Double wishbone suspension

A double wishbone suspension is an independent suspension design for automobiles using two (occasionally parallel) wishbone-shaped arms to locate the wheel. Each wishbone or arm has two mounting points to the chassis and one joint at the knuckle. The shock absorber and coil spring mount to the wishbones to control vertical movement. Double wishbone designs allow the engineer to carefully control the motion of the wheel throughout suspension travel, controlling such parameters as camber angle, caster angle, toe pattern, roll center height, scrub radius, scuff (mechanical abrasion) and more.
Implementation.
The double-wishbone suspension can also be referred to as "double A-arms", though the arms themselves can be A-shaped, L-shaped, or even a single bar linkage. A single wishbone or A-arm can also be used in various other suspension types, such as variations of the MacPherson strut. The upper arm is usually shorter to induce negative camber as the suspension jounces (rises), and often this arrangement is titled an "SLA" or "short long arms" suspension. When the vehicle is in a turn, body roll results in positive camber gain on the lightly loaded inside wheel, while the heavily loaded outer wheel gains negative camber.
Between the outboard end of the arms is a knuckle. The knuckle contains a kingpin for horizontal radial movement in older designs, and rubber or trunion bushings for vertical hinged movement. In newer designs, a ball joint at each end allow for all movement. Attached to the knuckle at its center is a bearing hub, or in many older designs, a spindle to which the wheel bearings are mounted.
To resist fore-aft loads such as acceleration and braking, the arms require two bushings or ball joints at the body.
At the knuckle end, single ball joints are typically used, in which case the steering loads have to be taken via a steering arm, and the wishbones look A- or L-shaped. An L-shaped arm is generally preferred on passenger vehicles because it allows a better compromise of handling and comfort to be tuned in. The bushing in line with the wheel can be kept relatively stiff to effectively handle cornering loads while the off-line joint can be softer to allow the wheel to recess under fore-aft impact loads. For a rear suspension, a pair of joints can be used at both ends of the arm, making them more H-shaped in plan view. Alternatively, a fixed-length driveshaft can perform the function of a wishbone as long as the shape of the other wishbone provides control of the upright. This arrangement has been successfully used in the Jaguar IRS. In elevation view, the suspension is a 4-bar link, and it is easy to work out the camber gain (see camber angle) and other parameters for a given set of bushing or ball-joint locations. The various bushings or ball joints do not have to be on horizontal axes, parallel to the vehicle centre line. If they are set at an angle, then anti-dive and anti-squat geometry can be dialled in.
In many racing cars, the springs and dampers are relocated inside the bodywork. The suspension uses a bellcrank to transfer the forces at the knuckle end of the suspension to the internal spring and damper. This is then known as a "push rod" if bump travel "pushes" on the rod (and subsequently the rod must be joined to the bottom of the upright and angled upward). As the wheel rises, the push rod compresses the internal spring via a pivot or pivoting system. The opposite arrangement, a "pull rod", will pull on the rod during bump travel, and the rod must be attached to the top of the upright, angled downward. Locating the spring and damper inboard increases the total mass of the suspension, but reduces the unsprung mass, and also allows the designer to make the suspension more aerodynamic.
Short long arms suspension.
A short long arms suspension (SLA) is also known as an unequal length double wishbone suspension. The upper arm is typically an A-arm, and is shorter than the lower link, which is an A-arm or an L-arm, or sometimes a pair of tension/compression arms. In the latter case the suspension can be called a multi-link, or dual ball joint suspension.
The four-bar linkage mechanism formed by the unequal arm lengths causes a change in the camber of the vehicle as it rolls, which helps to keep the contact patch square on the ground, increasing the ultimate cornering capacity of the vehicle. It also reduces the wear of the outer edge of the tire.
SLAs can be classified as short spindle, in which the upper ball joint on the spindle is inside the wheel, or long spindle, in which the spindle tucks around the tire and the upper ball joint sits above the tire.
Drawbacks.
Short spindle SLAs tend to require stiffer bushings at the body, as the braking and cornering forces are higher. Also they tend to have poorer kingpin geometry, due to the difficulty of packaging the upper ball joint and the brakes inside the wheel.
Long spindle SLAs tend to have better kingpin geometry, but the proximity of the spindle to the tyre restricts fitting oversized tyres, or snowchains. The location of the upper balljoint may have styling implications in the design of the sheetmetal above it.
SLAs require some care when setting up their bump steer characteristic, as it is easy to end up with excessive, or curved, bump steer curves.
History.
The double wishbone suspension was introduced in the 1930s. French car maker Citroën began using it in their 1934 Rosalie and Traction Avant models. Packard Motor Car Company of Detroit, Michigan, used it on the Packard One-Twenty from 1935, and advertised it as a safety feature. During that time MacPherson strut was still in the area of aviation technology and was derived from aircraft landing mechanism. Later on, until 1951, Ford Company decided to use the MacPherson strut on small production cars, the English Ford Consul and Ford Zephyr. Thus, the double wishbone was applied early in automobile history and there is no genetic relationship between MacPherson strut and double wishbone suspension.
Double wishbones have traditionally been considered to have superior dynamic characteristics as well as load-handling capabilities, and are therefore commonly found on sports cars and racing cars throughout automotive history. Examples of cars with double wishbone suspension include the Aston Martin DB7, the Mazda MX-5, and the third through eighth generation of the Honda Accord. Short long arms suspension, a type of double wishbone suspension, is very common on front suspensions for medium-to-large cars such as the Peugeot 407, Citroën C5, and the first two generations of the Mazda6/Atenza.
Advantages.
The double wishbone suspension provides the engineer more design choices than some other types do. It is fairly easy to work out the effect of moving each joint, so the kinematics of the suspension can be tuned easily and wheel motion can be optimized. It is also easy to work out the loads that different parts will be subjected to which allows more optimised lightweight parts to be designed. They also provide increasing negative camber gain all the way to full jounce travel, unlike the MacPherson strut, which provides negative camber gain only at the beginning of jounce travel and then reverses into positive camber gain at high jounce amounts.
Disadvantages.
Double wishbone suspensions are more complex, impose more difficult packaging constraints and are thus often more expensive than other systems like a MacPherson strut. Due to the increased number of components within the suspension setup, it takes much longer to service and is heavier than an equivalent MacPherson design. At the other end of the scale, it offers less design choice than the more costly and complex multi-link suspension system.


