CE00430-1 Design Principles Individual Assignment Page 1 of 67

ACKNOWLEDGEMENT

The topic of this assignment is one of the best of our carrier. Our goal was to give an

appreciating and outstanding performance we have put our determination, knowledge,

hard labour and perseverance which help us to put our best in this assignment. We are

fully satisfied with the commitment which we have shown in our Assignment. A single

word would not justify the contribution made by MR. HARPAL SINGH KALRA, our

Professor without whose constant guidance and support, this assignment would have not

been possible. He was always there in times of need to help us out.

Next, we would like to thank our college for providing us with the very best of facilities

in the form of library, computer labs, books, etc which formed the back-bone of this

assignment. Lastly, we would like to thank all our peers and friends who were a constant

help during the entire research work and helped us improve.

Yours Truly

Kapil Makhija

(PT1086604)

Level 1 Asia Pacific Institute of Information Technology 2012

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CERTIFICATE

It is certified that, KAPIL MAKHIJA (PT1086604) studying in Mechatronics Branch of

level- 1 has completed their Individual Assignment in due time as per the rules and

regulation of APIIT SD INDIA affiliated to STAFFORDSHIRE UNIVERSITY,UK.

MR. Harpal Singh Kalra

(MODULE LECTURAR)

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TABLE OF CONTENTS

1(a)

1. Extrude 4-82. Revolve 8-103. Fillet 10-114. Dimensioning 125. Tolerance 126. Basic shaping processes: 12-201. Solid: 1. Forging 13 2. Rolling 14 3. Extrusion 14-164. Drawing 16-172. Liquid: 1. Casting 17-182. Injection moudling. 18-193. Powder: 1. Powder metallurgy process. 207. Basic joining processes: 21-271. Fasteners 21-222. Welding 22-233. Brazing 23-244. Soldering 24-278. Basic modeling and sketching techniques: 281. Wireframe modeling 28

1(b)

Assembly drawing 29-61

Appendix A 62-64

Appendix B 65

References 66

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1. EXTRUDE:

This command is used to create a 3D object from a closed 2D shape object. We have sketch a circle on top view with diameter 200mm as shown below in figure 1:

Figure 1.

Clicking on done and extrude icon, giving the height 500mm we will see the entity will be like shown below in figure 2:

Figure 2.

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Another view of entity to show extrusion of circle in figure 3:

Figure 3.

We can also flip using given icon without doing done to extrude and entity will be like as shown in figure 4:

Figure 4.

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By using the blend hole and giving the thickness as 10mm the entity will be like as shown in Figure 5:

Figure 5.

We can change the direction of extrude between one side, other side or both sides of

sketch using the icon shown and One side extrusion of profile in figure 6:

Figure 6.

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Another side extrusion of profile in figure 7:

Figure 7.

Both side extrusion as shown in figure 8:

Figure 8.

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We can extrude from sketch plane by a specified depth value using icon as shown below in figure 9:

Figure 9.

We can also extrude one entity to another surface also.

2. REVOLVE:

This command used to revolve closed object to create 3D solid and open object to create surfaces. Object can be revolve at 360o or any particular angle. A positive angle revolves the objects in a counterclockwise direction. A negative angle revolves the objects in a clockwise direction. With the revolve command, you can create a new solid or surface by revolving an open or closed planar curve about Horizontal axis, vertical axis, perpendicular axis or inclined along any of axis. You can revolve more than one object. You can select the objects to revolve before you start the command. You cannot revolve objects contained within a block.

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We made a reference line and make a profile like using spline as shown below in figure 10:

Figure 10.

Click on done icon after that selecting the revolve icon the entity will be like shown below in figure 11:

Figure 11.

We can also edit the angle of Revolution from below icon ‘or’ direct by double clicking on 360o written as shown below in figure 12:

Figure 12.

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The entity will be now as shown below in figure 13:

Figure 13.

Similar, a way we can make solid entity also.

3. FILLET:

Fillet in pro/engineer is known as circular. A circular is used to give round corner to profile.

We made a rectangle and choose two consecutive lines successively and edit the dimensions to 5mm as shown below in figure 14, 15, 16:

Figure 14.Level 1 Asia Pacific Institute of Information Technology 2012

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Figure 15.

Figure 16.

We can also give circular to 3-D objects.

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4. DIMENSIONING:

Pro/engineer itself give dimensioning to sketch profile as we have drawn a rectangle and we get automatic dimension as shown above in figure 14. We can edit the values of horizontal and vertical lines of rectangle.

Similar, a way we can edit the values of different sketches like circle as shown below in figure 47, 48. We can also edit the values of line, spline, points etc….We can also edit the extruded entity by going to edit definition of sketch entity.

5. TOLERANCE:

In general, tolerance is deviation in values. For example a supplier gets an order of 50,000 pieces of screw. So he given the tolerance of diameter (25+-0.1)mm i.e the pieces may have diameter of 24.99mm or 25.01mm.

Geometrical tolerance show acceptable deviation of form, profile, orientation, location and of a feature.

You add geometric tolerance in feature control frames. These frames contain all the tolerance information for a single dimension. Geometric tolerance can be created with or without leader lines, depending on whether you create them with tolerance or leader.

A feature control frame consists of two or more components. The first feature control frame contains a symbol that represents the geometric characteristic to which a tolerance is being applied, for example, location, profile, form, orientation.

