Unit 2 Assignment 1
Rail Clamp Component
,Introduction: body of rail clamp
I’m going to be focusing on the body of the ‘Rail Clamp’ component which
has a batch production of 1000. I will also be giving information on two
processes that i think would be used for this certain component, and those
two components will be; sand casting and drop forging. I am going to
evaluate the effectiveness and engineering processes and how human
factors affect them.
,Process 1:
Sand Casting:
Sand casting, which is also known as sand moulded casting, will involve using a
furnace, molten metal, a sand mould and a pattern. The metal has to be melted in
the furnace which will turn to molten metal and it will be poured into the sand
mould which is formed by the pattern that was pressed into the sand to make the
mould. The sand mould separates from the parting which usually goes straight
down the middle and the solidified metal casting can be removed. Sand casting is
usually used for small pieces or for like blacksmiths to make tools, swords, knives
etc.
Sand Casting for the Rail Clamp:
To create a product like the rail clamp with sand casting, i suggest 3D printing your model first
with a CAD program such as ‘Fusion 360’. Then you will need to 3D print it and create your sand
mold. Next you will need to pour your molten metal into the mould through the vents and the
molten metal will need to be low carbon steel. When the mold hardens and cools down you will
need a way to drill the holes. I would suggesting using a pillar drill, and because we are batch
producing 1000 parts of the same component its better to use a jig when drilling. A jig is a tool to
keep another tool/ component in place, It's so you're able to repeat the same process such as
drilling accurately. You will put your rail clamp into the jig in the pillar drill, making sure you wear
safety goggles, and then drill your holes into the component and repeat with every other rail
clamp. You can also finally use sand paper to finish off the surface and to make it shiny and
smooth.
, Advantages & Disadvantages
Sand Casting:
Advantages:
-Timing. As all you will need to do is to make a mould then have pre heated
molten metal then pour it into a mould and it will turn back to a hard solid pretty
quickly.
-Low production cost. You wont need a big expensive machine to do sand
casting just sand a mould and some molten metal.
-Versatile. It is versatile in size, shape and weight and can be used to
manufacture parts in almost any metal, even metals with high melting points.
Disadvantages:
-Low strength. Low material strength due to high porosity compared to a
machined part.
-Low dimensional accuracy. Because of shrinking and the surface finish,
dimensional accuracy is very poor.
-Poor surface finish – Due to internal sand mould wall surface texture.
Rail Clamp Component
,Introduction: body of rail clamp
I’m going to be focusing on the body of the ‘Rail Clamp’ component which
has a batch production of 1000. I will also be giving information on two
processes that i think would be used for this certain component, and those
two components will be; sand casting and drop forging. I am going to
evaluate the effectiveness and engineering processes and how human
factors affect them.
,Process 1:
Sand Casting:
Sand casting, which is also known as sand moulded casting, will involve using a
furnace, molten metal, a sand mould and a pattern. The metal has to be melted in
the furnace which will turn to molten metal and it will be poured into the sand
mould which is formed by the pattern that was pressed into the sand to make the
mould. The sand mould separates from the parting which usually goes straight
down the middle and the solidified metal casting can be removed. Sand casting is
usually used for small pieces or for like blacksmiths to make tools, swords, knives
etc.
Sand Casting for the Rail Clamp:
To create a product like the rail clamp with sand casting, i suggest 3D printing your model first
with a CAD program such as ‘Fusion 360’. Then you will need to 3D print it and create your sand
mold. Next you will need to pour your molten metal into the mould through the vents and the
molten metal will need to be low carbon steel. When the mold hardens and cools down you will
need a way to drill the holes. I would suggesting using a pillar drill, and because we are batch
producing 1000 parts of the same component its better to use a jig when drilling. A jig is a tool to
keep another tool/ component in place, It's so you're able to repeat the same process such as
drilling accurately. You will put your rail clamp into the jig in the pillar drill, making sure you wear
safety goggles, and then drill your holes into the component and repeat with every other rail
clamp. You can also finally use sand paper to finish off the surface and to make it shiny and
smooth.
, Advantages & Disadvantages
Sand Casting:
Advantages:
-Timing. As all you will need to do is to make a mould then have pre heated
molten metal then pour it into a mould and it will turn back to a hard solid pretty
quickly.
-Low production cost. You wont need a big expensive machine to do sand
casting just sand a mould and some molten metal.
-Versatile. It is versatile in size, shape and weight and can be used to
manufacture parts in almost any metal, even metals with high melting points.
Disadvantages:
-Low strength. Low material strength due to high porosity compared to a
machined part.
-Low dimensional accuracy. Because of shrinking and the surface finish,
dimensional accuracy is very poor.
-Poor surface finish – Due to internal sand mould wall surface texture.
