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2020

REPORT METROLOGY
AND WORKSHOP
PTB 10104
NUR NABILAH SYAZWANI BINTI RAHMAD ISKANDAR 58215119044
1) HELICAL GEAR

How helical gear is manufactured?


The cutting edge of the cutting tool has a shape that is similar to the appearance of the
gap between the gear teeth when cutting in gear form. Two machining operation, milling
and broaching operations can be used to shape cut gear teeth.
In milling process, the cutter called a shape cutter moves axially along the length of the
gear tooth to deliver the gear tooth at the correct depth. After each tooth is cut, thecutter
is removed, the gear blank is rotated, and another tooth is cut by the cutter. The cycle
goes on until all of the teeth are cut.
Gear hobbing is a machining procedure in which a sequence of cuttings with a helical
cutting tool gradually produce gear teeth. Both hobbing movements are turning, and the
blank hob and gear rotates continuously as in two gears meshing until all the teeth are
removed.
Sometimes,the surface finish and dimensional accuracy may not be accurate enough
for certain applications. Several finishing operations are available, including the
conventional process of shaving, and a number of abrasive operations, including
grinding, honing, and lapping.

2)Deep groove ball bearing


How deep groove ball bearing are made?
The manufacturing process used to manufacture a ball bearing's inner and outer rings is
almost identical.
Bearing ring.
1) The rings start out as tube stock. Automatic machines similar to lathes, such as
screw machines, use cutting tools to cut the ring to the basic shape, leaving extra
material for machining.
2) Outer ring faces are stamped with bearing number and manufacturer information.
3)The next step in the process of ring manufacturing is hardening. The rings are heated
to a temperature of 1565 degrees F for 15-20 minutes, quenched in oil at 375 degrees F
for 15-20 minutes, and then tempered at 340 degrees F for 2 hours.
4)Grinding to achieve final dimension. Face grinding is used to get proper bearing width,
OD grinding is for the outer and inner rings and lastly race grinding is for the radius,
race location and the geometry.
5) lastly, honing the races so that it has proper surface finish.
Bearing balls.
1) Balls start out as a wire or rod slug containing the proper amount of material required
in the finished ball
2) cold heading process is needed for the slugs to undergo cold heading process to
form a net spherical shape.
3) The balls are filed to remove flash and burrs.
4) Soft grinding is needed in the process to make it all in uniform size balls.
5) Balls are hardened
6) The balls that are already hardened undergo a finish grinding process.
7)Finally, the balls undergo a lapping process to achieve final tolerances and surface
finish requirements

Assembly
Once the bearing components are manufactured, the components are measured,
matched and assembled to make a finished bearing. Matching is an important part of
the assembly process. Inner and outer ring ball groove shape and radius are measured
and matched with balls of the correct diameter to produce a finished bearing that meets
the specified tolerances for bearing runout.
3)Compression spring

How compression spring are made?


1) Coiling
First, the wire needs to undergo the straightening process. With straighter wire that
enter the coil, the better it will produce. In this process, preprogrammed CNC equipment
adjusts the arms and arbores to manufacture the spring, fine tuning elements including
the spring’s free length, pitch, and coils. The speed camera is used when the machine
produce the wire so that it allows us to measure each part and make arrangement that
necessary. From here, the machine cuts the spring from its wire, and the product travels
into the stress relieving process.

2)Stress relieving
The coiling process subjects the wire’s material to stress, causing it to become brittle.
Heating the spring in the oven van correct this and allow the coil to form metallic bonds
and settle in new shapes. The oven holds the coiled wire at an appropriate temperature
for a predetermined amount of time, and then slowly allows the coil to cool.

3)Finishing
The coil then subjects it to a number of finishing processes depending on its intended
use. Some of the processes that go into spring finishing include grinding where we grind
the end of the coil so it can be easily attached.
4)Bolt and nut

How bolt and nut are made?


1) the steel wire that need to be used is uncoiled and straightened usually using
ISO898-1. Then, the wire is cut to the suitable length.
2) the steel is molded into the right shape at room temperature.
3) the steel then is formed by forcing it into varies dies at high pressure.
4) Threads are formed by rolling or cutting.
5) The bolt is left uncovered to extreme heat so that the bolt can harden.
6) Surface treatment - It depends on the application. Zinc-plating is common to increase
corrosion resistance.
7) Some additional turning or drilling may be needed for more complex bolt designs,
which cannot be controlled by cold forging alone

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