6. BASIC SHAPING PROCESSES:

Solid: 5. Forging 6. Rolling 7. Extrusion8. Drawing

Liquid:

3. Casting 4. Injection moudling.

Powder:

2. Powder metallurgy process.

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Forging:

A deformation process in which the material is compressed between dies, using impact or gradual pressure to form the part. A work-piece is compressed between opposing dies so that the material is forced into the die shape.

Hot Forging: Hot forging is done on material when the material is heated to above its re-crystallization temperature. Hot forging as shown below in figure 17:

Cold Forging: Increases strength from strain hardening. Cold forging is used when material is not heated to its re-crystallization temperature.

Figure 17.http://www.google.co.in/imgres?q=forging&hl=en&sa=X&biw=1366&bih=624&tbm=isch&prmd=imvnsb&tbnid=S34JH78nJaPZ5M:&imgrefurl=http://www.art.com/products/p14109413-sa-i2800982/russell-young-knife-maker-forging-steel-blank-norway.htm&docid=sOguCqx5reqecM&imgurl=http://cache2.artprintimages.com/lrg/27/2750/733TD00Z.jpg&w=400&h=300&ei=eV59T5LdKMfmrAecyeXXDA&zoom=1&iact=hc&vpx=328&vpy=157&dur=31&hovh=194&hovw=259&tx=120&ty=140&sig=110103460067059534571&page=3&tbnh=133&tbnw=190&start=51&ndsp=25&ved=1t:429,r:1,s:51,i:250

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Rolling:

The thickness of a slab or plate is reduced by cylindrical rolls which rotate to pull the material between them and compress it. Uses grooved rolls to reduce thickness and increase length of round or flat bars.Rolling of slab as shown below in figure 18:

Figure 18.http://www.google.co.in/imgres?q=rolling&um=1&hl=en&sa=N&biw=1366&bih=624&tbm=isch&tbnid=8nh6GcoGvt39uM:&imgrefurl=http://fa.wikipedia.org/wiki/%25D9%25BE%25D8%25B1%25D9%2588%25D9%2586%25D8%25AF%25D9%2587:Rolling.png&docid=ew-JQ2r7eIHhNM&imgurl=http://upload.wikimedia.org/wikipedia/commons/b/ba/Rolling.png&w=1722&h=1249&ei=xmJ9T_PcE4eqrAfE_eT2DA&zoom=1&iact=hc&vpx=914&vpy=274&dur=327&hovh=191&hovw=264&tx=122&ty=103&sig=110103460067059534571&page=2&tbnh=134&tbnw=185&start=27&ndsp=31&ved=1t:429,r:14,s:27,i:224

Extrusion:

Extrusion is the process in which metal is caused to flow through a restricted orifice so creating an extremely elongated strip of uniform, but comparatively small cross-section. The operation is identical to the squeezing of tooth paste out of the tooth paste tube. It is also similar to operation is often carried out at high pressure. By the extrusion process, it is possible to make components which have a constant cross-section over any length as can be had by the rolling process. Large diameter thin walled tubular products with excellent concentricity can also be made.

The extrusion pressure for a given material depends on the extrusion temperature, the reduction in area and the extrusion speed. The extrusion speed depends on the work material. Too high extrusion speed would cause excessive heat generation in extruded metal causing lateral cracks.

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Materials that can be extrudes are aluminum, copper, steel, magnesium, and plastics. Aluminum, copper and plastics are most suitable for extrusion.

Extrusion process is shown below in figure 19:

Figure 19.http://www.reliance.com/prodserv/standriv/appnotes/d7741.pdf

Molten material or resin is feed in barrel through hopper after that screw will rotate with the help of motor and rotating screw forces the raw material forward in barrel which heated to desired melting temperature. If in an extrusion process extensive friction and pressure is created inside barrel then heaters shut down and melting process maintained by friction and pressure. In some extruders cooling fans are present to keep temperature low. Now molten material leaves the barrel and passes to breaker plate. In this plate molten material is filtered, if any dust or unwanted particals available in molten form that will be filtered.Now the raw material passes to die and gets final product. Die must be designed so that molten material flows from a cylindrical profile to product profile shape.

Direct extrusion:Direct extrusion is one of the most commonly used extrusion process and also known as forward extrusion. The metal billet is placed in a container and driven through a die by the ram. In between billet and ram a dummy block which is reusable used for separating both. Friction at the die and container wall required high pressure than indirect extrusion.Direct extrusion is shown below in figure 20:

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Figure 20.

http://www.google.co.in/imgres?um=1&hl=en&biw=1366&bih=624&tbm=isch&tbnid=pymZDSctEJvM:&imgrefurl=http://www.roymech.co.uk/Useful_Tables/Manufacturing/Extruding.html&docid=GU8VcPYfWxmgOM&imgurl=http://www.roymech.co.uk/images21/Extrusion_direct.gif&w=488&h=210&ei=SpqDT7qpHpDzrQfuZi9Bg&zoom=1&iact=hc&vpx=268&vpy=170&dur=2777&hovh=147&hovw=342&tx=171&ty=72&sig=117952913528644375974&page=1&tbnh=74&tbnw=172&start=0&ndsp=19&ved=1t:429,r:1,s:0,i:67