Drawbar force gauge

A drawbar force gauge is a gauge designed to measure forces on a machine tool's drawbar. These types of machines are found in metalworking, woodworking, stone cutting, and carbon fiber fabricating shops. Many modern machines generate well in excess of 50,000 N (12,000 lbf). Measuring and maintaining this force is an important and necessary part of a machine shop preventative maintenance plan.
How drawbar force gauges work.
Modern drawbar force gauges typically are based on a force sensor that uses bonded strain gauges and electronics to convert the resulting output into a digital display for the user to view. Earlier versions of these gauges sometimes also used a sealed hydraulic cavity with a pressure gauge to measure and display force. These hydraulic gauges are generally considered less accurate because of the physical limitations of the indicator.
Why drawbar force is measured.
Drawbar force gauges allow early detection of problems with the spindle's Belleville spring stack, verification of performance of the clamping system as a whole, help prevent damage to spindle taper and other machine features critical to machining accuracy, and ultimately help to keep the machine operator safe.
Drawbar force measurement has been made much more important in recent years with the introduction of radically higher RPM machines. These machines are necessary to work the modern materials required in a multitude of applications—new types of composite wood material, carbon fiber, and high strength materials such as titanium. High speed machining of these materials is considered to begin at 10,000 rpm and may reach as high as 50,000 rpm. The need for regular verification of the spindle clamping system becomes obvious.
As the required machining speeds become higher, the need for machines to be built with smaller diameter spindle components increases. When the spring pack, bearings, and hydraulic units become smaller, the stresses placed upon them become greater. As a result, the clamping system will remain in good shape for fewer and fewer "cycles", or "clamp/unclamp" procedures. Again, this requires gauges and routine procedures to monitor this process. Many operators do not realize that this is something that has changed over time.
Any metal or wood working machine that takes advantage of the HSK taper system should be routinely checked. The slightest stroke mis-adjustment, dirt, or slight wear of the drawbar system can result in significantly reduced holding force. A preventative maintenance schedule, with a strict timetable for testing is a necessity when operating any type of high speed machine utilizing the HSK system.
Retention knob.
Drawbar force gauges are able to detect broken or weakening components of the drawbar clamping system, can give indications that the unit needs lubrication, detect gripper mis-adjustment, or demonstrate that the incorrect retention knob is being used for the machine. A retention knob is a device screwed into the narrow end of a tool holder, enabling the drawbar to pull the tool holder into the spindle. With a highly accurate electronic gauge, deficiencies can be noted and corrected. Many hours of expensive machine operating time can be put to use while avoiding fretting, chatter, "stuck" tool holders in a spindle, etc., by employing proper preventative maintenance techniques using an accurate electronic gauge and other spindle health management tools.
Drawbar force gauges in tool holder standards.
The following tool holder standards specifically address tool retention force as measured by a drawbar force gauge:


