College of Engineering

Mechanical & Aerospace Engineering Department

Design and Manufacture Lab, Spring 2024

Assignment 1 – Whether to Cast, Weld or Machine

Student Name ID
Shahad Albedwawi 201904439
Mouza Alameri 201804597
Mouna Alketbi 201903428
Elbatoul Mohammed 201917094

Submission date: 14th of Feb, 2024

 Table of Contents
Introduction..................................................................................................................................4
Organisation of the work ..............................................................................................................5
Process Description .......................................................................................................................6
Criteria, weights, and the Decision Matrix .................................................................................. 12
Learning experience ................................................................................................................... 23
References .................................................................................................................................. 24

Table of Figures

Figure 1: Support bracket................................................................................................................ 4

Figure 2: Casting Process................................................................................................................ 7
Figure 3: Welding process .............................................................................................................. 9
Figure 4 Machining Process......................................................................................................... 11
Figure 5: Decision matrix ............................................................................................................. 12
Figure 6: 3D model of the support bracket ................................................................................... 14
Figure 7: Defined workpiece ........................................................................................................ 14
Figure 8: Facing operation ............................................................................................................ 15
Figure 9: Adaptive clearing operation .......................................................................................... 15
Figure 10: Paralleling operation.................................................................................................... 16
Figure 11: Boxford code ............................................................................................................... 16
Figure 12: Home page of boxford machine .................................................................................. 17
Figure 13: Facing operation on the real workpiece ...................................................................... 18
Figure 14: Facing operation simulation ........................................................................................ 18
Figure 15: Adaptive clearing operation simulation ...................................................................... 19
Figure 16: Picture of the operation on the actual workpiece ........................................................ 19
Figure 17: Paralleing simulation ................................................................................................... 19
Figure 18: Extra material (debris) ................................................................................................. 20
Figure 19: Deburring tool ............................................................................................................. 20
Figure 20: Semi - finished workpiece ........................................................................................... 20
Figure 21: 20 mm measured using the height cage....................................................................... 21
Figure 22: Apicture of a student measuring 40 mm on the workpiece ......................................... 21
Figure 23: Another student measuring 22.5 mm on the workpiece .............................................. 21
Figure 24: Intersection of the 4 lines ............................................................................................ 22
Figure 25: 7 mm drilling tool ........................................................................................................ 22
Figure 26: Drilling operation ........................................................................................................ 23
Figure 27: 4 mm drilling tool ........................................................................................................ 23
 Table of Tables

Table 1: Task table .......................................................................................................................... 5

Table 2: Adv. and Disadv. .............................................................................................................. 7
Table 3: Adv. and Disadv. .............................................................................................................. 9
Table 4: Adv. and Disadv. ............................................................................................................ 11
Introduction

In this assignment, our goal was to figure out the best way to make a support bracket: by casting,
welding, or machining. After looking at things like cost, strength, and how complicated each
method is, we found that each has its pros and cons.
Casting, which involves using molds and molten metal, is the cheapest and easiest method. But it
doesn't make the strongest brackets and needs extra steps after casting.
Welding makes strong brackets at a decent cost, but it requires skilled workers and can sometimes
mess up the metal.
Machining makes the most precise and durable brackets, but it's the most expensive and takes the
longest. Plus, it wastes a lot of material.
Ultimately, the best choice depends on what the project needs and how much time and money we
have. We need to think about things like strength, budget, and how complex the bracket is. It's
important to weigh all these factors and pick the method that fits our project best. Also In this
experiment, we used plastic piece to make it easier to cut and shape the workpiece. We started
by facing then paralleling and lastly to make it smooth finishing, then drilled holes, which was a
bit tricky. After that, we smoothed out the surface to make it look nice. The final product turned
out just like we wanted like the CAD model although we had to do adjustments as seen in the
manufacturing process.