Indirect extrusion:Indirect extrusion is also known as backward extrusion process. In this process die is constant and billet & container move together. A ‘stem’ is used for keeping the die constant the length of stem must be longer than length of container. The hollow ram is containing the die is kept stationary and the container with billet is caused to move. Friction at die only requires roughly constant pressure means no relative movement at container wall. In indirect extrusion there is less tendency for crack because no heat formation takes place due to friction. Some defects also alter this process. Impurities on the billet surface affect the extrusion`s process, these affect destroy the piece. To eliminate this affects billets have to be wired brushed, chemically cleaned or machined before use.Indirect extrusion is shown below in figure 21:

Figure 21.

http://www.google.co.in/imgres?um=1&hl=en&biw=1366&bih=624&tbm=isch&tbnid=snyRGJuQwkp7vM:&imgrefurl=

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http://www.industrialextrusionmachinery.com/extrusion_process_direct_extrusion_and_indirect_extrusion.html&docid=nx8RB1b9GwTC4M&imgurl=http://www.industrialextrusionmachinery.com/images/direct-extrusion.jpg&w=338&h=149&ei=SpqDT7qpHpDzrQf-uZi9Bg&zoom=1&iact=hc&vpx=113&vpy=226&dur=7488&hovh=119&hovw=270&tx=184&ty=58&sig=117952913528644375974&page=1&tbnh=78&tbnw=176&start=0&ndsp=19&ved=1t:429,r:6,s:0,i:78

DRAWING:

In this process the cross section of a round rod or wire is typically reduced or changed by pulling it through a die. Die angle has great influence on the drawing force and the quality of the drawn product.Drawing process is shown below in figure 22:

Figure 22.http://www.google.co.in/imgres?q=wire+drawing+manufacturing+process&um=1&hl=en&biw=1366&bih=624&tbm=isch&tbnid=gcIfRkx53_sMBM:&imgrefurl=http://www.aluminiumwire.co.uk/AboutUs.asp&docid=YspqpJ1CKVe9eM&imgurl=http://results.demopage.co.uk/percy/clientimages/wire%252520drawing%252520in%252520process.jpg&w=480&h=320&ei=ZGN9T4C6N4TnrAf7yJSEDQ&zoom=1&iact=hc&vpx=110&vpy=4&dur=31&hovh=183&hovw=275&tx=159&ty=77&sig=110103460067059534571&page=3&tbnh=143&tbnw=174&start=47&ndsp=25&ved=1t:429,r:12,s:47,i:198

Casting:

A casting object is produced by pouring molten metal into a mould cavity and allowing it to solidify. The mould cavity is of shape of the required component. For the casting metal should have a high fluidity and low melting point. For example, cast iron, with its high carbon content, has a high fluidity and low melting point compared to low carbon steel. Casting process is shown in figure 23:

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Figure 23.

http://www.google.co.in/imgres?q=casting&hl=en&gbv=2&biw=1366&bih=667&tbm=isch&tbnid=fT9mXu2AT0K4oM:&imgrefurl=http://www.ustudy.in/node/447&docid=2DNZIrqMy0ekM&imgurl=http://www.ustudy.in/imagebrowser/view/image/3676/_original&w=450&h=377&ei=_EKCT8ziMIrVrQemnITtBQ&zoom=1&iact=hc&vpx=183&vpy=181&dur=1331&hovh=205&hovw=245&tx=176&ty=124&sig=117952913528644375974&page=1&tbnh=137&tbnw=171&start=0&ndsp=21&ved=1t:429,r:0,s:0,i:131

In all casting processes the pattern has to be made oversize to allow for any contraction of the metal that may occur during the change of state from liquid to solid and also to allow for the continued contraction as the solid metal cools to room temperature. Note that cast iron is exceptional in that it expands as it solidifies and this helps it to take a sharp impression for the mould. However, after solidification, it contracts like any other metal. In addition to shrinkage allowance, a machining allowance also has to be provided when a surface is to be machined. Not only must sufficient additional metal be provided to ensure that the surface cleans up during machining, but also that there is sufficient depth of metal for the nose of the cutting tool to operate below the hard and abrasive skin of casting.

Injection moulding:

The process is used to produce large quantities of identical plastic items. One of the most common types of thermoplastics used in injection moulding is high impact polystyrene (HIPS). Injection Moulding is the most important plastics manufacturing process. It produces such small products as bottle tops; sink plugs, children's toys, containers, model kits, disposable razors and parts of cameras. It is also used to manufacture larger items such as dustbins, and milk crates. The process can even mould such large items as dingy hulls and kit car body shell parts.

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1. Material granules from the hopper feed into the heated barrel and rotating screw. Material melted by heat, friction and shear force is forced through a check valve to the front by the rotating screw.

2. Having been moved backward by the shot of material at the front, the screw is forced forward by a hydraulic motor. This action injects the module cavity in the closed mould tool.

3. The tool is held closed under pressure until the plastic material cools and sets hard in the mould tool cavity. This is often the longest part of the injection moulding process.

4. The screw starts to move back for the next moulding. The tool then opens and the finished plastic part is ejected. The tool is closed and the injection moulding process starts again at step 1.

Injection moulding is shown below in figure 24, 25:

Figure 24.

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Figure 25.

http://www.technologystudent.com/equip1/inject1.htm

Powder metallurgy:

Powder metallurgy uses sintering process for making various parts out of metal powder. The metal powder is compacted by placing in a closed metal cavity (the die) under pressure. This compacted material is placed in an oven and sintered in a controlled atmosphere at high temperatures and the metal powders coalesce and form a solid. A second pressing operation, repressing, can be done prior to sintering to improve the compaction and the material properties.Typical parts that can be made with this process include cams, ratchets, sprockets, pawls, sintered bronze and iron bearings (impregnated with oil) and carbide tool tips. Powder metallurgy provides good surface finishes.Enables cost-effective, high volume manufacture of complex or unique shapes impractical with other metalworking processes. Offers long term performance reliability in critical applications. Powder metallurgy is shown below in figure 26, 27:

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Figure 26.