Roof crush

Roof crush is the failure and displacement of an automobile roof into the passenger compartment during a rollover accident.
Every year approximately 10,000 Americans are killed in rollover accidents, accounting for about 30% of all light vehicle occupant fatalities. The number of occupant injuries is significantly higher. The relationship between injury levels and intrusion or roof crush has been statistically established, but the mechanism has been thought sometimes to be somewhat obscure. Theories advocating the idea that rollover injuries are caused by the occupants "falling" or "diving" into the vehicles interior have been advanced, but the severity of these events, and thus their potential for causing injury, has been questioned.
Observations from school bus and heavy truck rollovers also suggests that the fall and dive theories are incorrect and that another theory of the mechanism of injury in rollover accidents is required, one that relates injury to the intrusion of the roof structure into the occupant compartment or more simply to "roof crush". Today it is generally realized that the primary injury mechanism in light vehicle rollover accidents is not crushing. Rather, it is widely acknowledged that the principal injury process for contained, i.e., non-ejected, occupants involves the impact between the occupant and the vehicle interior. Since the severity of an impact depends to a large extent on the relative velocity between the impacting objects; the impact theory of injury causation in rollovers has sought to explain the increase in injuries associated with increased roof crush with an increase in the relative velocity between the occupant and the vehicle's interior which is generated by the roof crush. In the simplest terms, when the occupants hits a collapsing roof, they hit harder because the roof is moving in on them. If the roof was not collapsing, and thus moving towards the occupants, their velocity relative to the roof would be lower and the impact less severe.
Roof crush has also been identified as a cause of both full and partial ejection in rollover accidents because of ejection portals created by the collapsing roof structure. These chiefly involve broken windows but occasionally also involve the body structure. The current Federal regulation involving roof strength - 49 CFR 571.216 (FMVSS 216) - has been found to offer little benefit and is currently being reviewed. Many European manufacturers provide stronger roofs than do U.S. or Asian manufacturers despite the fact that there is no European (EEC) roof strength regulation for light vehicles. The Volvo XC90 may be a good example of this.


2011 UEFA European Under-21 Championship qualification play-offs

The play-off first legs were played on 8 October 2010, while the second legs were played on 12 October 2010. Winners of play-off round and host nation Denmark will participate in the championship next year.
Matches.
The draw took place on 10 September 2010 in Herning, Denmark. Fourteen teams were drawn into seven two-legged ties. The matches between Iceland and Scotland were moved back a day to avoid a fixture clash with full internationals.
Second leg.
"Switzerland won 5–2 on aggregate"
"Iceland won 4–2 on aggregate"
"England won 2–1 on aggregate"
"Spain won 5–1 on aggregate"
"Belarus won 3–2 on aggregate"
"Czech Republic won 5–0 on aggregate"
"3–3 on aggregate, Ukraine won on away goals rule."


Whinfield coke works

Whinfield coke works was a large industrial complex located near Rowlands Gill in Tyne and Wear, North East England. The complex comprised a coking plant, alloy factory and power station. Waste heat from the plant provided heat for a power station. This was later converted to generate electricity by burning coke.
Alloy factory.
An alloy factory was opened in 1909 and was operated by the Newcastle Alloy Company, producing ferro alloys such as ferrosilicon, ferromolybdenum, ferrotungsten and ferrochrome. Because ferrochrome was an important ingredient in the manufacture of armoured steel, and Whinfield was the only manufacturer of this alloy in England, the factory was extended during World War I.
At the end of World War I the demand for the alloy quickly vanished and the Newcastle Alloy Company went into liquidation in 1922 and the factory closed.
Power station.
The station was built in 1896 to utilise waste heat from the coke works. The waste heat was used to make steam which powered generators and produced electricity. Initially the electricity powered the Victoria Garesfield Colliery and lit the coke works. In 1902 the station began providing electricity to light the villages of Victoria Garesfield, Highfield, Barlow and Rowlands Gill.
The station had further surplus electricity, which was used in an alloy factory adjacent to the coke works. A new alloy factory was built and the power station was also extended with the building of a new station in 1914. This station used Babcock & Wilcox boilers, which burned coke instead of just using waste heat from the works. Its generating capacity was larger than that of the Dunston A power station. As demand increased, electric supplies were supplemented with the laying of a cable from Dunston power station to Whinfield in 1917.
Following the closure of the alloy factory after World War I, the power station's surplus electricity was sold to the Newcastle-upon-Tyne Electric Supply Company to supply Tyneside, exported using the cable from Dunston. The station closed in 1932 with the introduction of the national grid. It operated on a 50 hertz (Hz) frequency, and it would have proven uneconomical to convert Whinfield from its 40 Hz frequency, and so it closed down. The station's main structure was still standing in the late 1970s, but has since been demolished.
Present.
Whinfield Industrial Estate has since been built on the site.


Production equipment control

Production equipment control involves production equipment that resides in the shop floor of a manufacturing company and its purpose is to produce goods of a wanted quality when provided with production resources of a required quality. In modern production lines the production equipment is fully automated using industrial control methods and involves limited unskilled labour participation. Modern production equipment consists of mechatronic modules that are integrated according to a control architecture. The most widely known architectures involve hierarchy, polyarchy, hetaerarchy and hybrid. The methods for achieving a technical effect are described by control algorithms, which may or may not utilize formal methods in their design.


