POWDER METELLURGY

A
Seminar Report
Submitted
in partial fulfillment
for the award of the Degree of
Bachelor of Technology
in Department of Mechanical Engineering
(With specialization in Mechanical Engineering)

(Batch 2014-18)
Supervisor Submitted by:
Ms. Anita Manish Maheshwari
Assistant Professor Roll No.-14ESDME036
Yadav

Department of Mechanical Engineering

Poornima Group of Institutions, Jaipur
Rajasthan Technical University
February,2018

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 POORNIMA GROUP OF
INSTITUTIONS

CERTIFICATE

This is to certify that Final Year Technical Seminar 8ME8A Report entitled
“Powder Metallurgy” has been presented by “Manish Maheshwari
(PGI/ME/14/035)” for partial fulfilment of the Degree of Bachelor of Technology
to Department of MECHANICAL ENGINEERING, Poornima Group Of
Institutions. It is found satisfactory and approved for submission.

Date: 26-feb-2018

Mr. Ashwani Kapoor,

Ms. Anita Yadav
HOD,
Department of
Mechanical
Assistant Professor Engineering

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 ACKNOWLEDGEMENT

I have undergone Technical Seminar which was meticulously planned and guided at every
stage so that it became a life time experience for me. This could not be realized without the
help from numerous sources and people in the Poornima Group of Institutions.

I am also very grateful to Mr.Ashwani Kapoor (HOD, Dept. of Mechanical Engineering)

for his kind support and guidance.

I would like to take this opportunity to show our gratitude towards Ms. Anita Yadav
(Seminar Coordinator) who helped me in successful completion of my Technical Seminar.
She has been a guide, motivator & source of inspiration for us to carry out the necessary
proceedings for completing this report and related activities successfully

I would also like to express our hearts felt appreciation to all of our friends whom direct or
indirect suggestions help us to develop this project.

Lastly, thanks to all faculty members of Department of Mechanical for their moral support
and guidance.

Manish Maheshwari

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 ABSTRACT

Powder metallurgy (PM) is a popular processing technique to fabricate ceramic, metallic or

composite components, typically of small size and of complex shape. In effect, PM is a near
net shape process, which can produce components with high precision at low cost with little
waste. There has been a significant expansion in the PM industry over the past decade. PM
components are replacing a wide range of casting, forging and machined components. Also,
more and more complex multileveled engineering components are being manufactured using
PM technology. This increasing complexity challenges quality control of the finished parts.
Consequently, proper handling techniques throughout the entire PM process are required to
manufacture consistent, uniform products. This must be based on a full understanding of each
stage of the entire PM process.

Powder metallurgy has a unique set of benefits, most importantly being quite economical.
Therefore, this method is very suitable for batch production of parts with complex shapes.
Nowadays, powder metallurgy is considered a conventional manufacturing method even in
high stress application. Using powder metallurgy, it is possible to fabricate components, which
otherwise would decompose or disintegrate. This is because powder processes are more
flexible than casting, extrusion forming, or forging techniques.

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 Table of contents

Sr.no Topic Page no.

1. Introduction 7
1.1 objective
1.2 scope
1.3 conclusion
2. Literature survey 8-9
3. Theory 10-12
3.1 computer aided process planning 10
3.2 Computer aided design 11
3.3 computer aided manufacturing 11
3.4 application areas 11
3.5 methodology 12
3.6 advantages & disadvantages 12
4. Future scope 13
5. Conclusion 14
6. references 15

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 List of abbreviations

 CAPP – Computer Aided Process Planning.

 CAD - Computer Aided Design.
 CAM - Computer Aided Manufacturing.
 API - Application Programme Interface.
 ERP - Enterprise Resource Planning.
 EDM - Electrical Discharge Machining.

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Chapter - 1
INTRODUCTION

1.1 Aim and Objectives

To get knowledge about Powder Metallurgy, its applications, future development, advantages
& disadvantages.

1.2 Scope
 Light weight technology in automotive fields.
 Hitachi chemicals.
 Engaged in the development of wear resistant part, magnetic parts for the development
of high performance parts.

1.3 Conclusion
Powder Metallurgy is the techniques; how to produce solid metal objects from powdered metal
by compacting and sintering.

1.4 Selection of topic

The topic Powder Metallurgy was selected because the powder metallurgy plays a important
role in manufacturing of product from metal powder.

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 Chapter - 2

LITERATURE SURVEY

Powder metallurgy is the process of blending fine powdered materials, pressing them into
a desired shape or form (compacting),and then heating the compressed material in a
controlled atmosphere to bond the material (sintering).
The Powder metallurgy process generally consists of four basic steps: powder
manufacture, powder blending, compacting, and sintering.