FIGURE 1: SUPPORT BRACKET

 Organisation of the work
T ABLE 1: TASK TABLE
Team Joint/Individual Tasks Planned Progress Evaluation Minutes
Member Accountability Meetings
Elbatoul Joint 1. Organization of the Weekly Review the 1 hr and
work and tasks (Wednesday) manufacturing procedure 30
distributed to each checking the pictures minutes
member. aligned with the steps.
2. Describing the
Manufacturing Planning
and manufacturing of
the bracket.
Shahd Individual 1. Overall Project Weekly Review report progress, 1 hr and
coordination and (Wednesday) address the chosen 30
oversight criteria and Decision minutes
2. Schedule management matrix
3. Choosing the criteria
and weight and
Choosing the Decision
Matrix
Mouza Individual 1. Describing the Weekly All Members should 1 hr and
Introduction (Wednesday) review the learning 30
2. Describing the learning experiences stated in the minutes
experience and gaining report and should include
insights from members about their insights and
the items that they have opinions.
learned.

Mona Joint 1. Process description. Weekly Review the 1 hr and

2. Describing the (Wednesday) manufacturing procedure 30
Manufacturing Planning by checking the pictures minutes
and manufacturing of aligned with the steps.
the bracket.
Process Description

a) Manufacturing using Casting Process:

Manufacturing with casting means making parts by pouring melted material into a shaped mold.
When the material cools down, it becomes solid and takes the shape of the mold, creating the
finished product. This method can make different shapes and sizes, from simple to very detailed
designs. The Process of casting has five steps:

1. Making the Pattern: First, a model of the part is made from wood, metal, or plastic. This
model shows exactly how the final part will look.
2. Building the Mold: Next, a mold is made around the pattern. The mold usually has two
halves that fit together and create a hole where the melted material will be poured.
3. Melting and Pouring: The material, like metal, is melted in a very hot furnace. Then, it's
poured into the mold through a channel called a sprue, which helps the material flow into
the mold.
4. Cooling Down and Getting Hard: The melted material cools down and becomes solid inside
the mold, taking the mold's shape. Sometimes, cooling down happens faster with special
cooling methods.
5. Taking Out and Finishing: Once the material is cool and hard, the mold is opened, and the
new part is removed. It might need extra work, like cutting or polishing, to make it look
just right.

FIGURE 2 SAND CASTING

To make a bracket using casting :

Casting involves pouring molten metal or other materials into a mold cavity, allowing it to
solidify, and then removing the finished part from the mold.
To make a bracket using casting, a mold is created with the desired bracket shape, and molten
metal is poured into the mold cavity.
Sand casting is a common method where sand molds are used to create the mold cavity.
Casting can produce brackets with complex shapes, but the surface finish may be coarse due to
the texture of the sand mold and potential for sand grains to become embedded in the finished
part.

T ABLE 2: ADV. AND DISADV.

Advantage: Disadvantage:
Creating Intricate Shapes: Casting lets you Needs Extra Finishing: Parts made with
make intricate shapes that might be hard to casting might need extra work to get the
make with other methods. surface smooth.

Works with Many Materials: It can use Accuracy Can Be Tricky: It's hard to get
different materials like metals, plastics, and really exact measurements and tight fits,
ceramics, giving you lots of options. especially for detailed parts.

Less Waste: It doesn't waste as much material Might Have Holes or Imperfections:
because you can recycle the extra. Sometimes, there can be holes or other things
in the material that weaken the part.

FIGURE 2:
3 CCASTING
ASTING P
PROCESS
ROCESS
 b) Manufacturing using Welding Process:
Making things with welding means sticking metal pieces together by melting them and mixing
them up. People do this a lot in different industries to create stuff like buildings, machines, cars,
and more. Here's how welding works in simple steps:

1. Getting Ready: First, the metal pieces are cleaned to get rid of any dirt or rust that could
mess up the weld. Sometimes, the edges are shaped to make sure the weld is strong.
2. Adding Heat: Welding needs heat to melt the metal and make it stick together. Different
types of welding use different heat sources, like electric sparks, flames, or super bright
lights.
3. Melting and Mixing: When the metal gets hot, it melts and mixes. As it cools down, it
turns back into solid metal, but now it's joined with the other pieces.
4. Adding More Metal (If needed): Sometimes, extra metal is added to make the weld
stronger. This extra metal melts along with the main metal and fills any gaps between the
pieces.
5. Cooling Down: After welding, the joint cools off and becomes solid. Now, the pieces are
stuck together.
6. Checking and Finishing: The weld is checked to make sure it's good. This could mean
looking at it or doing tests to see if there are any problems. Depending on what it's for,
the welded part might be smoothed out or painted.