Capacitor discharge sintering

Capacitor discharge sintering (CDS) is an electric current assisted sintering (ECAS) technique. The technique is based on storage of electromagnetic energy in a high voltage capacitor bank, and discharge into the sintering apparatus at low voltage (transformers on a pre-compacted powder compact which is kept under pressure. The sintering mould and Electrodes are similar to those employed in field assisted sintering techniques (FAST) such as spark plasma sintering and single electromagnetic pulse sintering technologies.
The method, analogous to resistive sintering, is a direct evolution of a welding technology named Capacitor Discharge Welding . CDS seems like an improvement of the less powerful capacitor discharge compaction patented by W.Knoess and M.Schlemmer (EP 0671232, US Patent 5529746).
Advantages of the technique are:
Disambiguation.
The technique has been studied by Element Six under the name of electro-discharge sintering. This name has been adopted by many authors in the past to describe a range of different technologies which typically adopt very high voltages and completely different machines. For this reason the technique which employs low voltages and high currents adapted from capacitor discharge welding has been named capacitor discharge sintering. Other authors also refer to this technology as spark plasma compaction (in reference to the well known spark plasma sintering with whom it has in common only the use of electric currents).
Developments.
Capacitor discharge sintering is at an experimental/research stage of development in Germany at the Ruhr-Universität Bochum where a prototype machine is installed.


Birk Manufacturing

Birk Manufacturing is a privately owned manufacturing company based in East Lyme, Connecticut. Birk engineers and manufactures custom flexible thermal solutions and temperature sensor assemblies for multiple industries including the medical, defense, aerospace, semi-conductor, food service and commercial industries. Birk's main product offerings are Polyimide (Kapton) and Silicone Rubber flexible heating elements.
Birk specializes in engineering and manufacturing components for the most challenging applications, and performs all design and manufacturing at their headquarters in East Lyme, CT.
History.
Birk Manufacturing was formed in 1989 by Norman Birk, the current owner of Birk Manufacturing. Norman served as president of Birk Manufacturing for the company's first 21 years, guiding Birk from a "start-up" company to the industry leader it is today. Birk continues to grow and develop new products and innovations in thermal management.
Certifications.
Birk currently holds UL, CSA, AS9100, ISO 9001, ISO 13485 and ITAR certifications.