Figure 27.http://www.sterlingsintered.com/process/index.htm7. BASIC JOINING PROCESSES:

5. Fasteners6. Welding7. Soldering8. Brazing

Fasteners:

Fasteners are used to provide mechanical linkage between two objects.Mechanical fasteners are most widely used for temporary joints. Joints obtained by bolts and screws are temporary in nature and can be dismantled easily whenever necessary. Rivets are semi-permanent fastening devices and the joint can be separated only by destroying the rivet without affecting the parent elements

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If a product is in use for a long time and there is wear and tear, the parts need to be dismantled for maintenance, repair or replacement. A temporary joint can be easily dismantled separating the original parts without any damage to them. In case it is a permanent joint, an attempt to separate the parts already joined will result in the damage of the parts. In a permanent joint, the joint is made such that it has properties similar to the base metal of the two parts. The joined parts become one piece. These parts cannot be separated into their original shape, size and surface finish. Fasteners are shown below in figure 28:

Figure 28.http://www.google.co.in/imgres?q=Fasteners&hl=en&biw=1366&bih=667&tbm=isch&tbnid=NP6LXkaSKgzSPM:&imgrefurl=http://www.shivshaktiimpex.com/fasteners.htm&docid=BVu7MipejJgZrM&imgurl=http://www.shivshaktiimpex.com/images/fasteners-ss.jpg&w=470&h=300&ei=vkaCT4vXK4m8rAfFhZnTBQ&zoom=1&iact=hc&vpx=718&vpy=103&dur=425&hovh=179&hovw=281&tx=95&ty=130&sig=117952913528644375974&page=1&tbnh=125&tbnw=212&start=0&ndsp=20&ved=1t:429,r:3,s:0,i:74

Permanent fasteners: Rivets are permanent fasteners. Rivets are shown below in figure 29:

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Figure 29.http://www.google.co.in/imgres?q=rivets&hl=en&biw=1366&bih=667&tbm=isch&tbnid=58i89ACuYgA4kM:&imgrefurl=http://www.engineeredpartsinc.com/rivets.htm&docid=1CP1gOMgw7wAPM&imgurl=http://www.engineeredpartsinc.com/images/rivets_lg.jpg&w=1645&h=1200&ei=4kiCT_TlN4PtrAf6h_XVBQ&zoom=1&iact=hc&vpx=522&vpy=187&dur=4999&hovh=192&hovw=263&tx=106&ty=145&sig=117952913528644375974&page=1&tbnh=135&tbnw=173&start=0&ndsp=21&ved=1t:429,r:2,s:0,i:148

Soldering:

Soldering is a method of joining similar or dissimilar metals by the application of heat and using a filler metal, whose melting temperature is below 4500 C. The filler metal is called solder. Though soldering obtains a good joint between the two plates, the strength of the joint is limited by the strength of the filler metal used. Soldering is used for obtaining a leak proof joint or a low resistance electrical joint. The soldered joints are not suitable for high temperature applications because of the low melting temperatures of the filler metals used.Soldering is a quick method of making joints in light articles made from steel, copper and brass.Soldering process is shown below in figure 30:

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Figure 30.http://www.google.co.in/imgres?q=soldering&hl=en&biw=1366&bih=667&tbm=isch&tbnid=zdh__Kx6VgpJVM:&imgrefurl=https://csel.cs.colorado.edu/~bauerk/legorobots/assembly.html&docid=EeQraY8GOpOOGM&imgurl=https://csel.cs.colorado.edu/~bauerk/legorobots/images/goodsold9.gif&w=614&h=280&ei=bUeCT4eRMoynrAeY27zcBQ&zoom=1&iact=hc&vpx=338&vpy=298&dur=1076&hovh=151&hovw=333&tx=208&ty=85&sig=117952913528644375974&page=2&tbnh=86&tbnw=189&start=21&ndsp=24&ved=1t:429,r:19,s:21,i:159

Brazing:

It is a process of joining two metal pieces in which a non-ferrous alloy is introduced in the liquid state between the pieces to be joined and allowed to solidify.Brazing is a process for joining two work pieces together with a filler metal that is sandwiched between them,  where in only this filler metal undergoes melting, i.e., the work pieces do not experience any melting. The temperature at which brazing is done must therefore be high enough to melt the filler material, but not the work pieces.   Materials used as fillers for brazing are those that melt above 450 deg C.  Flux is also used during brazing for the purpose of eliminating oxide films from the surfaces of the work pieces and preventing oxidation. This would ensure a good metallurgical bond between the work pieces and the filler once the brazing process is completed.

Brazing process is shown below in figure 31:

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Figure 31.http://www.google.co.in/imgres?q=brazing&hl=en&biw=1366&bih=667&tbm=isch&tbnid=zxMYdSwOoNFauM:&imgrefurl=http://user.xmission.com/~ranthon/lapidary.htm&docid=ROdI7WhARigjYM&imgurl=http://user.xmission.com/~ranthon/dia-brazing1.gif&w=400&h=259&ei=z0eCT7STKs7rrQfKnuyFBg&zoom=1&iact=hc&vpx=466&vpy=194&dur=466&hovh=181&hovw=279&tx=149&ty=113&sig=117952913528644375974&page=1&tbnh=104&tbnw=161&start=0&ndsp=20&ved=1t:429,r:2,s:0,i:135

Combination of allow for brazing:1. Aluminium-Silicon2. Copper-Phosphorus3. Silver4. Gold5. Copper6. Copper-Zinc7. Magnesium

Welding:

It is the method of joining metals by applications of heat, without the use of solder or any other metal or allow having a lower melting point then the metal beings joined.