FIGURE 4 FIXTURE FOR THE CORNER JOINT

In welding, especially when joining metal pieces at a corner fig 4 , it's crucial to ensure precise
alignment and stability to achieve a strong and accurate weld. Fixtures for corner joints are
designed to securely hold the pieces in place during the welding process, maintaining the desired
angle and alignment.
These fixtures come in various forms, ranging from simple clamps to more complex structures
tailored to specific joint configurations. They provide support and stability, allowing the welder
to focus on the welding process itself without worrying about the alignment shifting or the pieces
moving out of place.
Overall, fixtures for corner joints in welding play a critical role in achieving high-quality welds
by ensuring proper alignment, stability, and consistency in the joint configuration.

To make a bracket using welding:

Welding involves joining metal pieces together by melting them at the joint and allowing them to
cool, forming a bond.
To make a bracket using welding, metal plates or rods are positioned and aligned, and then welding
equipment, such as a welding machine or torch, is used to fuse the pieces together at the desired
locations.
Welding produces a sturdy bracket, but the surface finish may be rough with irregularities due to
the molten metal deposition and weld beads.

T ABLE 3: ADV. AND DISADV .

Advantage: Disadvantage:
Strong Connections: Welding makes tough Heat Effects: Welding can change the
and lasting joints, perfect for joining metal properties of the metal around the weld,
parts in buildings and machines. making it weaker or harder.

Saves Money: Welding often costs less than Safety Concerns: Welding can be risky
other ways of joining parts when making lots because of the high temperatures and fumes,
of things, as it doesn't need many extra so it's important to follow safety rules to keep
materials or tools. workers safe.

Works Quickly: Welding machines can do Pollution Problems: Welding can create
jobs fast, which helps get things made faster harmful gases and waste, which can harm the
and more efficiently. environment if not handled properly.

FIGURE 3 : W ELDING PROCESS

 c) Manufacturing using Machining process:
Manufacturing with machining means shaping and cutting raw materials into the right shape and
size using different cutting tools and machines. This method is used in many industries to make
parts that are the right size and have smooth surfaces. Here's how it works:

1. Choosing Materials: First, we pick the right raw material, like metal, plastic, or wood,
based on what the final part needs to be.
2. Design and Programming: After selecting the material, we turn the part design into
instructions for the machining equipment. This involves programming CNC machines
with specific paths and settings to make the part.
3. Setting Up: The raw material is put securely in the machine, like a lathe or milling
machine, to make sure it stays in place while we work on it.
4. Cutting and Shaping: We use cutting tools, like drills or mills, to remove material from
the workpiece according to the instructions we programmed. This can involve different
operations like turning, milling, drilling, or grinding, depending on what we need.
5. Precision: Machining is done with very high accuracy to make sure the final part is
exactly the right size and shape.
6. Finishing: After machining, we might do extra processes like deburring or polishing to
make the surface smooth and clean.
7. Checking: We carefully inspect the finished parts to make sure they meet our quality
standards. We measure them and check for any defects.
8. Packing and Shipping: Finally, once everything looks good, we pack up the parts and
send them out to customers or to be used in assembly lines.

To make a bracket using machining :

• Machining involves removing material from a workpiece using cutting tools such as
drills, mills, or lathes to achieve the desired shape and dimensions.
• To make a bracket using machining, a solid block or bar of metal is clamped in a
machine, and cutting tools are used to remove material and shape the bracket.
• Machining allows for precise control over dimensions and surface finish, resulting in
smooth and accurately sized brackets.