Theory of Constraints in streamline manufacturing

Theory of constraints (TOC) is an engineering management technique used to evaluate a manageable procedure, identifying the largest constraint (bottleneck) and strategizing to reduce task time and maximise profit. It assists in determining what to change, when to change it, and how to cause the change. The theory was established by Dr. Eliyahu Goldratt through his 1984 bestselling novel The Goal. Since this time, TOC has continued to develop and evolve and is a primary management tool in the engineering industry. When Applying TOC, powerful tools are used to determine the constraint and reduce its effect on the procedure, including:
Although still limited by varying factors, time factors and human identification, TOC is the ideal engineering solution to increasing profit and reducing idle time in a production through its elimination of 'the weak link.'
History.
Theory of Constraints is a method to determine a procedure in a sequence of procedures which has the greatest negative effect on the production line. The theory was first derived by Dr Eliyahu Goldratt through his 1984 bestselling novel, 'The Goal.' Dr Goldratt was a well-regarded educator in the construction industry, being sought-after by many large companies. In the mid 1990s, Goldratt in 2000, established Goldratt's Marketing Group to further enhance the TOC knowledge to those interested. Goldratt's Marketing Group was established to further enhance the knowledge of businesses in product production, suppliers and distributors, project managers and retail workers, further develop the quality of decision-making, improving communication and stimulating new solutions.
The theory operates with the assumption that every process has at least one influencing constraint, of which must be improved for the process to become more economic. Time spent trying to maximise processes which are not considered the bottleneck will not provide any benefits to the system. Attempting to reduce the influencing factor the bottleneck has on the entire system, will further the 'goal.' The procedure of reducing the influencing factor the bottleneck has on the system, continues as one bottleneck is minimised the attention turns to the new largest hindering procedure.
Bottleneck.
In streamline manufacturing, the bottleneck is the station of a production line where greatest limiting factor lies. It is generally the station with the greatest amount of work in process at the work station. Bottlenecks often results in slow production times, surplus of raw material and low employee morale.
Nearly every manufacturing system initially has a bottleneck. It is critical to be able to determine the procedure in the production line which is the limiting factor. Generally the station which has accumulated the largest amount of WIP can be considered the Bottleneck, however other engineering management techniques can be applied to determine the bottle neck.
Application.
There are several practiced techniques applied to streamline manufacturing to reduce and or eliminate the constraining factor in the system. The methods applied to the systems all are designed to isolate the constraint, break it down into its components and find a suitable solution to reducing the negative impact the station has on the entire system. The thinking processes as well as the identification of the bottleneck is conducted in different manners. The four most common practiced techniques include; Five Focusing Steps, Thinking Process, Throughput Accounting and the Drum-Buffer-Effect.
Five Focusing Steps.
The five focusing steps of TOC is an ideal approach to identifying the bottleneck and the correct procedure to reduce the impact keeping in mind the 'goal.' The five focusing steps are:
Identify the Constraint.
The first step is to determine which process in the system is increasing the procedures overall throughput. Indicators of the bottleneck in the system will have accumulated a large amount of work in progress (WIP) and will have a higher average cycle time.
Exploit the Constraint.
Exploiting the constraint is the procedure of quickly improving the current bottleneck with minimal disruption to the production line. Common rapid relief techniques include:
Improvements in these fields will have a quick solution to improvement of the constraint which will result in improved throughput
Subordinate to the Constraint.
This step focuses on techniques to mitigate impact from upstream or downstream processes which may further delay the operations of the bottleneck. Techniques include:
Elevate the Constraint.
In this step, actions are taken to break the constraints by the implementation of larger changes to improve the bottleneck. These changes usually include a large investment of time and or money. Techniques used include:
Repeat the Process.
Once the initial steps of the Five Focusing Steps have been executed, the bottleneck of focus should no longer be the hindering process of the system. The implementation of the Five Focusing Steps is not used for one off improvement but for continuous improvements to the process. If the bottleneck has been broken, the next step is to repeat the focusing steps for the new bottleneck. If the bottleneck has not been broken, a new approach needs to be taken, including verifying that the investigated constraint has correctly been identified as the bottleneck.
Thinking Process.
The thinking process in TOC, are tools used to determine, and fixing a problem in a system. In streamline processing it is a fundamental approach to always be striving to improve processes, eliminate bottlenecks and reduce manufacturing time. A common approach is to answer the following questions:
Asking these questions when faced with a problem in a production line, will offer a range of solutions simultaneously to improve the current situation. The thinking process allows a smooth transition through the layers of the process to be able to adapt a more suitable method to improve the manufacturing system.
Throughput Accounting.
Throughput accounting (TA) is a simple management accounting technique providing managers with information support to make profitable decisions for their system. It is an alternative method to traditional cost accounting, in which limiting factors in a system are identified and simple solutions are adapted to move towards reaching the businesses goal. The actions of throughput accounting maximize the net profit from a system in the shortest amount of time, with limited resources and limited expenditures.
Throughput accounting uses through methods in dealing with income and expenses in a system
Throughput (T) is the rate at which a system can produce a unit. For profit orientated systems, throughput is considered net sales (S) minus totally variable cost (TVC).
Investment (I) is the monetary value of the system. The value of inventory, buildings, machines and other assets are considered investments.
Operating expenses (OE) is the cost of the supply chain operating to produce the unit. For a system manufacturing a physical item, the operating expense is the investment cost minus the cost of raw materials but including the cost of maintenance, rent and taxes.
Constraints and Limitations.
A key process in TOC is the identification of the limiting factor in a production system to ultimately improve the production of units. A major limitation in the theory is that of identifying the station which is in fact the limiting procedure.
Identification.
It is not uncommon that when applying TOC the wrong work station is being examined as the limiting station when, however this station may only be the bottleneck due to another constraining factor not being focused on. This limitation theory, may encourage the waste of resources and times on a station which may in fact not require optimizing.
Variation.
Another limitation of the theory is the lack of consideration towards varying factors. Factors such as demand for a product are not directly examined when TOC is applied. If the market demand for a product is varying, the use of resources to improve the situation may be better used expanding production capacity.
Time.
Time is an influential constraint when applying TOC. The theory does not consider the current time frame for the production system and the duration of the demand for the product. The theory limits itself to short-term effects on the system rather than forecasting for the future. Overcoming this constraint means examining the long-term effects of work done to improve the constraint. If findings in a short-term analysis seem to repeat they can be considered as long-term effects, therefore implementing changes may be appropriate.


Wearwell

The Wearwell Cycle Company was a bicycle manufacturing company founded in 1889 in Wolverhampton by the five sons of Henry Clarke, founder of the late Cogent Cycle Company. Wearwell were also motorcycle manufacturers under the Wearwell Stevens, Wolf and Wulfruna brands.
In 1928 Jack Waine and his brother George Waine took over the Wearwell Cycle Company Ltd. from the liquidators of the Wulfruna Engineering Co Ltd. The new company was registered as the Wearwell Cycle Co. (1928) Ltd and Jack's son Vincent and George's son Theo were brought on as Directors. They also purchased the plant, tools and stock-in-trade of the cycle manufacturing side of the Vulcan Manufacturing Co. (Wolverhampton) Ltd.
By 1929 a full range of cycles was offered including tradesmen's cycles, juvenile cycles, scooters, and the distinctive 'Duplex'. In 1931 the company showed the new 'Schneider' sports machine at Olympia, and a cheaper version called the 'Wanderer'.
The company produced motorcycles until the outbreak of World War II, from which point they manufactured only bicycles. The factory was partly destroyed by fire during an air raid but some production was soon restored. After World War II production of cycles continued and motorcycle production resumed.
By the middle of the 20th Century, 75% of the company's production was exported to over 30 different countries. The company began sponsoring a professional cycle team through the 1950s, winning the Tour of Britain cycle race in 1953, which was amongst the team's best domestic racing highlights. Riders in the victorious Wearwell Cycle Company Team were Les Scales, John Pottier, Ian Greenfield, Trevor Fenwick, Ken Mitchell and John Welch.
The Vulcan Manufacturing group went into voluntary liquidation in 1969, and its assets were sold off. In 1972 Wearwell Cycle Company was sold off and its production was moved out of Wolverhampton to Aleveley, near Bridgnorth, but was subsequently sold onto Elswick-Hopper Cycle Company where production was moved to Brigg in Lincolnshire. It survived a few more years until the company was finally closed in 1975. A great-great-grandson has revived the Wearwell name in 2017 as a cycling clothes company.