OrIt is a process of joining of two similar or dissimilar metals by fusion, with or without application of pressure and with or without use of filler metal.

Arc welding:

Arc welding is a category of welding that utilizes a direct or alternating current to generate an electric arc that is able to bond metal by fusing a base metal and the addition of metal to the joint. During the arc welding process, the operator uses a consumable electrode, fastened to a hand-held electrode holder, and manually directs the electrode

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along the joint as the weld is made. The arc can be struck by either lightly tapping the electrode against the metal or scratching the electrode against the metal at high speed.

Welding process is show in figure 32:

Figure 32.

http://visual.merriam-webster.com/house/do-it-yourself/soldering-welding-tools/arc-welding.php

Gas welding:

Gas welding also known as oxy-acetylene gas welding uses a fuel gas such as acetylene is mixed inside a welding torch with oxygen to produce a flame. This flame is used to melt the materials to be welded. A filler road is melted into the puddle of molten metal to reinforce the weld. When highly reactive metals such as aluminum are gas welded, they must be covered with flux to exclude oxygen from molten metal and keep oxides from forming which would decrease the strength of weld. Gas welding process is shown below in figure 33:

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Figure 33.http://www.google.co.in/imgres?q=oxy+acetylene+gas+welding&um=1&hl=en&sa=N&biw=1366&bih=667&tbm=isch&tbnid=GFfYQfi-bxFWuM:&imgrefurl=http://www.solidmetals.net/2011/02/20/oxyacetylene-welding/&docid=NWYZV8MpKzvFIM&imgurl=http://www.solidmetals.net/wp-content/uploads/2011/02/oxyacetylene-setup.png&w=305&h=326&ei=lVp9T5qeEcSJrAeto62KDQ&zoom=1&iact=rc&dur=804&sig=110103460067059534571&page=1&tbnh=155&tbnw=145&start=0&ndsp=18&ved=1t:429,r:2,s:0,i:71&tx=94&ty=54

TIG welding:

Gas Tungsten Arc Welding (GTAW) is frequently referred to as TIG welding.  TIG welding is a commonly used high quality welding process.  TIG welding has become a popular choice of welding processes when high quality, precision welding is required. In TIG welding an arc is formed between a non-consumable tungsten electrode and the metal being welded. Gas is fed through the torch to shield the electrode and molten weld pool.  If filler wire is used, it is added to the weld pool separately. TIG welding is shown in figure 34:

Figure 34.http://www.weldingengineer.com/1tig.htm

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MIG welding:Gas Metal Arc Welding (GMAW) is frequently referred to as MIG welding.  MIG welding is a commonly used high deposition rate welding process.  Wire is continuously fed from a spool.  MIG welding is therefore referred to as a semiautomatic welding process. MIG welding is shown in figure 35:

Figure 35.http://www.weldingengineer.com/1mig.htm

Plasma arc welding:

Plasma arc welding is the welding process utilizing heat generated by a constricted arc struck between a tungsten non-consumable electrode and either the work piece or water cooled constricting nozzle. Plasma is a gaseous mixture of positive ions, electrons and neutral gas molecules. Plasma welding is shown below in figure 37:

Figure 37.http://www.substech.com/dokuwiki/lib/exe/detail.php?id=plasma_arc_welding_paw&cache=cache&media=plasma_arc_welding.png

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8. WIREFRAME MODELING:

A wireframe model is skelatan representation of a 3D object using lines and curves.

With the help of wireframe style you can visualize overall structure of 3D object. Wireframe models consist only of points, lines, and curves that describe the edges of the object.Wireframe is diagram is shown below in figure 38, 39:

Figure 38.

Figure 39.

Wireframe modeling helps in viewing the 3D object from any vantage point. This modeling also helps in making standard orthographic views. Helps in generating perspective as well as auxiliary views of objects. Helps in finding distance between corners and edges.

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ALGORITHM FOR DRAWING USING PRO/ENGINEER WILDFIRE 5.0:

On opening new file in pro/engineer wildfire 5.0 the screen will appear will be like as shown below in figure 40:

Figure 40.

Click on sketch icon on right above side of screen and dialog box will appear like as shown below in figure 41:

Figure 41.

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Click on top view and click ‘ok’ on dialog box of sketch command as shown below in figure 42:

Figure 42.

The screen will appear like as shown below in figure 43:

Figure 43.Click on rectangle icon on right above side of screen and make a rectangle as shown below in figure 44:

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Figure 44.

Click on one by one icon. You got dimensions of rectangle as shown below in figure 45:

Figure 45.

Change the rectangle dimensions to 110*210. The entity will be like in figure 46:

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Figure 46.

Make a circle at corner of rectangle and click on one by one icon the figure 47 shown below to clearify:

Figure 47.

Change the diameter of circle to 15 and distance from x & y axis to 17.5 & 17.5 as shown below in figure 48:

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Figure 48.