Why machining is the better option:

Surface Finish: Machining produces the best surface finish among the three methods. It results in
smooth, uniform surfaces free from irregularities, making the bracket aesthetically pleasing and
suitable for applications where surface finish is important, such as visible parts or parts requiring
tight tolerances.
Precision: Machining allows for tight tolerances and precise control over dimensions, ensuring
the bracket meets exact specifications.
Versatility: Machining can be used on a wide range of materials, including metals, plastics, and
composites, providing flexibility in material selection for the bracket based on factors such as
strength, weight, and corrosion resistance.
Customization: Machining offers flexibility in designing and refining the bracket's shape and
features to meet specific requirements or design preferences.
Consistency: Machining processes are highly repeatable, ensuring consistent quality and
dimensional accuracy from bracket to bracket.
Overall, machining is the preferred method for making brackets due to its ability to produce
high-quality parts with excellent surface finish, precision, versatility, customization, and
consistency.

T ABLE 4: ADV. AND DISADV .

Advantage:
Accurate Shaping: Machining enables
precise shaping and cutting of materials,
ensuring parts have exact dimensions and
close tolerances.
Disadvantage:
Material Loss: Machining produces a lot of
waste material when shaping parts, leading to
higher material costs and environmental
issues.

Material Flexibility: It works with various Time Consumption: Machining processes

materials like metals, plastics, and wood, can take a long time, especially for intricate or
providing versatility for making different large-scale projects, resulting in delays in
kinds of parts. production.

Diverse Operations: Machining includes Expensive Equipment: Machining

many operations such as milling, turning, equipment like CNC machines and tools can
drilling, and grinding, allowing for complex be costly to buy and maintain, adding to the
shapes and features initial investment for manufacturing.

FIGURE 5 MACHINING PROCESS

 Less
Criteria, weights, and the Decision Matrix Important

1. Complexity of Design: How suitable is the process for complex shapes and intricate Figure
designs. 5:
2. Cost: Evaluate the cost of the process, including tooling, setup, and material costs. decisio
3. Tolerances: Consider the achievable tolerances through the process and ensure they meet n
the design requirements. matrixL
4. Joint Strength: Ensure the joints can withstand the expected load and stress. ess
5. Material Waste: Assess the amount of material waste generated during the process. Important
6. Surface Finish: Consider the required surface finish and how it can be achieved through
the process.
7. Material Hardness: Check if the material is suitable for the process, considering its
hardness.
Very
Important

Figure
7 : 3d
model
of the
support
bracket
Very
Important

FIGURE 5: DECISION MATRIX

Surface finish refers to the texture or quality of the surface of a material after a manufacturing
process. In welding, sand casting, and machining, each process produces different surface finishes.

1. Welding: Welding often results in rough surfaces with irregularities caused by the
deposition of molten metal and the formation of weld beads. The surface may have weld
spatter, rough edges, and unevenness.
2. Sand Casting: Sand casting produces surfaces with a coarse texture due to the sand molds
used in the casting process. The surface may have sand grains embedded in it, resulting in
a rough finish.
3. Machining: Machining typically yields the best surface finish among these processes. It
involves cutting away material using tools such as lathes, mills, or drills to achieve precise
dimensions and smooth surfaces. Machined surfaces are smooth, uniform, and free from
irregularities.

Machining is often considered the best option for achieving high-quality surface finishes due to
several reasons:

• Precision: Machining allows for tight tolerances and precise control over surface features,
resulting in smooth and accurately sized parts.
• Versatility: Machining can be used on a wide range of materials, including metals, plastics,
and composites, making it suitable for various applications.
• Customization: Machining offers flexibility in designing and refining surface finishes to
meet specific requirements or aesthetic preferences.
• Consistency: Machining processes are highly repeatable, ensuring consistent surface
finishes from part to part.

Overall, machining is preferred when a smooth and precise surface finish is desired, making it the
best option among welding, sand casting, and machining processes.