Literature reviews are a form of systematic reviews determines an objective list of criteria,
and find all the previously published original research papers that the criteria, then
compare the results presented in these papers. Literature reviews, provides a summary of
what the authors believe are the best and most relevant prior publication.
A brief review of research papers

Authors Journal Year Country Objective Key Findings

M.Delavari, International 2011 IRAN The effect of The powder size has
Journal of Powder intense effect on the
A.Salarvand,
Engineering Metallurgy dimensional changes in
A. Rahi , Science and Process sintering.
Technology Parameters With increase in the
F.Shahri on percentage of the
Mechanical lubricant in powder
properties of mixture, the samples
micro and raw density decreases.
nano-iron
powder
Behrokh International 2002 U.S.A Metallic part The SIS-metal process
khoshnevis, Journal of fabrication can provide benefits
Engineering using such as low cost and
Yong chen,
Science and selective fast building speed for
Mahdi Technology inhibition metallic part
yoozbbbashi sintering fabrication.
zadeh

Dalcy Journal of 2004 CANADA Production of Titanium and its alloy

Roberto dos Science and low young provide high strength –
Santos, Technology modulus to-weight ratio ,good
titanium alloy fatigue strength and
Carlos
by powder increased corrosion
Alberto
metallurgy resistance compared
Alves Cario
with others marerials.

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Elham International 2002 IRAN Study the Green density is
Jafar-Salehi Journal of relationship defined as the state of
Engineering between powder in which the
Science and green density powder is copacted
Technology and under high pressure.
compaction
pressure in
powder
metallurgy.

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 Chapter 3
Theory

3.1 Computer Aided Process Planning

CAPP is a linkage between the CAD & CAM module. It provides the planning of the process
to be used in producing a designed part. Process planning is concerned with determining the
sequence of individual manufacturing operations needed to produce a given part or product.
The resulting operation sequence is documented on a form typically referred to as a route sheet
(also called as process sheet/method sheet) containing a listing of the production operations
and associated machine tools for a work part or assembly. Process planning in manufacturing
also refers to the planning of use of blanks, spare parts, packaging material, user instructions
(manuals) etc.
The term "computer-aided production planning" is used in different contexts on different
parts of the production process; to some extent CAPP overlaps with the term "PIC" (production
and inventory control).
Process planning translates design information into the process steps and instructions to
efficiently and effectively manufacture products. As the design process is supported by many
computer-aided tools, computer-aided process planning (CAPP) has evolved to simplify and
improve process planning and achieve more effective use of manufacturing resourcesprocess
planning is of two types as:

1. Generative type computer aided process planning.

2. Variant type process planning.

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3.2 Computer Aided Design
Computer-aided design (CAD) is the use of computer systems (or workstations) to aid in
the creation, modification, analysis, or optimization of a design. CAD software is used to
increase the productivity of the designer, improve the quality of design, improve
communications through documentation, and to create a database for manufacturing. CAD
output is often in the form of electronic files for print, machining, or other manufacturing
operations.

3.3 Computer Aided Manufacturing

Computer-aided manufacturing (CAM) is the use of software to control machine tools and
related ones in the manufacturing of workpieces. This is not the only definition for CAM, but
it is the most common. CAM may also refer to the use of a computer to assist in all operations
of a manufacturing plant, including planning, management, transportation and storage.Its
primary purpose is to create a faster production process and components and tooling with more
precise dimensions and material consistency, which in some cases, uses only the required
amount of raw material (thus minimizing waste), while simultaneously reducing energy
consumption.

3.4 APPLICACTION AREAS

1. In Medical field like surgery, MRI.

2. In Electronic field like bare circuit manufacturing.
3. In Textile industries for garments design& patternmaking.
4. In Shipbuilding.
5. In robotics for example robot assembly.
6. In EDM process.

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3.5 METHODOLGY
Selection of research papers

Reading of papers

Data collection

Applications Advantages & Future scope

Disadvantages

Result & discussion

Conclusion

3.6 Advantages and disadvantages

Advantages
 With the help of CAPP,We can systematically produce accurate and consistent process
plans.
 It can reducethe cost and lead times of process plan.
 Skill requirement to develop feasible process plan for process planer are reduced
 Interfacing of software for cost, manufacturing lead time estimation, and work
standards can easily be done.
 Leads to the increased productivity of process planer

Disadvantages
While compared with manual process planning CAPP system have few disadvantages.
 The inability to show special manufacturing techniques.
 The initial cost of establishing a CAPP system is high while compared with manual
process planning.

