01-11-2016, 03:02 PM
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1. INTRODUCTION:
The motor is used to convert electrical energy into mechanical energy .The main parts of the motor is the stator and the rotor. The stator is the stationary part of the motor and it is placed in the casing, while The rotor is a moving component of an electromagnetic system in the electric motor, electric generator, or alternator. Its rotation is due to the interaction between the windings and magnetic fields which produces a torque around the rotor's axis.In manufacture of the rotor the material we used is MS(Mild Steel) of material grade: IS1079EDD sheets are used.
The cut tool length machine is used to cut the sheet in the required square block. Here the rollers are used to give the feed to the sheet and the cutting is done by the rollers.The press machines are the main machinery used in the manufacturing process. In this machine, the press tool is arranged in between the ram and table, the press tool in the press machine is designed for multipurpose. Here, the machine is intended for doing blanking and piercing.
The composition of the material used is: Carbon-0.08%, Manganese-0.35%, Phosphrous-0.03%,Sulphur-0.03%,Micro-Alloy none. The required size of sheet is manufactured by using the following composition.
The specifications of the “YAMAHA RAY Z & ZR SCOOTY” are:
113 cc four stroke motor engine
53 kmpl mileage
8.1 Nm @ 5500 rpm torque
7 Bhp @ 7500 rpm power
Automatic transmission
MANUFACTURINGPROCESS:
The raw material is selected for the manufacturing of the rotor by conduction quality test on the raw material by using universal testing machine and Spector meter and its thickness is measured by micrometer. Then the following process are:
Blanking
Phosphating
Draw
Center hole Piercing
Center hole extrusion & Flattening
All holes Piercing, Dimpling & Tapping hole extrusion
Pip Embossing
V-Marking
Face Turning & Center hole extrusion turning
Pip Turning
Tapping M 6 x 1.0-H
Zinc Coating
. Blanking:
Blanking is a mechanical process of cutting, punching, or shearing of a piece of metal into a desired shape. In blanking the punched out piece is used and called a blank. The remaining piece is called scrap.
The machine used for the blanking is 500T Mechanical Press. The diameter of the blank is ø162.0 ± 0.2.and thickness of the sheet is 3.2 ± 0.15.
The calculation for the capacity of the machine is:
{(πd×thickness of sheet×shearstess)/1000}
. Phosphating:
The phosphating is a process of the coating the MS piece with the solution of the iron, zinc or manganese phosphate salts, in phosphoric acid. Phosphating is used to reduces the draw of die & punch of friction.
The main uses of phosphating are:
Corrosion protection in conjunction with organic coatings, such as paints and polymer films.
Facilitation of cold-forming processes, such as wire drawing and tube drawing, or deep drawing.
Corrosion protection in conjunction with oils and waxes.
Corrosion protection with no subsequent treatment.
Improving anti-friction properties, such as break-in, wear resistance, anti-galling and coefficient of friction.
Providing strong adhesion bonding for subsequent painting or other organic coating.
. Draw:
Drawing is a metalworking process which uses tensile forces to stretch metal. As the metal is drawn (pulled), it stretches thinner, into a desired shape and thickness. Drawing is classified in two types: sheet metal drawing and wire, bar, and tube drawing.
The machines we used in the drawing are:
200T Capacity Hydraulic press.
160T Capacity Hydraulic press.
100T Capacity Hydraulic press.
80T Capacity Hydraulic press.
The calculation for the capacity of load of hydraulic press:
{(πd'×thickness of sheet×shearstess)/1000}
{(πd''×thickness of sheet×shearstess)/1000}
d’= outer diameter of the rotor,d”=chamfer diameter of the rotor
The dimensions of the rotor after drawing:
Inner Diameter : Ø 106.6 ± 0.15
Outer Diameter : Ø 113.0 ± 0.2
Radius : R2 ± 0.5
Face Flatness : 0.10 Max
Wall thick Variation : 0.10 Max
Strain of Cup : 0.10 Max
Cup Height : 36.0 Min
Chamfer Dia : Ø39 + 0.2
Chamfer Depth : 2.0 ± 0.2
. Center hole Piercing:
Piercing is a shearing process where a punch and die are used to create a hole in sheet metal or a plate. The process and machinery are usually the same as that used in blanking, except that the piece being punched out is scrap in the piercing process.
The machine used to create a center hole piercing is: 65 T / 45 T capacity mechanical press. The diameter of the center hole is: Ø33.50 ± 0.2.
The calculation for the capacity of the load of mechanical press:
{(πd×thickness of sheet×shearstess)/1000}
d= diameter of the center hole / top hole.
. Center hole extrusion & Flattening:
Extrusion is the process by which a block/billet of metal is reduced in cross section by forcing it to flow through a die orifice under high pressure.
Flattening is the process of increasing of flatness of the hole or anything.
The dimensions of the rotor after completion of the extrusion & flattening process
Center Hole extrusion dia : Ø39.0 ± 0.15.
Center hole inner diameter : 36 + 0.06.
Center hole extrusion height : 3.5mm Min.
Flatness : 0.1mm Max.
Radius : R 0.5 Max.
The machine we used to center hole extrusion & flattening is:65 T/ 45 T.
The calculation for the capacity of load of mechanical press:
{(πd×thickness of sheet×shearstess)/1000
d= diameter of the center hole.
