manufacturing Process

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· Engineering Report

· The design of manufacturing and the design of assembly is the art of bringing together product design and product planning in single activity to achieve the goal of ease of manufacturing, reliable and cost effective product. The aims of applying DFM and DFA to a product are

· To design a product on the basis of ease of manufacturing.

· To select manufacturing processes which are simplest, economical and have least manufacturing time.

· To reduce the total number of parts as this is the most effective method to bring the cost down as well as it reduces the intensity of all the activities related to product during its entire life.

· The maximize the use of standard components because of their ease of availability and reduction in lead time.

· To avoid use of separate fasteners as they increase the cost of manufacturing due to handling and feeding operations that have to be performed.

· To decrease the manufacturing and assembly costs and at the same time improving quality and reliability of the product.

· The product that I have chosen for my project is an X-ray glasses.

· Parts of X-ray glasses

· Frame

· Lenses

· Feather

· Raw material for X-ray glasses

· Plastics,

· Cardboard,

· Feathers, and

· Finishing materials.

· Frames

· The plastics used for x-ray glasses manufacture easily colored, heat stable, and durable. Thermoplastic may be used as a material. To increase the usefulness of plastic different materials are mixed with the plastics. To match the design requirements, colorants are added to the plastic. To improve the flexibility and workability of the materials, glycerol as plasticizers have been added. Fiberglass has been added as reinforcement materials. At last, antioxidants and stabilizers has been added to increase the durability of the plastic.

· Commonly, the plastic delivered to manufacture in a semi-prepared form such as sheets that can be punched out or pellets that can be melted down from a plastic supplier. In x-ray glasses frame, some additives may need to be mixed with plastic during the process of molding and formation.

· Lenses

· The manufacturing process plan consists of the following stage in the manufacturing of frame and lenses

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· The details of each manufacturing step are as follows:

· Frame:

· The injection molding is applied to the raw material plastic for the formation of x-ray glass frames.

· The preparation involves the hollow metal matrix desired shape and size of the frame. The frame unit may be either single or separated which must be connected. Usually, manufactured as single unit. The shell mold casting process has been involved in the production of frame molding. The frame is made up of the plastic material which make it more reliable to use in the x-ray exposure places.

· The melting process melts the plastic polymer pellets by transferring pellets from the holding bin to the liquefying machine. At extremely high temperature, almost 300°F (149°C), the plastic pellets have been melted. After the liquefaction of the plastic, molding takes place again through injection. The melt passed at extremely high speed and pressure into the mold. The mold is filled by the melt and some more melt is added to overcome the plastic contraction after solidification and cooling. The melting plastic is injected into mold by the help of the injecting machine.

· After the cooling of plastic polymer, it has been separated from the mold and then passed from the conveyer belt automatically for further processing.

· Finally, the frames have been smoothed. The abrasive machine smoothed the frames by removing rough edges and extra plastic.

· Following is the workflow for frame manufacturing:

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· Lenses of x-ray glasses have been made by using cardboard. The grade and thickness of the cardboard have been depending on the designer’s choice. Before the cutting of the lenses, the cardboard sheets have been sent to the printing press. The printing press drawn sheets in the huge rollers machine. The ink from the rollers have been transferred to the sheets creating black and white spiral outward appearance.

· The blanking machines cut the lenses from the cardboard sheets, after the settlement of decoration. The cardboard sheet rolled into stamper machine. The stampers have a series of metal cookie cutters essentially to cut the sheet in the exact size and shape of the lens. As the cardboard sheet have been rolled, stampers reached down towards the cardboard and cut exact shape of the lens.

· The lens is positioned perfectly on the front side for the decoration after cutting. The shaped lens folded over to make a double layered lens.

· At the end all the pieces of the x-ray glasses have been joined to form a look of glasses. The joining of frame boundary with temple and bridge has been done by the help of steel bolt. The bolted connection has been done by the help of steel.

· By the help of puncturing machine, holes are stamped into double layered lenses. The cut-outs are placed so that a metal rod with the same diameter as the desired holes can punch through the center of each lens. The lens is then opened and a feather is glued over each hole. The lens is then refolded and glued together. The lenses are then attached to the plastic frame. A groove on the frame inside each lens area allows the cardboard lenses to snap in. The x-ray glasses are then put into a plastic bag packaging and a cardboard card is stapled to the top to close the bag. The card is decorated with illustrations to show how the glasses are used.

· Engineering Drawings

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Vendor Specifications & Literature

· "Paper." Kirk-Othmer Encyclopedia of Chemical Technology. Vol. 18. R. E. Kirk and D. F. Othmer, eds. New York John Wiley & Sons, 1996.

· "Plastics Processing." Kirk-Othmer Encyclopedia of Chemical Technology. Vol. 19. R. E. Kirk and D. F. Othmer, eds. New York John Wiley & Sons, 1996.

Molding

Melting

Separation

Finishing

FRAME

Cutting

Conditioning

Finishing

LENSES

Joining

Extrusion

Injection Molding

Blow Molding

Thermoforming

Turning

Drilling

Milling

Broaching

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