Process management (project management)

In civil engineering and project management, process management is the management of "systematic series of activities directed towards causing an end result such that one or more inputs will be acted upon to create one or more outputs".
Process management offers project organizations a means of applying the same quality improvement and defect reduction techniques used in business and manufacturing processes by taking a process view of project activity; modeling discrete activities and high-level processes.
Overview.
The term "process management" usually refers to the management of engineering processes and project management processes where a "process" is a collection of related, structured tasks that produce a specific service or product to address a certain goal for a particular actor or set of actors.
Processes can be executed with procedures. They can be described as a sequence of steps that can execute a process and their value lies in that they are an accepted method of accomplishing a consistent performance or results.
Process management provides engineering and project managers with a means of systemically thinking of project organizations, semantics concepts and logical frameworks that allow project activities to be planned, executed, analyzed and facilitate learning.
In order for process management as defined to deliver consistent performance, it requires definition, elimination of non-value-added activities, continuous improvement, project stakeholder focus and team based approach. Mitchell (2016) notes that managing processes across divisional and organizational boundaries requires a more flexible management strategy as well as close cooperation among managers in diverse functional and operational units to ensure that the process flow is not interrupted by conflicts over lines of authority.
History.
Process management originated as part of the manufacturing-based application of statistical quality control movement in the late 1920s and early 1930s. What is relatively new, however, is the transition of process management methods from a manufacturing environment to a total company orientation and project management.
Process management in the context of project management or engineering represents a change from the traditional concept of organizational authority using hierarchies and organizational structure to one requiring flexibility to ensure efficient process workflows. Mitchell (2016) notes that managing processes across divisional and organizational boundaries requires a more flexible management strategy as well as close cooperation among managers in diverse functional and operational units to ensure that the process flow is not interrupted by conflicts over lines of authority.
Cooper, et al. note that manufacturing has been "a constant reference point and a source of innovation in construction". There is a new phenomenon occurring within the construction sector that is based upon the development and use of fundamental core management processes to improve the efficiency of the industry.
Topics.
The notion of process.
In the field of process management the notion of process, according to Mitchell (2016), can be characterized by:
These concepts provides management with the following:
Process management in this context requires engineering knowledge, management activities and skill sets whereas business processes or manufacturing processes require operations management activities, and skill sets.
Tools and models.
Process models are 'an effective way to show how a process works'. Project management process modeling tools provide managers and engineering professionals with the ability to model their processes, implement and execute those models, and refine the models based on actual performance. The result is that business process modeling tools can provide transparency into project management processes, as well as the centralization of project organization process models and execution metrics.
A number of modelling/systems analysis techniques exist such as data flow diagrams (DFD), HIPO model (hierarchy + input-process-output), data modeling and IDEF0 (integration definition language 0 for function modelling) process modelling technique.
Threaded processes.
A process activity that is concurrent or simultaneously executing can be termed a thread.
ISO 9000.
ISO 9000 promotes the process approach to managing an organization.
 ...promotes the adoption of a process approach when developing, implementing and
improving the effectiveness of a quality management system, to enhance customer satisfaction by meeting customer requirements.


Die swell

Die swell, also known as extrudate swell or Barus effect, is a common phenomenon in polymer processing. Die swell occurs in instances of polymer extrusion, in which a stream of polymeric material is forced through a die, a specialized tool in manufacturing to shape or cut polymeric materials. Die swell is an instance where a polymer stream is compressed by entrance into a die, and is followed by a partial recovery or "swell" back to the former shape and volume of the polymer after exiting the die, hence the term die swell.
Die swell is a phenomenon directly related to entropy and the relaxation of the polymer within the flow stream. Initially, a flow stream has a constant rate before entering the die, and the polymers within the stream occupy a roughly spherical conformation, maximizing entropy. Extrusion through the die causes an increase in flow rate through the polymer flow stream. As the polymer spends time inside the die and is subject to the much increased flow rate, the polymers lose the spherical shape, becoming longer due to the increased flow rate. Physical entanglements may relax, if the time scale of the polymer within the die is long enough. When the polymer stream leaves the die, the remaining physical entanglements cause the polymers in the die stream to regain a portion of its former shape and spherical volume, in order to return to the roughly spherical conformation that maximizes entropy.
The disentanglement of polymer chains is a kinetic process, and so the longer the die is, the more time is given for the physical entanglements within the polymer stream to disentangle. With a longer die and a slower polymer flow stream, less pronounced die swell will be observed. This is due to the longer die providing a longer time period for polymer, when subject to the increase flow rate, to disentangle. This characteristic relaxation time determines the length of time the polymer must spend inside the die to minimize die swell.


