05-09-2014, 03:04 PM
It is a well-known fact that theoretical knowledge is totally handicap without the practical approach to the thing. Main purpose of the industrial training is to expose the trainees with practical experience of actual industrial conditions in which they will require to work in future and make them aware of the difference between the environment of industrial and college or homes. Thus the aim of the industrial training is to understand the layout of the industry, dealings with the various operations going in it and makes trainees to learn from the experiences of the professional Managers and skilled workmen with whom they are placed for training who have to work together with cooperation to achieve the common goal of the industry. This type of training gives chance for future advancement, thus giving trainee’s chance for specialization in particular fields. In industry, we perform the work, which we have studied in our theory portions. We get an extra knowledge by working in an industry and we also came to k
PROJECT: ROTTEL FORGING THE VARIOUS STEPS INVOLVED IN DESIGNING AND MANUFACTURING OF ROTTEL FORGING ARE EXPAINED IN DETAIL BELOW: PREPARING CAD DATA FOR ROTTEL FORGING Sketch: - Sketch is a combination of entities, which can be a closed figure or a open figure. It is 2D view of a component, which is used for a protrusion of component. By using the entities like line, arc and ellipse, a sketch is created in the workspace of the CAD software. Figure must be close because the object which we have to create is a solid. Lines are drawn using the Line chain command and Arcs are drawn by using the ARC command. In Creo Parametric, an arc can be drawn in 5 different ways. Extrude Command :- After creation of the sketch, the next step is to convert the 2-Dimensional Sketch into a 3-dimensional Model. This is done by selecting the already created sketch and then applying the Extrude Command. The extrude command simply creates a 3-Dimensional solid (or surface) by projecting a 2-Dimensional section at a specifies distance, normal to the sketching plane. In short, we can say that it gives the Height or Depth of the Object/Model into the third axis (i.e. Z-axis). We can use Extrude in two different modes: 1. Add Material 2. Remove Material The Add material mode will add the material to already existing model or to a sketch. We usually use the Add material option when we need to create a feature above another feature or while converting a sketch into a model. Whereas the Remove material option needs an existing model from which we have to remove the material. The remove material option is usually used to create Slots, Holes or features having depth into the existing model. By default, the Extrude command works in the Add Material mode. Steps: 1. Select the sketch to be extruded. 2. Click on the Extrude button provided in the ‘Shapes’ Group. 3. Specify the Height/Depth of the feature to be generated. 4. Use the ‘Flip Side’ option if there is a need to flip the direction of extrude from the sketching plane. 5. Use the Remove Material option (present next to the flip side option in Extrude Command dashboard) if we need to cut out some material or to create a slot or hole in a pre-existing model. 6. Then click ‘Preview’ to check whether the Extrude command has been applied in a desired way or not. 7. If it is Ok then Click ‘Complete Geometry’ button in the Extrude Dashboard which will save the features created and will exit the extrude command. If the extrude command has not been desirably applied, then before clicking the Complete Geometry button we can click on the ‘play/pause’ button in the Extrude dashboard and make necessary changes or else we can also make changes by using ‘Edit’ or ‘Edit definition’ options. Hole Command :- Hole is the pick and place type of feature, which is used for generating the Cylindrical holes on the part/feature/model. A hole is different from other cut-outs in the following manner: Only the features with a circular cross section are categorized under the category of ‘Holes’. All other types of cut outs having non-circular cross sections are categorized under ‘Slots’. Steps: 1. Select the surface on which we have to create a hole. 2. Click on the ‘Hole’ command present in the Engineering Group. 3. A hole appears on the selected surface with two Green colored Draggers or Boxes. 4. Click on the Green boxes one by one and drag them to an edge/surface or a point from where we want to specify the distance of the centre of the Hole. 5. Then specify the diameter of the hole to be created. 