Now click on circle icon and make 3 more circles at each corner, here ‘R’ mean same diameter as that of previous circle. Click on one by one and you will get dimensions. As shown below in figure 49:

Figure 49.

Change the dimensions of circles, 1st circle distance from x & y axis to 17.5 & 17.5, 2nd

circle by 92.5 & 17.5 from x & y axis respectively, 3rd circle by 92.5 & 192.5 and 4th

circle by 17.5 & 192.5 respectively. As shown below in figure 50:

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Figure 50.

Click on circular icon, you will get a dialog box as shown below in figure 51:

Figure 51.

Do not click on ‘ok’ button. Just click on two different lines you will get a fillet on corner. Similar away make fillet at each corner. Click one by one you will get radius of fillet. As shown below in figure 52:

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Figure 52.

Now change the fillet radius to 5mm as shown below in figure 53:

Figure 53.

Now click on done icon. The profile will be like shown below in figure 54:

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Figure 54.

Click on extrude icon. Click on done icon and extrude the whole entity by 15. The entity will be like as shown below in figure 55:

Figure 55.

On giving the value of extrusion click on this icon shown below in figure 56:

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On clicking ‘Ctrl+D’ the entity will look like as shown below in figure 57:

Figure 57.

Click on planer icon on right above side of screen. You will get a dialog box and make offset distance 15 above from top view as shown below in figure 58:

Figure 58.

You will get another plan ‘DTM1’ above the top view at an height of 15 as shown below in figure 59:

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Figure 59.

Make two rectangles on ‘DTM1’ click one by one icon the entity will be like as shown below in figure 60:

Figure 60.

Change the dimension as shown below in figure 61:

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Figure 61.

Make one circle in 1st rectangle click on one by one icon and edit dimensions as 10 & 10 units from x & y axis respectively from 1st rectangle. As shown below in figure 62:

Figure 62.

Make 3 more circles and change the dimensions as shown below in figure 63:

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Figure 63.

Click on done icon and extrude the entity by 20mm as shown below in figure 64:

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Figure 64.

On giving the value of extrusion click on this icon shown below in figure 65:

Figure 65.

Ctrl + D view of entity as shown below in figure 66:

Figure 66.

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Click on planer icon on right above side of screen. You will get a dialog box and make offset distance 75 above from top view as shown below in figure 67:

Figure 67.

You will get another plan ‘DTM2’ above the top view at a height of 75. And use sketch command to sketch entity on ‘DTM2’ plane as shown below in figure 68:

Figure 68.

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Now make a circle on ‘DTM2’ plane after that click on one by one command and edit the dimensions as shown below in figure 69:

Figure 69.Now make 3 more circles and follow same procedure as that of last one used and edit dimensions as shown below in figure 70:

Figure 70.

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Now click on done icon and extrude all the 4 circles by -20 as shown below in figure 71:

Figure 71.

On giving the value of extrusion click on this icon shown below in figure 72:

Figure 72.

Ctrl + D view of entity as shown below in figure 73:

Figure 73.

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Again use sketch icon and sketch on ‘DTM2’ plane and make a rectangle. as shown below in figure 74:

Figure 74.

Click on one by one icon and change the dimension of rectangle to 110 * 210 as shown below in figure 75:

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Make one circle on one corner now use one by one command and edit dimensions as the diameter of circle to 15 and distance from x & y axis to 17.5 & 17.5 as shown below in figure 76:

Figure 76.

Now click on circle icon and make 3 more circles at each corner, here ‘R’ mean same diameter as that of previous circle. Click on one by one and you will get dimensions.Change the dimensions of circles, 1st circle distance from x & y axis to 17.5 & 17.5, 2nd

circle by 92.5 & 17.5 from x & y axis respectively, 3rd circle by 92.5 & 192.5 and 4th

circle by 17.5 & 192.5 respectively as shown below in figure 77:

Figure 77.

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Now extrude rectangle of 110 * 210 and 4 corner circles by 15 which are at height of 75 from top view as shown below in figure 78:

Figure 78.

On giving the value of extrusion click on this icon shown below in figure 79:

Figure 79.

Ctrl + D view of entity as shown below in figure 80:

Figure 80.

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Any other view of entity to clearify view as shown below in figure 81:

Figure 81.

Click on planer icon on right above side of screen. You will get a dialog box and make offset distance 90 above from top view as shown below in figure 82:

Figure 82.

You will get another plan ‘DTM3’ above the top view at a height of 90. And use sketch command to sketch entity on ‘DTM3’ plane as shown below in figure 83:

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Figure 83.

Make a rectangle on ‘DTM3’ plane which is at height of 90mm from Top view. Now click on one by one icon and you will get dimensions as shown below in figure 84:

Figure 84.

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Edit the dimensions of rectangle as shown in figure 85:

Figure 85.

Make one circle in between rectangle which is on ‘DTM3’ plane. Click on one by one icon and you will get drawing like shown below in figure 86:

Figure 86.

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Edit the dimension of circle as shown below in figure 87:

Figure 87.

Now extrude the rectangle and circle which is at 90mm above from top view at an height of 15. Click on extrude icon and change the value of extrusion to 15mm as shown below in figure 88:

Figure 88.

On giving the value of extrusion click on this icon shown below in figure 89:

Figure 89.

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Ctrl + D view of entity as shown below in figure 90:

Figure 90.

Click on planer icon on right above side of screen. You will get a dialog box and make offset distance 100 above from top view as shown below in figure 91:

Figure 91.