The less the RMS the higher surface finish , our cast surface is Normal Non-Ferrous Sand which
it RMS is between 300-500

FIGURE 6 CAST MICROFINISH

COMPARATOR S URFACE ROUGHNESS
Manufacturing planning and manufacturing of the bracket

Manufacturing planning of the bracket:

Step 1: Designing the specified Shape in Auto Desk inventor.

FIGURE 7 : 3D MODEL OF THE SUPPORT BRACKET

FIGURE
Step 2: We clicked 7 : 3CAM
on the D MODEL
optionOF THE
and SUPPORT
then to setup BRACKET
to create a tool operation for the BoxFord
machine by first defining our workpiece and defining the starting axis our workpiece. One of the
requirements that we stated that the shape should have a depth and height and width of 100 mm.

CAM

CAM
Setup

Figur
e8
:defin
ed
work
piece
Setup

FIGURE 8 :DEFINED WORKPIECE

Step 3: First operation is Facing.

FIGURE 9 : FACING OPERATION

Step 4: Second operation is Adaptive clearing.

FIGURE 10 : ADAPTIVE CLEARING OPERATION

Step 5: Third operation is Paralleling to create a flat surface on the z-axis.

FIGURE 11: PARALLELING OPERATION

Step 6: We create a code that is suitable for the Boxford and we save it to a flash drive so we can
connect to the machine.

FIGURE 12: BOXFORD CODE

FIGURE 12: BOXFORD CODE

Manufacturing of the plastic block by machining
Step 1: Clicking on the setup to start the program.

Setup

Figure
13
:home
page
of
FIGURE 13 :HOME PAGE OF BOXFORD MACHINE boxfor
d
FIGURE 15: FACING OPERATION ON THE REAL machi
WORKPIECE FIGURE 13 : HOME PAGE OF BOXFORD neSetu
MACHINE p
 Step 2:- First operation by machining is Facing

F IGURE 14 :FACING OPERATION SIMULATION FIGURE 15: FACING OPERATION ON THE REAL
WORKPIECE
F IGURE 16: ADAPTIVE CLEARING OPERATION
SIMULATION FIGURE 14 : FACING OPERATION FIGURE 14 :FACING OPERATION
Step 3:- Second Operation by machining is Adaptive clearing
SIMULATION SIMULATION FIGURE 15: FACING OPERATION ON
THE REAL WORKPIECE

Feed Rate
v

Spindle Speed

We utilize the BoxFord machine instead

of a CNC machine because the workpiece
is cubic in shape not cylindrical.
 FIGURE 16: ADAPTIVE CLEARING OPERATION SIMULATION
Step16:
FIGURE 4: ADAPTIVE
Third Operation by machining is Paralleling
CLEARING OPERATION SIMULATION

Extra
material that
wasn’t
removed by
FIGURE 17: PARALLELING SIMULATION FIGURE 18:PICTURE OF THE the machine.
OPERATION ON THE ACTUAL
FIGURE 20: EXTRA MATERIAL WORKPIECE Figure
(DEBRIS)FIGURE 17: PARALLELING 18:picture of
Step 5 : We used the Deburring tool used to remove
SIMULATION FIGURE
the debris.
17: PARALLELING the operation
SIMULATION FIGURE 18: PICTURE OF on the actual
THE OPERATION ON THE ACTUAL workpieceEx
WORKPIECE tra material
that wasn’t
removed by
the machine.
 FIGURE 19 :DEBURRING TOOL FIGURE 20: EXTRA MATERIAL (DEBRIS)

FIGURE 21: SEMI - FINISHED

WORKPIECE FIGURE 19
:DEBURRING TOOL

FIGURE 21: SEMI - FINISHED WORKPIECE

Drilling Procedure to create 4 holes.

