Manufacturing processes lab

Lab Project
Submitted By:

22-ME-04
22-ME-08
22-ME-12
22-ME-52
22-ME-64
22-ME-68
22-ME-136
22-ME-164
22-ME-180

Submitted To: Engr. Muhammad Nouman

Faculty of Mechanical & Aeronautical Engineering

University of Engineering & Technology Taxila

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1.1 Objective
The goal of this project is to design and implement an efficient and cost-effective manufacturing
process to produce metal components. The process will involve welding and finishing operations
and will focus on optimizing these stages to achieve superior product durability, appearance, and
performance. In this report, we will explore the various steps involved in welding together the
components of the car body to form a cohesive structure. After the welding was complete, we
paid close attention to detail to make sure the surface was smooth and free of imperfections. This
finishing touch not only enhances the appearance of the car but also ensures its durability and
strength. In this report, we will discuss the welding process we used, the challenges we faced,
and the methods we employed to achieve a high-quality finish.

1.2 Material Selection

Automobile outer bodies are commonly made from a variety of materials, each offering different
properties and advantages. Some of the most famous materials used in automobile outer body
manufacturing include:

i. Steel
Traditional steel remains a popular choice due to its strength, durability, and cost-
effectiveness. It's often used in body panels and structural components.
ii. Aluminum
Aluminum is lightweight and corrosion-resistant, making it ideal for reducing vehicle
weight and improving fuel efficiency. It's commonly used in body panels, hoods, and
doors.
iii. Carbon Fiber
Carbon fiber composites offer exceptional strength-to-weight ratio and are used in high-
performance vehicles to reduce weight and improve rigidity. They're typically found in
premium and sports cars.
iv. Plastic
Various types of plastics, such as ABS (Acrylonitrile Butadiene Styrene) and
polycarbonate, are used for non-structural body components like bumpers, trim pieces,
and interior panels due to their lightweight nature and design flexibility.
v. Fiberglass

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 Fiberglass composites are lightweight and offer good impact resistance. They're often
used in custom car bodies and aftermarket components.
 High-quality steel sheets were carefully selected based on their suitability for welding
and shaping into the prototype.
 Steel sheets offer the necessary structural integrity to withstand loads and stresses,
ensuring the longevity and robustness of the prototype.
 Steel sheets are widely available and cost-effective compared to other materials, making
them a practical choice for manufacturing the prototype within budget constraints.

Steel sheets offer a smooth and uniform surface finish, providing an excellent base for applying
automotive-grade paints and finishes to achieve the desired aesthetic appeal of the prototype. The
sheets were accurately cut and shaped to match the dimensions specified for the model.

1.3 Manufacturing Operations

Following are the operations that we have performed:
 Cutting
 Bending
 Welding
 Finishing
1.3.1 Cutting

1.3.2 Bending
Sheet metal bends are formed using metal bending. Metal bending is a process by which metal
can be deformed when applying force to the subject, which causes it to bend at an angle and
form the anticipated shape, which often results in it being in a ‘V’ or a ‘U’ shape.

A press brake is a tool used in order to and uses a punch and die to do this. Although press
braking may seem straight forward, it can be quite difficult to remain accurate throughout the
process. There are several types of press brakes which deliver different levels of force applied,
such as mechanical, pneumatic, hydraulic and CNC to name a few examples.

 Mechanical
Due to this press brakes design, it isn’t a suitable option for air bending. The two major

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 benefits of a mechanical press brake are speed and accuracy, however other press brakes are
safer and easier to use, such as the CNC press brakes.
 Pneumatic
A compressor is used to supply air power for bending the metal sheets. This type of press
brake is often used when less pressure is needed. A pneumatic press brake is also best used
for bending small parts of metal.
 Hydraulic
Hydraulic press brakes often have the latest technology incorporated within them and are
best used for precise bending of metal sheet, which makes them a popular choice for sheet
metal bending.

1.3.2.1 Avoid Bending to a Sharp Internal Corner

It’s important to avoid bending to a sharp internal corner when producing sheet metal bends
because it could cause cracking or weakening of the metal. This can be avoided by having a
radius on your tool.

Note: The thickness of the material you’re producing should be the same as the inside bend
radius.

1.3.2.2 Use a Press Brake

Brakes are extremely useful for creating a clean bend, as the metal won’t be wavy or even
warped. The two biggest advantages of a mechanical press brake have to be the speed and
accuracy it offers when bending sheet metal.

1.3.2.3 Protect the Surfaces

Take care of the appearance of your metal by avoiding scratching its surface.

Note: The best way to avoid scratches is to use masking tape anywhere that might come into
contact with something hard. Similarly, you could also use wood blocks to protect the section
when bending.

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1.3.2.4 Bend Allowance
Bending metal involves pushing, pulling, or stretching the material. Therefore, you need to
calculate the bend allowance because this will offer you reliable numbers to work from when
you lay out a flat sheet.

Certain factors need to be considered with this, such as material thickness and internal radius
size. Bend allowance is compensation for what happens to the material when it is stretched and
formed from a flat pattern into the desired bend. By working out this bend allowance, you can
figure out how much of a flange will remain when you’ve made the desired bend.

1.3.3 Welding
Welding is a fabrication process that joins materials, typically metals, by melting and fusing
them together. This fusion is achieved by applying heat and sometimes pressure, creating a
strong and permanent bond between the materials. There are several welding processes
commonly used for joining steel sheets in various industries. Here are some of the most prevalent
ones:

i. Shielded Metal Arc Welding (SMAW)

Also known as stick welding, SMAW uses a consumable electrode coated in flux to
create an arc between the electrode and the workpiece. It's versatile and can be used in
various positions.
ii. Gas Metal Arc Welding (GMAW)
Also known as MIG (Metal Inert Gas) welding, GMAW uses a continuously fed wire
electrode and a shielding gas to protect the weld pool. It's efficient for welding thin to
thick steel sheets.
iii. Flux-Cored Arc Welding (FCAW)
Like GMAW, FCAW uses a tubular wire electrode filled with flux, eliminating the need
for an external shielding gas. It's suitable for depositing and can provide higher deposit
rates.
iv. Gas Tungsten Arc Welding (GTAW)
Also known as TIG (Tungsten Inert Gas) welding, GTAW uses a non-consumable
tungsten electrode and a separate filler material if necessary. It produces high-quality
welds but requires more skill and control.

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 v. Submerged Arc Welding (SAW)
SAW involves feeding a continuous wire electrode under a blanket of granular flux. The
arc is submerged beneath the flux layer, resulting in deep weld penetration and high
deposition rates.

The arc welding process, specifically Shielded Metal Arc Welding (SMAW), was utilized for
joining the steel sheets together. SMAW, commonly known as stick welding, provides excellent
control and penetration, making it suitable for welding thin steel sheets.

 Shielded Metal Arc Welding (SMAW) was selected for its ability to provide precise and
accurate welds, essential for fabricating intricate components of the prototype.
 It is a versatile process that can be easily adapted to various thicknesses of steel sheets,
allowing for flexibility in design and construction.
 This versatility enables the fabrication of complex geometries and intricate details. The
welding parameters were carefully adjusted to ensure strong and uniform welds,
maintaining the structural integrity of the prototype.