ME 406 Manufacturing and Design 191-Term Project Instructors Dr. Ahmed Sarhan/Dr Numan Abu Dheir (Due on or before December 16 2019) Part of the vision of 2030 is to transform the Kingdom Oil-based economy to knowledge based added value economy. As a result local investors with large capitals are eager to find opportunities to take part in achieving this vision. You as a young engineer are targeting those local investors to start a jointventure in the manufacturing sector. You decided to come up with the idea of manufacturing Powder Metallurgy metal Porous Sliding Bearing as shown in Fig. 1. Porous-metal bearings are used widely in instruments and general machinery, in which their self-lubricating characteristics and load-carrying ability is very desirable. Most porous-metal bearings consist of either bronze or iron which has interconnecting pores. These voids take up 10% to 35% of the total volume. In operation, lubricating oil is stored in these voids and feeds through the interconnected pores to the bearing surface. When properly designed, they can be both economical and highly functional. Their manufacturing method consists of compacting the metal powder mixtures to the proper density. Subsequently, they are sintered for different duration subject to the temperatures. Sintered bearings are then sized to obtain the required dimensional characteristics. This is followed by inspection and impregnation with a lubricating oil. If the targeted production volume per year is 1M parts, then prepare your technical report and provide details for the following: 1- Basic overview for processes plan. (5pts) 2- Materials selection: What are the possible different powder and die materials for manufacturing the bearing. Justify your selection of the powder and die materials (10pts) 3- Design for the Porous Bearing (provide dimensions; Engineering Drawing 2D+3D), sizing of Porous-Metal Bearings and Bearing Clearances. (10 pts) 4- A design for the mechanical compacting die-punch (Sketch and Engineering Drawing 2D+3D). Show Press Fits and how the die will be fixed on machine and measures for die alignment. (25pts) 5- Force and power requirement for the press performing the compacting process and estimate the resulting green density at the proper porosity. (15pts) 6- Sintering process and its parameter and an estimate for the resulting properties. (10pts) 7- Heat treatment process (5pts) 8- Details for finishing processes with reasons and the expected dimensional tolerances of the part and surface finish expected. (5pts) 9- Detailed estimate for the cost of the part. (15 pts) 10- Providing a simulation showing the processing (compaction and/or sintering) will carry extra grade to the team. (extra 10 pts) Note: the report must be formatted to show all elements of technical reports. The report will be check for plagiarism. Make sure to provide references as needed. Both hard and soft copy of the report and the associated drawing and simulation files if any must be submitted on or before the due date. Figure 1
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