6. Finally, specify the depth of the hole. A hole can be created in any of the following 6 modes : a) Blind (ends up within the Model/Part) b) Symmetric (Symmetric about the Plane/Surface at which it being created) c) Through (Through the Model/Part) d) To selected (To a selected surface, Plane or edge) e) Through until (Through all the surfaces which are parallel to the surface at which hole is being created) f) To next (To the surface which comes next in the selected direction) A similar hole, with a different diameter and depth is also created on the top side of the rottel forging using the Hole command. Extrude Command :- Extrude command is again used to create the protrusions on the top side of the forging. The section(sketch) was created using sketch command and then extruded to the desired height. Extrude Command:- After creating the above protrusions, we need to cut them into desired shape. For this, we will use the extrude command again. But now, as we need to cut the material from an existing feature, so we will use extrude command with Remove material mode. We will create a sketch of the shape to be cut on a plane, perpendicular to the required cut out. After creating the section, we will extrude it in such a way that the model takes the shape as required. Round Command:- Then, we will use the Round command to obtain rounded edges on the rottel forging. It is done by following steps: 1. Click on the Round tool present in the Engineering group. 2. Then select the edge on which we want to apply the fillet. 3. Then specify the Fillet radius. 4. Click on complete Geometry Icon after applying the fillet to exit the round command. Advantages of filleting the sharp edges: 1. It removes the sharp edges which may cause injury. 2. It converts the sharp edge into a surface which uniformly distributes the stress which is subjected on the edge. i.e. converts the concentrated load into a UDL. 3. It also saves the material. (only when filleting is done on external edges) 4. It gives an aesthetic look to the Compents. 5. A component which has filleted edges will not lock into the core and cavity assembly when it is manufactured. Hence it can be easily withdrawn from the core- cavity assembly. The edges after filleting are shown in the following picture: Draft Angle Command:- After all the features of Rottel forging were created, we gave the Draft allowance by using the Draft Commnad present in the Engineering Group. The draft allowance is provided on all the vertical surfaces/walls of the component/model. It is provided in order to facilitate the easy withdrawal of the component from its core and cavity. Steps: 1. Select the Draft command from engineering group. 2. Press CTRL and select all the vertical surfaces on which we want to apply the Draft Angle. 3. Then click on the References tab and click on the ‘Draft Hinge’ option. 4. Select the horizontal plane/surface from which we have to apply the Draft angle. 5. Then set its direction according to our requirement. 6. Give the draft angle value in degrees. 7. In order to give a variable draft, click on the ‘split’ tab located next to the Split tab. 8. In the split dialog box, select ‘split by draft hinge’. 9. Specify the different draft angles for the different sides about the draft hingle plane. 7. Select the required side of the draft angle. (i.e. inwards or outwards) 8. Click on complete geometry icon to complete the component and exit the draft command. first the draft angle applied on the inner side of the vertical protrusion. DRAFT ANGLE ON INNER SIDE OF VERTICAL PROTRUSION DRAFT ANGLE ON THE OUTER SURFACE OF PROTRUSION DATA MIGRATION: Data migration is done to convert the CAD data into other format for Prototype production and CNC manufacturing purposes. For data migration, copy of the cad file is saved as in some other file format according to required format. (usually .stp format)
PROJECT: ROTTEL FORGING THE VARIOUS STEPS INVOLVED IN DESIGNING AND MANUFACTURING OF ROTTEL FORGING ARE EXPAINED IN DETAIL BELOW: PREPARING CAD DATA FOR ROTTEL FORGING Sketch: - Sketch is a combination of entities, which can be a closed figure or a open figure. It is 2D view of a component, which is used for a protrusion of component. By using the entities like line, arc and ellipse, a sketch is created in the workspace of the CAD software. Figure must be close because the object which we have to create is a solid. Lines are drawn using the Line chain command and Arcs are drawn by using the ARC command. In Creo Parametric, an arc can be drawn in 5 different ways. Extrude Command :- After creation of the sketch, the next step is to convert the 2-Dimensional Sketch into a 3-dimensional Model. This is done by selecting the already created sketch and then applying the Extrude Command. The extrude command simply creates a 3-Dimensional solid (or surface) by projecting a 2-Dimensional section at a specifies distance, normal to the sketching plane. In short, we can say that it gives the Height or Depth of the Object/Model into the third axis (i.e. Z-axis). We can use Extrude in two different modes: 1. Add Material 2. Remove Material The Add material mode will add the material to already existing model or to a sketch. We usually use the Add material option when we need to create a feature above another feature or while converting a sketch into a model. Whereas the Remove material option needs an existing model from which we have to remove the material. The remove material option is usually used to create Slots, Holes or features having depth into the existing model. By default, the Extrude command works in the Add Material mode. Steps: 1. Select the sketch to be extruded. 2. Click on the Extrude button provided in the ‘Shapes’ Group. 3. Specify the Height/Depth of the feature to be generated. 4. Use the ‘Flip Side’ option if there is a need to flip the direction of extrude from the sketching plane. 5. Use the Remove Material option (present next to the flip side option in Extrude Command dashboard) if we need to cut out some material or to create a slot or hole in a pre-existing model. 