. All holes Piercing, Dimpling &Tapping hole extrusion:
Piercing is a shearing process where a punch and die are used to create a hole in sheet metal or a plate. The process and machinery are usually the same as that used in blanking, except that the piece being punched out is scrap in the piercing process.
Tapping is the process of cutting a thread inside a hole so that a cap screw or bolt can be threaded into the hole. Also, it is used to make threads on nuts. Tapping is done with a tool called a "Tap".
The machine we used to piercing, dimpling & tapping is:63 T/ 45 T mechanical press. The calculation for the capacity of the load by mechanical press:
{(πd×thickness of sheet×shearstess)/1000
d=diameter of the of the holes.
The dimension of the rotor after completion of the above operation are:
ID Run Out : 0.20 Max
2 Holes Diameter : Ø10 = 0.2
3 Holes Diameter : Ø 6.1 + 0.1
2 Holes Diameter : Ø 4.6 + 0.2
4 Holes Diameter : Ø 5.15 ± 0.10
Center distance (dia10.00) : 18.24 ± 0.15, 35.6 ± 0.15
Center distance (dia6.1 with position 0.1) : 0, 24.5, 21.22, 12.25,
21.22,12.25.
Center distance (dia04.60) : 8.6 ± 0.2, 40.6 ± 0.20,
8.6 ± 0.2, 40.6 ± 0.20
Center distance (dia5.15 with PCD 78.900) :32.8 ± 0.1, 21.1 ± 0.1,
21.1 ± 0.1, 32.8 ± 0.1,
32.8 ± 0.1, 21.1 ± 0.1,
21.1 ± 0.1, 32.8 ± 0.1
Hole extrusion height : 3.5 Min
Tapping hole OD : Ø 7.0 Min
Flatness : 0.1mm Max
Dimple with : 5 – 0.2
Dimple depth : 2 – 0.5
Dimple distance : 47.5 + 0.3
Dimple Angular Position :00 ± 0.250
Radius :R 1.5 Max
. Pip Embossing:
Embossing is a stamping process for producing raised or sunken designs or relief in sheet metal. This process can be made by means of matched male and female roller dies, or by passing sheet or a strip of metal between rolls of the desired pattern.
The machine we used for pip embossing is: 110 T mechanical press.
The dimensions of the rotor after completion of the above operation are;
Pip Length : 58.5 ± 0.1
Pip Width : 9 ± 0.2
Pip Height : 20.0 ± 0.3(21.3)
Pip Radius : R 58.9 ± 0.2
Pip Position : 29.25 ± 0.10
ID Runout : 0.2 Max.
. V-Marking:
V-Marking is a process of marking the indications of the and direction of the
assemble in assembling process.
The dimensions of the rotor after completion of the above operation are:
V-Marking length : 10mm
V- Marking distance from end : 27mm
V- Marking position : 81.70± 0.50
V- Marking depth : 0.5mm
. Face Turning & Center hole extrusion turning:
In machining, facing is the act of cutting a face, which is a planar surface, onto the workpiece. Within this broadest sense there are various specific types of facing, with the two most common being facing in the course of turning and boring work (facing planes perpendicular to the rotating axis of the workpiece) and facing in the course of milling work (for example, face milling). Other types of machining also cut faces (for example, planing, shaping, and grinding), although the term "facing" may not always be employed there.
The machine we used for facing is CNC machine1,2
The dimensions of the rotor after completion of the above operation are:
Cup Height : 34.0
Face out : 0.20Max
I.D Chamfer : 0.50 ± 0.3
O.D Chamfer : 0.50 ± 0.3
Extrusion height : 2.0 Max.
Pip Turning:
Turning is a form of machining, a material removal process, which is used to create rotational parts by cutting away unwanted material. The turning process requires a turning machine or lathe, workpiece, fixture, and cutting tool. The workpiece is a piece of pre-shaped material that is secured to the fixture, which itself is attached to the turning machine, and allowed to rotate at high speeds. The cutter is typically a single-point cutting tool that is also secured in the machine, although some operations make use of multi-point tools. The cutting tool feeds into the rotating workpiece and cuts away material in the form of small chips to create the desired shape.
The machine we used to complete this operation is CNC 1&2 machine.
The dimensions of the rotor after completion of the above operation is:
Pip Radius : r58.5 ± 0.1
Tapping :
Tapping is the process of cutting a thread inside a hole so that a cap screw or bolt can be threaded into the hole. Also, it is used to make threads on nuts. Tapping is done with a tool called a "Tap".
The machine we used for the tapping is tapping machine.
The dimetions of the rotor after completion of the above operation is:
Thread size : m6 x1.0-6h – 4 places
Tap major diameter : 6.00mm
Zinc Coating :
Zinc coatings for iron and steel provide excellent corrosion resistance in most atmospheres, in hard fresh waters, and in contact with many natural and synthetic substances. Zinc coatings are widely used to protect finished products ranging from structural steelwork for buildings and bridges, to nuts, bolts, strip, sheet, wire and tube. The electrochemical relationship between zinc and steel enables zinc coatings also to protect steel at cut edges and at breaks in the coating by a sacrificial action.
The thickness of the zinc coating is minimum 8 Microns and after its color is light yellow.