Indian Institute of Technology Madras
Department of Mechanical Engineering
Project Report
ME2300- Manufacturing process
January - May 2024
Submitted by-
SEENIVASA RAGHURAM ME22B053
HARSH RAJ ME22B071
PART - A: Digitally Manufacturing the Parts
Strategy - A: 3D Printing
To 3D print the given shape, the 3D printer requires specific G-Codes and M-Codes. To
obtain these codes, the software needs an STL file as input. To create the STL file, a
CAD file must first be designed. We started by analyzing the provided drawing and
decided to 3D print the lid and the bottom base separately, then assemble them
together.
After converting it into an STL file, we used the slicing software FlashForge to slice and
convert it into G-codes and M-codes. To ensure the material didn't fall off and to reduce
the printing time, we used an infill of about 30%. The G-code file was then uploaded to
the 3D printer, and the printing process began. The estimated time to complete the print
was about 1 hour and 30 minutes.
Strategy - B: CNC Machining
A similar approach to creating a CAD model was followed for this step. However, the
required input was a STEP file. This STEP file was then fed into the MasterCAM
software. Using this software, we could verify the correctness of our model and
simulate the tool path and machining processes. This allowed us to set the spindle
RPM speed and make various adjustments to ensure accurate and efficient machining
of the workpiece.
Strategy - C: Mold Making
To make the mold for the given part, we first made the mold using the CAD software. To
do that we first used the CAD model which we had initially made. We then made the
inverted part for both the lid and the Bottom part separately.
PART - B: Physically making in the central workshop
Workshop Activities:
Preparation:
- We first confirmed the suitability of our CAD models by discussing them with the
workshop associates
- The models were checked for any errors or potential issues using the slicing software
we even changed accordingly.
Printing Process:
- The models were printed using PLA filament.
Support Structures:
- Support structures were essential for maintaining the hollow interior rest is self
explanatory.
- We used tree supports, which are efficient in saving material and very easy to remove
without much effort.
Post-Processing:
- After printing, the parts were carefully removed from the print bed.
- The support structures were removed using pliers and a deburring tool to clean the
parts.
- The hollow interiors were inspected to ensure there was no residual support material.
Challenges and Solutions:
Support Removal:
- Some supports were difficult to remove from the hollow sections.
- We adjusted the support settings to reduce density, making removal easier.
Lessons Learned:
- Learnt about the slicing software used in 3D printing which can be used to check any
errors.
- Ensuring good bed adhesion and optimal support structure settings is crucial for
high-quality prints.
- Post-processing steps, including careful support removal, are essential to maintain
part integrity.
Strategy B: CNC Machining
Workshop Activities:
Preparation:
- We prepared the Polyphenylene Ether (PPE) workpieces and secured them on the
CNC machine bed.
- The digital models were imported from the machine’s controller.
Joint Design:
- Special attention was given to the machining of the joints, ensuring the dimensions
were accurate to fit the parts together seamlessly.
Quality Control:
- After machining, each part was measured using calipers to ensure it met the specified
dimensions.
- The surface finish was checked for any imperfections.
Challenges and Solutions:
Proper Fit:
- The two pieces had to fit snugly without being loose or unable to fit, so the dimensions
had to be accurate.
- We used milling to correct any imperfections in dimensions to make them fit perfectly.
Lack of Material:
- Aluminum alloy wasn't available during our slot, so we used Polyphenylene Ether
(PPE) instead.
Tool Wear:
- There was noticeable tool wear during roughing.
- Tool changes were performed as needed to maintain quality.
- Vibration: Minor vibrations during finishing were mitigated by adjusting the feed rate
and RPM.
Lessons Learned:
- Proper tool selection and parameter settings are essential for achieving desired
surface finishes and dimensional accuracy.
- Regular tool maintenance and monitoring are necessary to avoid defects.
- We couldn’t get a good finish due to the less shear strength of Polyphenylene Ether
(PPE) so aluminum alloy gives a better finish.
Strategy C: Mold Cavity and Wax Pouring
Workshop Activities
1. Initial Mold Making and Wax Casting:
- Initially, the mold was created using 3D printing. Wax was then poured into the mold
to form the part.
- However, due to inadequate releasing mechanisms, the initial part was damaged.
2. Transition to Sand Casting:
- Preparation: The mold cavity was designed considering parting lines and shrinkage.
It was machined from PPE using settings similar to Strategy B.
- Mold Preparation:The mold was created primarily using sand casting. The actual
part, made from CNC, was placed in the sand to form the mold as illustrated in the
figure.
- Wax Melting and Pouring: Wax was melted in a controlled environment to ensure
consistent pouring. The molten wax was poured into the pre-heated mold cavity to
prevent premature solidification.
- Mold Opening: Once the wax solidified, the mold was carefully opened to retrieve
the cast parts. Any excess material (flash) was removed using trimming tools.
3. Challenges and Solutions
- Shrinkage: The wax parts exhibited some shrinkage. This was addressed by slightly
increasing the cavity dimensions in the CAD model.
- Mold Release: Proper treatment of the mold with a release agent facilitated easier part
removal.
- Improper Releasing Mechanisms: The initial mold, made using 3D printing with thinner
walls to reduce printing time, started melting due to insufficient thickness.
4. Lessons Learned
- Designing molds with proper allowances for material shrinkage is crucial for accuracy.
- Pre-heating the mold and using release agents are important steps for successful
casting.
- Ensuring proper releasing mechanisms for molds is essential for producing
undamaged parts.