Step 1: We used the Height cage to draw accurate measurements (metric scale) to find the
interactions of the 4 lines. We first drew horizontally 20 mm for the first circle then also drew
horizontally 40 mm for the second circle then flipped the object vertical to draw horizontally
22.5 mm on both ends of the object.
 FIGURE 23: A PICTURE OF A STUDENT
FIGURE 22: 20 MM MEASURED USING THE MEASURING 40 MM ON THE WORKPIECE
HEIGHT CAGE
FIGURE 24: ANOTHER STUDENT MEASURING
FIGURE 23: A PICTURE OF A STUDENT 22.5 MM ON THE WORKPIECE FIGURE 23: A
MEASURING 40 MM ON THE PICTURE OF A STUDENT MEASURING 40 MM
WORKPIECE FIGURE 22: 20 MM MEASURED ON THE WORKPIECE
USING THE HEIGHT CAGE

FIGURE 24: ANOTHER STUDENT MEASURING 22.5 MM

ON THE WORKPIECE

FStep 2: - 24:
IGURE ANOTHER
Marking STUDENT
red dotes MEASURING
to show 22.5 of
the intersection MM the 4 lines.
ON THE WORKPIECE
 20 mm

20 mm
100-22.5=77.5mm
We had to mark a 77.5 mm so that
the spacing between the top and
bottom circles in the figures would
40 mm
be 55 mm apart since we had
inclined part of plastic in the top as
40 mm
seen in the red circle, so we had to
do some adjustments.
22.5 mm

100-22.5=77.5mm
Figur We had to mark a 77.5 mm so that
e 25: the spacing between the top and
inters bottom circles in the figures would
ection be 55 mm apart since we had
inclined part of plastic in the top as
of the seen in the red circle, so we had to
4 do some adjustments.
linesF22IGURE 25: INTERSECTION OF THE 4 LINES
.5 mm Step 3: - We drilled holes using a 7mm drilling tool and followed up with a 4mm drilling tool to
F IGURE 27:the
deburr 7 MM DRILLING
holes, ensuringTOOL FIGURE
a smooth finish25:
on the circles."
INTERSECTION OF THE 4 LINES

FIGURE 27: 7 MM DRILLING TOOL

 FIGURE 26:DRILLING OPERATION

FIGURE 28: 4 MM DRILLING

TOOL F IGURE 26:DRILLING OPERATION

F IGURE 28: 4 MM DRILLING TOOL

Learning experience

In this experiment, we utilized Autodesk Inventor (CAD/CAM software ), to construct a digital

3D model of the support bracket design.
The machining process for the support bracket encompassed three key stages: design, toolpath
generation, and physical machining and are explained below.
o Design: Employing Autodesk Inventor, we formulated a virtual design of the support bracket,
encompassing all essential features, dimensions, and angles.
o Toolpath Generation: Subsequent to the design phase, the CAD/CAM software generated
toolpaths instructing the Boxford machine's cutting tools on shaping the bracket accurately.
o Machining: Following the toolpaths, we proceeded to manufacture the support bracket
physically using the Boxford machine.
The precision and quality of the support bracket were upheld by the Boxford machine's precise
cutting capabilities.Through machining and CAD/CAM software, we expedited the creation of a
support bracket with intricate shapes and high precision.This experiment underscored the
significance of (CAD/CAM) software in the manufacturing process, streamlining design, toolpath
generation, and ensuring fabrication precision, thereby demonstrating its value and advantages.
References
- Course document on blackboard
- https://www.rapiddirect.com/blog/different-types-of-casting-process/
- https://www.westermans.com/submerged-arc-welding-process.aspx
- https://www.custompartnet.com/wu/milling
- https://templatelab.com/decision-matrix/#google_vignette
- Degarmo, E. Paul, et al. "Materials and Processes in Manufacturing." Wiley, 2011.
- Groover, Mikell P. "Fundamentals of Modern Manufacturing: Materials, Processes, and
Systems." Wiley, 2018.
- Cary, Howard B., and Scott C. Helzer. "Modern Welding Technology." Goodheart-
Willcox Publisher, 2019.
- Kalpakjian, Serope, and Steven R. Schmid. "Manufacturing Engineering and
Technology." Pearson, 2019.
- Campbell, John. "Castings." Butterworth-Heinemann, 2003
- Hicks, John. "Welded Design: Theory and Practice." CRC Press, 2001.