Laser drilling

Laser drilling is the process of creating thru-holes, referred to as “popped” holes or “percussion drilled” holes, by repeatedly pulsing focused laser energy on a material. The diameter of these holes can be as small as 0.002” (~50 μm). If larger holes are required, the laser is moved around the circumference of the “popped” hole until the desired diameter is created.
Applications.
Laser drilling is one of the few techniques for producing high-aspect-ratio holes—holes with a depth-to-diameter ratio much greater than 10:1.
Laser-drilled high-aspect-ratio holes are used in many applications,
including the oil gallery of some engine blocks, aerospace turbine-engine cooling holes,
laser fusion components, and printed circuit board micro-vias.
Manufacturers of turbine engines for aircraft propulsion and for power generation have benefited from the productivity of lasers for drilling small (0.3–1 mm diameter typical) cylindrical holes at 15–90° to the surface in cast, sheet metal and machined components. Their ability to drill holes at shallow angles to the surface at rates of between 0.3 and 3 holes per second has enabled new designs incorporating film-cooling holes for improved fuel efficiency, reduced noise, and lower NOx and CO emissions.
Incremental improvements in laser process and control technologies have led to substantial increases in the number of cooling holes used in turbine engines. Fundamental to these improvements and increased use of laser drilled holes is an understanding of the relationship between process parameters and hole quality and drilling speed.
Theory.
Following is a summary of technical insights about the laser drilling process and the relationship between process parameters and hole quality and drilling speed.
Physical phenomena.
Laser drilling of cylindrical holes generally occurs through melting and vaporization (also referred to as "ablation") of the workpiece material through absorption of energy from a focused laser beam.
The energy required to remove material by melting is about 25% of that needed to vaporize the same volume, so a process that removes material by melting is often favored.
Whether melting or vaporization is more dominant in a laser drilling process depends on many factors, with laser pulse duration and energy playing an important role. Generally speaking, ablation dominates when a Q-switched Nd:YAG laser is used. On the other hand, melt expulsion, the means by which a hole is created through melting the material, dominates when a flashtube pumped Nd:YAG laser is used. A Q-switched Nd:YAG laser normally has pulse duration in the order of nanoseconds, peak power on the order of ten to hundreds of MW/cm2, and a material removal rate of a few micrometers per pulse. A flash lamp pumped Nd:YAG laser normally has a pulse duration on the order of hundreds of microseconds to a millisecond, peak power in the order of sub MW/cm2, and material removal rate of ten to hundreds of micrometers per pulse. For machining processes by each laser, ablation and melt expulsion typically coexist.
Melt expulsion arises as a result of the rapid build-up of gas pressure (recoil force) within a cavity created by evaporation. For melt expulsion to occur, a molten layer must form and the pressure gradients acting on the surface due to vaporization must be sufficiently large to overcome surface tension forces and expel the molten material from the hole.
The "best of both worlds" is a single system capable of both "fine" and "coarse" melt expulsion. "Fine" melt expulsion produces features with excellent wall definition and small heat-affected zone while "coarse" melt expulsion, such as used in percussion drilling, removes material quickly.
The recoil force is a strong function of the peak temperature. The value of Tcr for which the recoil and surface tension forces are equal is the critical temperature for liquid expulsion. For instance, liquid expulsion from titanium can take place when the temperature at the center of the hole exceeds 3780 K.
In early work (Körner, et al., 1996), the proportion of material removed by melt expulsion was found to increase as intensity increased. More recent work (Voisey, et al., 2000) shows that the fraction of the material removed by melt expulsion, referred to as melt ejection fraction (MEF), drops when laser energy further increases. The initial increase in melt expulsion on raising the beam power has been tentatively attributed to an increase in the pressure and pressure gradient generated within the hole by vaporization.
A better finish can be achieved if the melt is ejected in fine droplets. Generally speaking, droplet size decreases with increasing pulse intensity. This is due to the increased vaporization rate and thus a thinner molten layer. For the longer pulse duration, the greater total energy input helps form a thicker molten layer and results in the expulsion of correspondingly larger droplets.
Previous models.
Chan and Mazumder (1987) developed a 1-D steady state model to incorporate liquid expulsion consideration but the 1-D assumption is not suited for high aspect ratio hole drilling and the drilling process is transient. Kar and Mazumder (1990) extended the model to 2-D, but melt expulsion was not explicitly considered. A more rigorous treatment of melt expulsion has been presented by Ganesh, et al. (1997), which is a 2-D transient generalized model to incorporate solid, fluid, temperature, and pressure during laser drilling, but it is computationally demanding. Yao, et al. (2001) developed a 2-D transient model, in which a Knudsen layer is considered at the melt-vapor front, and the model is suited for shorter pulse and high peak power laser ablation.
Laser energy absorption and melt-vapor front.