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You will get another plan ‘DTM4’ above the top view at a height of 100. And use sketch command to sketch entity on ‘DTM4’ plane as shown below in figure 92:

Figure 92.

Sketch a circle at corner on ‘DTM4’ and click on one by one icon you will get the dimension as shown below in figure 93:

Figure 93.

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Change the diameter of circle to 15 and distance from x & Y axis to 17.5 & 17.5 as shown below in figure 94:

Figure 94.

Now click on circle icon and make 3 more circles at each corner, here ‘R’ mean same diameter as that of previous circle. Click on one by one and you will get dimensions as shown below in figure 95:

Figure 95.

Change the dimensions of circles, 1st circle distance from x & y axis to 17.5 & 17.5, 2nd

circle by 92.5 & 17.5 from x & y axis respectively, 3rd circle by 92.5 & 192.5 and 4th

circle by 17.5 & 192.5 respectively as shown below in figure 96:

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Figure 96.

Click on done icon. Click on extrude icon and extrude 4-circles at an height of -100 as shown below in figure 97:

Figure 97.

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On giving the value of extrusion click on this icon shown below in figure 98:

Figure 98.

Ctrl + D view of entity made as shown below in figure 99:

Figure 99.

Click on planer icon on right above side of screen. You will get a dialog box and make offset distance 105 above from top view as shown below in figure 100:

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Figure 100.

You will get another plan ‘DTM5’ above the top view at a height of 105. And use sketch command to sketch entity on ‘DTM5’ plane as shown below in figure 101:

Figure 101.

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Sketch a circle at corner on ‘DTM5’ and click on one by one icon you will get the dimension and change the dimensions as shown below in figure 102:

Figure 102.

Now make another circle on ‘DTM5’ plane and edit the dimensions as shown below in figure 103:

Figure 103.

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Now join a line to 2 opposite quadrant of 2nd circle as shown below in figure 104:

Figure 104.

Similar a way, join another line to 2 opposite quadrant of 2nd circle as shown below in figure 105:

Figure 105.

Similar a way, join another two opposite lines to 2 opposite quadrant of 1 st circle as shown below in figure 106:

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Figure 106.

Ctrl + D view of entity as shown below in figure 107:

Figure 107.

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Another view to show press-die drawing as shown below in figure 108:

Figure 108.

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Appendix A

S.NO. Figure No. Description Page No.1 Figure No.1 Result of circle command used Page No.12 Figure No.2 Result of extrude command Page No.13 Figure No.3 Another view of entity to show extrusion Page No.24 Figure No.4 Result of using flip icon Page No.25 Figure No.5 Result of using blend hole and giving the

thickness as 10mmPage No.3

6 Figure No.6 One side extrusion of profile Page No.37 Figure No.7 Another side extrusion of profile Page No.48 Figure No.8 Both side extrusion of entity Page No.49 Figure No.9 Result of using centre icon Page No.510 Figure No.10 Result of spline command used Page No.611 Figure No.11 Result of revolve command Page No.612 Figure No.12 For editing the revolution angle Page No.613 Figure No.13 Result of revolution of profile to 180o Page No.714 Figure No.14 Rectangle as a profile Page No.715 Figure No.15 Result of using circular command to profile

each cornerPage No.8

16 Figure No.16 Result of editing the dimension of circular by 5mm

Page No.8

38 Figure No.38 Extruded circle Page No.2539 Figure No.39 Wireframe view of profile Page No.2540 Figure No.40 Result of opening new file in pro/engineer Page No.2641 Figure No.41 Result of sketch icon Page No.2642 Figure No.42 Result of selecting the top view and sketch

dialoug box will appearPage No.27

43 Figure No.43 After selection of top view the view of screen Page No.2744 Figure No.44 Result of making rectangle profile Page No.2845 Figure No.45 Result of clicking one by one icon Page No.2846 Figure No.46 Rectangle with strong dimension Page No.2947 Figure No.47 Result of using circle command Page No.2948 Figure No.48 Circle with strong dimensions Page No.3049 Figure No.49 Result of 4 circles at rectangle profile Page No.3050 Figure No.50 Result of strong dimension of 4-circles Page No.3151 Figure No.51 Circular dialoug box Page No.3152 Figure No.52 Result of using circular command Page No.3253 Figure No.53 Radius of fillet stronged to 5mm Page No.3254 Figure No.54 Done dialoug box Page No.3355 Figure No.55 Extrude dialoug box. Result of editing the

extrusion of entity 15mmPage No.33

56 Figure No.56 Dialoug box of applies and saves any changes you have made in featured tool and closes dashboard

Page No.33

57 Figure No.57 Ctrl + D view of entity Page No.3458 Figure No.58 Result of using plane command Page No.34Level 1 Asia Pacific Institute of Information Technology 2012

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59 Figure No.59 ‘DTM1’ plane above the 15mm of top view plane

