Abstract and full paper on THE DREAM PRODUCER

                 THE DREAM PRODUCER

                                                       - A fast CNC machine that will be the best

Abstract

               Amazing developments in production are now leading the 20^th century industry. No doubt these are sufficient for efficient production in bulk. But the ever green design always requires new design in a small quantitative and fast.

                           My  objective behind the paper is “If we want a hard copy of design we just give print command it gives faster  similarly if we give prepare command for dream producer it gives solid directly in short time”.

                       

                           Present paper is a blend of rapid prototyping, robotics, foundry and micro/nano laser machining. The dream producer has a robot arm to cut protypes at a fast rate directly from system to go down   by using quick investment casting and laser finishing. This makes the component strong and stiff in short span of manufacturing. Merits of interference of robots, investment casting, laser machining are mixed as a machine named as DREAM PRODUCER which was dream of most of us.

I hope that my concept is initiation and this will appear before us in a very short time with minor modifications and will lead our production technology

Key words

     Dream producer

     Rapid prototyping

     Robots in manufacturing

     Laser machining

     Nano and micro machining

     Fast production

     Investment casting

Introduction to manufacturing

                                                Generally bulk production is done by splitting component into small individual components. .Modern mass production has ability to produce more components at a time. The strength lies in plant layout and continuous production. All parts are assembled in line and finally produce component successfully. Consider a plant layout where we can observe all the wings of mechanical engineering working together for a successful product that can really last long n public and industry.

Every component must under go all the above as per present technology

Common problems in present technology

                                                                        As we discussed the product’s cost will be far less than protection and transportation costs and industry has to place it o M.R.P of product to avoid losses. Even the life of product is not good in market.

Even the strong and stiff product has to face the affects of demand they are

o   Taste of consumer

o   Image of company

o   Competition from others

o   Alternatives for design

o   Problems with duplicates

All these are key factors affecting life of product

As a technocrat it is our responsibility to find out solution for these issues.

Key solutions will be

     Improving flexibility of manufacturing

      Developing rapid protyping

     Using robots for production

     Opting for simple casting process

     Set manufacturing time <24 hours

     Use unique method of production

Practically rapid protyping can be done by using automated robots

Ø  The robots can be operated by a system efficiently

Ø  Investment casting is most suitable for efficient production

Ø  Laser machining that can be operated by robots

Ø  Using robots for packing components efficiently

Rapid protyping with robots

                                                Preparing protypes with robot arms is latest development. The protypes are not made with metals but of wax or thermo coal or any soft materials that can reduce to 2% of their original volume on heating. The soft materials are only used in preparing primary protypes instead of metals to produce ease of cutting with robot arms.

Principle of operation with program

                                                          The robot arm has a diamond shaped cutting tool at cutting end and is pointed to accuracy of 10^-2 mm and if tool moves from point to point automatically the profile can be cut in desired  shape and shape. The coding of robot can be done by using fundamental c-graphics and a simple c-program. This enables robot arm to move along the profile on top and it completes profile on bottom.

Thus a light weighed prototype is prepared very quickly giving 5% allowance

5% allowance = 3% for prototype + 2% for machining 

/* program to find least distance from each of axis and arrange

in ascending order so that the robot can follow the order provided */

#include

#include

Void main()

{

int i,j,k,a=0,b=0,c=0;

clrscr();

printf("enter distances from x,y,z,axes\n");

scanf("%d%d%d",&i,&j,&k);

printf("entered distances are (%d,%d,%d)",i,j,k);

if((i>>j)&&(i>>k))

{

a=i;

if(j>=k){b=j,c=k;}

if(k>>j){b=k,c=j;}

}

if((j>>i)&&(j>>k))

{

a=j;

if(i>=k){b=i,c=k;}

if(k>>i){b=k,c=i;}

}

if((k>>j)&&(k>>i))

{

a=k;

if(j>=i) {b=j, c=i;}

if(i>>j) {b=i, c=j;}

}

printf("now the increasing order is %d,%d,%d",a,b,c);

getch();

}

Algorithm for program

Ø  Take continuous location of ( x ,y ,z )

Ø  Move there considering least distance method

Ø  Then move along top surface to generate top surface

Ø  Then start moving on bottom to generate bottom surface

Investment casting

                                    The interesting part of production lies here. The casting is investment type where the prototype is rammed in cope and drag boxes. The ramming is done with automatic rammers with built in sand slingers. These ram up to desired level and prototype is fixed in it with bottom gate and top riser.

The equipment will be as follows

                        Investment casting

Laser machining

The advanced machining process that uses a guided laser to provide excellent surface finish is called laser machining.

Here also we use above algorithm and program to guide laser to produce plain surface

Chief advantages of process are

C  No heat damages, burrs, slag deposition

C  No fixed working distance, because the laser beam diameter is constant.

C  Low air dust, because the cutting waste is removed by force of laser

C  Cuts faster, because the laser jet is more efficient for good surface

C  Lower forces on the material but high impacts.

C  Time consumption is about  1/6^th of ordinary machining

Combination

The combination of above processes is the dream producer and it has all the properties of rapid prototyping, investment casting and laser machining.

The lay out will be as follows

Lets compare the our process and conventional process with respect to time.

For a simple v-block 

Work	Conventional process	Present trend
Drawing and drafting	½  hour	½  hour
Prototype making	½  hour	5 minutes
Casting	¾ hour	½ hour
machining	½  hour	¼ hour

Time saved =       2 ¼ -1 ¼

                        =   1 hours

 

So half the time hence double the speed & that’s what a ME needs exactly

 

Areas to be improved

Yet this process appears perfect there are some areas still to be improvised   they are

    Not suitable for mass production which may waste prototypes

    Approach for new robotics to improve speed

    Find better casting than investment to avoid wastage of wax

Conclusion

     This flexible process enables the user to get the type he required in minutes without wastage of man and money.

     We can build these even conveniently with embedded system.

     The code can be modified based on user requirement and time schedule.

     Very effective and strong products can be designed very quickly.

     This supports the line strategy of manufacturing and all other processes.

     This type of production strongly affects the current industry and it reduces manufacturing cost and M.R.P of product.

     Problem of duplicates can be completely avoided because we can change and even complicate the design at the same cost.

     R&D in this type of manufacturing may bring drastic development in mass production.

     In bulk production this setup can be used for only rapid protyping even this saves lot of time.

     Suits well for colleges and training institutes for small repairs and creations

Hence we can use this every where we are conventional.

12:27 PM