6. Then click ‘Preview’ to check whether the Extrude command has been applied in a desired way or not. 7. If it is Ok then Click ‘Complete Geometry’ button in the Extrude Dashboard which will save the features created and will exit the extrude command. If the extrude command has not been desirably applied, then before clicking the Complete Geometry button we can click on the ‘play/pause’ button in the Extrude dashboard and make necessary changes or else we can also make changes by using ‘Edit’ or ‘Edit definition’ options. Hole Command :- Hole is the pick and place type of feature, which is used for generating the Cylindrical holes on the part/feature/model. A hole is different from other cut-outs in the following manner: Only the features with a circular cross section are categorized under the category of ‘Holes’. All other types of cut outs having non-circular cross sections are categorized under ‘Slots’. Steps: 1. Select the surface on which we have to create a hole. 2. Click on the ‘Hole’ command present in the Engineering Group. 3. A hole appears on the selected surface with two Green colored Draggers or Boxes. 4. Click on the Green boxes one by one and drag them to an edge/surface or a point from where we want to specify the distance of the centre of the Hole. 5. Then specify the diameter of the hole to be created. 6. Finally, specify the depth of the hole. A hole can be created in any of the following 6 modes : a) Blind (ends up within the Model/Part) b) Symmetric (Symmetric about the Plane/Surface at which it being created) c) Through (Through the Model/Part) d) To selected (To a selected surface, Plane or edge) e) Through until (Through all the surfaces which are parallel to the surface at which hole is being created) f) To next (To the surface which comes next in the selected direction) A similar hole, with a different diameter and depth is also created on the top side of the rottel forging using the Hole command. Extrude Command :- Extrude command is again used to create the protrusions on the top side of the forging. The section(sketch) was created using sketch command and then extruded to the desired height. Extrude Command:- After creating the above protrusions, we need to cut them into desired shape. For this, we will use the extrude command again. But now, as we need to cut the material from an existing feature, so we will use extrude command with Remove material mode. We will create a sketch of the shape to be cut on a plane, perpendicular to the required cut out. After creating the section, we will extrude it in such a way that the model takes the shape as required. Round Command:- Then, we will use the Round command to obtain rounded edges on the rottel forging. It is done by following steps: 1. Click on the Round tool present in the Engineering group. 2. Then select the edge on which we want to apply the fillet. 3. Then specify the Fillet radius. 4. Click on complete Geometry Icon after applying the fillet to exit the round command. Advantages of filleting the sharp edges: 1. It removes the sharp edges which may cause injury. 2. It converts the sharp edge into a surface which uniformly distributes the stress which is subjected on the edge. i.e. converts the concentrated load into a UDL. 3. It also saves the material. (only when filleting is done on external edges) 4. It gives an aesthetic look to the Compents. 5. A component which has filleted edges will not lock into the core and cavity assembly when it is manufactured. Hence it can be easily withdrawn from the core- cavity assembly. The edges after filleting are shown in the following picture: Draft Angle Command:- After all the features of Rottel forging were created, we gave the Draft allowance by using the Draft Commnad present in the Engineering Group. The draft allowance is provided on all the vertical surfaces/walls of the component/model. It is provided in order to facilitate the easy withdrawal of the component from its core and cavity. Steps: 1. Select the Draft command from engineering group. 2. Press CTRL and select all the vertical surfaces on which we want to apply the Draft Angle. 3. Then click on the References tab and click on the ‘Draft Hinge’ option. 4. Select the horizontal plane/surface from which we have to apply the Draft angle. 5. Then set its direction according to our requirement. 6. Give the draft angle value in degrees. 7. In order to give a variable draft, click on the ‘split’ tab located next to the Split tab. 8. In the split dialog box, select ‘split by draft hinge’. 9. Specify the different draft angles for the different sides about the draft hingle plane. 7. Select the required side of the draft angle. (i.e. inwards or outwards) 8. Click on complete geometry icon to complete the component and exit the draft command. first the draft angle applied on the inner side of the vertical protrusion. DRAFT ANGLE ON INNER SIDE OF VERTICAL PROTRUSION DRAFT ANGLE ON THE OUTER SURFACE OF PROTRUSION DATA MIGRATION: Data migration is done to convert the CAD data into other format for Prototype production and CNC manufacturing purposes. For data migration, copy of the cad file is saved as in some other file format according to required format. (usually .stp format)