Page No.35

60 Figure No.60 Result of making two rectangles Page No.3561 Figure No.61 Result of editing the values of rectangles Page No.3662 Figure No.62 Circle is made in one rectangle and strong the

values of circlePage No.36

63 Figure No.63 3 more circle made on 2 rectangles above 15mm above top view

Page No.37

64 Figure No.64 Extrude the two rectangles by 20mm Page No.3865 Figure No.65 Dialoug box of applies and saves any changes

you have made in featured tool and closes dashboard

Page No.38

66 Figure No.66 Ctrl + D view of entity Page No.3867 Figure No.67 Result of using plane command Page No.3968 Figure No.68 ‘DTM1’ plane above the 75mm of top view

planePage No.39

69 Figure No.69 Result of made circle of diameter 8 and strong the value from x & y axis

Page No.40

70 Figure No.70 3 more circle made on ‘DTM2’ plane and strong the values

Page No.40

71 Figure No.71 Extrude the 4-circles at height of -20mm Page No.4172 Figure No.72 Dialoug box of applies and saves any changes

you have made in featured tool and closes dashboard

Page No.41

73 Figure No.73 Ctrl + D view of entity Page No.4174 Figure No.74 Sketch of ‘DTM2’ plane and rectangle created Page No.4275 Figure No.75 Strong the value of rectangle Page No.4276 Figure No.76 Circle with strong dimensions Page No.4377 Figure No.77 3 More circle on rectangle and strong these Page No.4378 Figure No.78 Extrude the rectangle and 4-circle of diameter

15mm to 15mmPage No.44

79 Figure No.79 Dialoug box of applies and saves any changes you have made in featured tool and closes dashboard

Page No.44

80 Figure No.80 Ctrl + D view of entity Page No.4481 Figure No.81 Another view of entity Page No.4582 Figure No.82 Result of using plane command Page No.4583 Figure No.83 ‘DTM3’ plane is made on 90mm height from

top viewPage No.46

84 Figure No.84 Result of made rectangle on ‘DTM3’ plane Page No.4685 Figure No.85 Result of strong rectangle Page No.4786 Figure No.86 Result of made circle in between rectangle Page No.4787 Figure No.87 Result of strong the circle Page No.4888 Figure No.88 Extrude the ‘DTM3’ entity by 15mm Page No.4889 Figure No.89 Dialoug box of applies and saves any changes

you have made in featured tool and closes dashboard

Page No.48

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90 Figure No.90 Ctrl + D view of entity Page No.4991 Figure No.91 Result of using plane command Page No.4992 Figure No.92 Ctrl + D view to show ‘DTM4’ plane Page No.5093 Figure No.93 Made circle at height of 100mm from top view

with diameter 15mmPage No.50

94 Figure No.94 Strong the circle Page No.5195 Figure No.95 3 more circle made on ‘DTM4’ plane Page No.5196 Figure No.96 Strong the circles dimensions Page No.5297 Figure No.97 Extrude the ‘DTM4’ entity by -100mm Page No.5298 Figure No.98 Dialoug box of applies and saves any changes

you have made in featured tool and closes dashboard

Page No.53

99 Figure No.99 Ctrl + D view of entity Page No.53100 Figure No.100 Result of using plane command Page No.54101 Figure No.101 Result of sketching ‘DTM5’ plane Page No.54102 Figure No.102 A circle with diameter 10mm are strong Page No.55103 Figure No.103 Another circle with diameter 10 are strong Page No.55104 Figure No.104 Result of using line command Page No.56105 Figure No.105 Result of using line command Page No.56106 Figure No.106 Result of using line command Page No.57107 Figure No.107 Ctrl + D view of entity Page No.57108 Figure No.108 Another view of die-press drawing Page No.58

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Appendix B

S.NO. Figure No. Description Page No.1 Figure No.17 Hot forging Process Page No.102 Figure No.18 Rolling Process Page No.113 Figure No.19 Extrusion process Page No.124 Figure No.20 Direct extrusion process Page No.125 Figure No.21 Indirect Extrusion Process Page No.136 Figure No.22 Drawing Process Page No.147 Figure No.23 Casting Process Page No.148 Figure No.24 Injection Moudling Page No.169 Figure No.25 Injection Moudling Page No.1610 Figure No.26 Powder Metallurgy Page No.1711 Figure No.27 Powder Metallurgy Page No.1712 Figure No.28 Fasteners Page No.1813 Figure No.29 Rivets Page No.1914 Figure No.30 Soldering Process Page No.2015 Figure No.31 Brazing Process Page No.2116 Figure No.32 Arc Welding Page No.2217 Figure No.33 Gas Welding Page No.2318 Figure No.34 TIG Welding Page No.2319 Figure No.35 MIG Welding Page No.2420 Figure No.37 Plasma Arc welding Page No.24

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REFERENCES

1. R.K.RAJPUT(2008).ManufacturingTechnology.NewDelhi:LAXMIPUBLICATIONS.p39.

2. R.K.RAJPUT(2008).ManufacturingTechnology.NewDelhi:LAXMIPUBLICATIONS.p152.

3. R.K.RAJPUT(2008).ManufacturingTechnology.NewDelhi:LAXMIPUBLICATIONS.p157.

4. Dr.DmitriKopeliovich.(2003).PlasmaWelding.Available:http://www.substech.com/dokuwiki/doku.php?id=plasma arc welding paw. Last accessed 11th March 2012.

5. ScJuang,YSTarng.(1998).TIGwelding.Available:http://www.weldingengineer.com/1tig.htm. Last accessed 11th March 2012.

6. LMGourd.(1995).OxyacetyleneGasWelding.Available:http://www.engineersedge.com/weld/gas welding.htm. Last accessed 16th March 2012.

7. JWKim.(1994).ArcWelding.Available:http://www.faqalert.com/what-is-arc-welding/.Last accessed 11th March 2012.

8. MLipa,PChappuis.(1991).Brazing.Available:http://www.siliconfareast.com/joiningprocess. Last accessed 14th March 2012.

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