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 Chapter 4
Future scope

Generative or dynamic CAPP is the main focus of development, the ability to automatically
generate production plans for new products, or dynamically update production plans on the
basis of resource availability. Generative CAPP will probably use iterative methods, where
simple production plans are applied to automatic CAD/CAM development to refine the initial
production plan.
A Generative CAPP system was developed at Beijing No. 1 Machine Tool Plant (BYJC) in
Beijing, China as part of a UNDP project (DG/CRP/87/027) from 1989–1995. The project was
reported in "Machine Design Magazine; New Trends" May 9, 1994, P.22-23. The system was
demonstrated to the CASA/SME Leadership in Excellence for Applications Development
(LEAD) Award committee in July 1995. The committee awarded BYJC the LEAD Award in
1995 for this achievement. In order to accomplish Generative CAPP, modifications were made
to the CAD, PDM, ERP, and CAM systems. In addition, a Manufacturing Execution System
(MES) was built to handle the scheduling of tools, personnel, supply, and logistics, as well as
maintain shop floor production capabilities.
Generative CAPP systems are built on a factory's production capabilities and capacities. In
Discrete Manufacturing, Art-to-Part validations have been performed often, but when
considering highly volatile engineering designs, and multiple manufacturing operations with
multiple tooling options, the decisions tables become longer and the vector matrices more
complex. BYJC builds CNC machine tools and Flexible Manufacturing Systems (FMS) to
customer specifications. Few are duplicates. The Generative CAPP System is based on the
unique capabilities and capacities needed to produce those specific products at BYJC. Unlike a
Variant Process Planning system that modifies existing plans, each process plan could be
defined automatically, independent of past routings. As improvements are made to production
efficiencies, the improvements are automatically incorporated into the current production mix.
This generative system is a key component of the CAPP system for the Agile Manufacturing
environment.

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 Chapter 5
Conclusion

A set of typical advantages are achieved when the systems are carried through CAPP. They
are reduced clerical effort, fewer calculations, immediate access to up-to-date information,
faster response to engineering production changes etc. While the variant method has the
advantage of mixing each of individual process and typical process with group operations, it
still depends on the knowledge of process planner. Presented manufacturing information
system is a unique one in cooperation with CAD/CAM system and its connectivity to other
systems. Such concept brings many advantages like flexible interconnections to different
segments, convenient price level, etc. [2]
In this research paper all the data regarding designing, process planning and material selection
have been validated with the help of a CAD / CAM tool. The CAD/CAM tool optimizes the
time for designing and process planning. The DFMA tool analyzes the lesser cost and high
quality product based on the Machine and volume of product manufactured. [3]
Application of general-purpose CAD/CAM/CAE software systems, the systems for database
developments, and systems for development of software applications, allows development of
software solutions for automation of design and manufacture. The dedicated software solution
developed in this work, i.e. the integrated CAPP system, allows
automationofasignificantnumberofactivitiesintheprocessof mold design and manufacturing
process planning, which contributes to rationalization of activities proceeding the
manufacturing process.[4]
Computer-Integrated Manufacturing has gained recognition as a most effective tool in
increasing manufacturing competitiveness. The paper provides a rigorous basis for the
understanding of process planning of rotational parts and the development of effective and
efficient Computer-Aided Process Planning systems. This paper defined CAPP module for
data transmissions which is based on information received from the computer aided design of
the products and on the technological database with information on technological equipment,
devices and cutting tools. Realizing the CAPP module for data transmissions has led to an
increase of the flexibility and correctness of the technological planning, having favorable
influences on the manufacturing costs. [5]

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References

1. Chin-Sheng Chen& Yin Tung Albert Sun,“Intelligent Computer-aided Process Planning

of Multi-axis CNC Tapping Machine”, IEEE, 2017.
2. Ravi Yerigeri, Dr. Abhimanyu Posangiri, Dr. S.S. Hebbal, & Seema S.
Billur,“Computer Aided Process Plan and Its Application System”,International Journal
of Innovative Research in Science, Engineering and Technology,2015.
3. Adarsh Kumar, Pranit Prakash Metkar, & Annamalai k,”Computer Aided Process
Planning for vaccum cleaner body casing with NC tool path Generation”,International
Journal Of Research Science & Management,2014.
4. J. Tepic, V. Todic, D. Lukic, M. Milosevic, S. Borojevic,‘Development Of The
Computer-Aided Process Planning (CAPP) System For Polymer Injection Molds
Manufacturing”,METALURGIJA, 2011.
5. Md. Deloyer Jahan & Golam Kabir,”Development of Computer Aided Process
Planning (CAPP) for Rotational Parts”,Global Journal of Researches in Engineering,
2010.

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