it is injected with melted wax.
• This is the first stage
• That is the “lost wax” process.
• After the propeller is created in wax,
• it is dipped several times into a ceramic material until a thick shell
covers the entire wax propeller. After the ceramic shell has
completely dried,
• the wax is melted out and replaced with molten stainless steel.
• Once the stainless steel has cooled, the shell is removed you are
left with a rough casting of
the propeller.

13. Finishing the propeller
~ Once the casting is inspected for the proper dimensions, it is hand
ground with three
different grits of sandpaper.
~ For the final process, the propeller is placed into a two stage
surface finishing machine.
~ This machine gives the propeller its reflective finish.
~ Every propeller produced through Signature propellers is made
with a quality craftsmanship
~ that is insured to give every boat the best performance possible.

14. THE SUITABLE HEAT
TREATMENT
PROCESS FOR THE
PRODUCT BASED ON
ITS APPLICATION

15. • The wax is warmed to 180 degrees and poured into a "wax
press," where a machine operator creates a pattern in the
shape of the propeller.
• Then it's dipped four more times in a secondary finish that
improves thickness and strength. In between each dipping,
there is another five-hour drying period.
• The pattern is left to dry under high-powered fans for 24 hours.
The entire dipping process takes more than two days.
• The wax pattern can be removed. Each piece is placed in an
autoclave where the molds are steam-heated for 18 minutes at
325 degrees Fahrenheit at 100 PSI of pressure.
• During the cycle, the wax melts and separates from the shell
and is later collected and recycled for future patterns.

16. • Next, the empty cavity, now free of most wax, is placed in a
burnout furnace. Inside, the furnace reaches more than 2000
degrees Fahrenheit.
• While the molds are in the burnout furnace, an hour-long
process, 500 pounds of stainless steel is melted at 3000
degrees Fahrenheit.
• After the shells are removed from the furnace, the liquid
metal is poured inside the cavities from a ladle 50 pounds at a
time.
• The process continues until all 500 pounds of melted metal
are poured. Usually, that equates to 24 average propellers or
10 pod or Zeus-drive props.
• Shells are then cooled on carts for about an hour before they
are transferred to the cleaning cell.

17. END