At the melt-vapor front, the Stefan boundary condition is normally applied to describe the laser energy absorption (Kar and Mazumda, 1990; Yao, et al., 2001).
where formula_2 is the absorbed laser intensity, "β" is the laser absorption coefficient depending on laser wavelength and target material, and "I(t)" describes temporal input laser intensity including pulse width, repetition rate, and pulse temporal shape. "k" is the heat conductivity, "T" is the temperature, "z" and "r" are distances along axial and radial directions, "p" is density, "v" the velocity, "Lv" the latent heat of vaporization. The subscripts "l", "v" and "i" denote liquid phase, vapor phase and vapor-liquid interface, respectively.
If the laser intensity is high and pulse duration is short, the so-called Knudsen layer is assumed to exist at the melt-vapor front where the state variables undergo discontinuous changes across the layer. By considering the discontinuity across the Knudsen layer, Yao, et al. (2001) simulated the surface recess velocity Vv distribution, along the radial direction at different times, which indicates the material ablation rate is changing significantly across the Knudsen layer.
Melt expulsion.
After obtaining the vapor pressure "pv", the melt layer flow and melt expulsion can be modeled using hydrodynamic equations (Ganesh et al.,1997). Melt expulsion occurs when the vapor pressure is applied on the liquid free surface which in turn pushes the melt away in the radial direction. In order to achieve fine melt expulsion, the melt flow pattern needs to be predicted very precisely, especially the melt flow velocity at the hole's edge. Thus, a 2-D axisymmetric transient model is used and accordingly the momentum and continuity equations used.
Ganesh's model for melt ejection is comprehensive and can be used for different stages of the hole drilling process. However, the calculation is very time consuming and Solana, et al. (2001), presented a simplified time dependent model that assumes that the melt expulsion velocity is only along the hole wall, and can give results with a minimum computational effort.
The liquid will move upwards with velocity u as a consequence of the pressure gradient along the vertical walls, which is given in turn by the difference between the ablation pressure and the surface tension divided by the penetration depth "x".
Assuming that the drilling front is moving at a constant velocity, the following linear equation of liquid motion on the vertical wall is a good approximation to model the melt expulsion after the initial stage of drilling.
where "p" is the melt density, "μ" is the viscosity of the liquid, "P(t)=(ΔP(t)/x(t))" is the pressure gradient along the liquid layer, "ΔP(t)" is the difference between the vapor pressure "Pv" and the surface tension formula_4.
Pulse shape effect.
Roos (1980) showed that a 200 µs train consisting of 0.5 µs pulses produced superior results for drilling metals than a 200 µs flat shaped pulse. Anisimov, et al. (1984) discovered that process efficiency improved by accelerating the melt during the pulse.
Grad and Mozina (1998) further demonstrated the effect of pulse shapes. A 12 ns spike was added at the beginning, middle, and the end of a 5 ms pulse. When the 12 ns spike was added to the beginning of the long laser pulse, where no melt had been produced, no significant effect on removal was observed. On the other hand, when the spike was added at the middle and the end of the long pulse, the improvement of the drilling efficiency was 80 and 90%, respectively. The effect of inter-pulse shaping has also been investigated. Low and Li (2001) showed that a pulse train of linearly increasing magnitude had a significant effect on expulsion processes.
Forsman, et al. (2007) demonstrated that a double pulse stream produced increased drilling and cutting rates with significantly cleaner holes.
Conclusion.
Manufacturers are applying results of process modeling and experimental methods to better understand and control the laser drilling process. The result is higher quality and more productive processes that in turn lead to better end products such as more fuel efficient and cleaner aircraft and power generating turbine engines.


Machine element

Machine element or hardware refers to an elementary component of a machine. These elements consist of three basic types:
While generally not considered to be a machine element, the shape, texture and color of covers are an important part of a machine that provide a styling and operational interface between the mechanical components of a machine and its users.
"Machine elements" are basic mechanical parts and features used as the building blocks of most machines. Most are standardized to common sizes, but customs are also common for specialized applications.
Machine elements may be features of a part (such as screw threads or integral plain bearings) or they may be discrete parts in and of themselves such as wheels, axles, pulleys, rolling-element bearings, or gears. All of the simple machines may be described as machine elements, and many machine elements incorporate concepts of one or more simple machines. For example, a leadscrew incorporates a screw thread, which is an inclined plane wrapped around a cylinder.
Many mechanical design, invention, and engineering tasks involve a knowledge of various machine elements and an intelligent and creative combining of these elements into a component or assembly that fills a need (serves an application).


Materialise NV

Materialise NV, headquartered in Leuven, Belgium, is a company in the 3D printing / additive manufacturing sector.
History.
1990s.
Materialise was founded in June 1990 by Wilfried Vancraen and his wife Hilde Ingelaere as a Rapid Prototyping service bureau. It was the first company of its kind in the Benelux region of Europe, through the acquisition of a single Stereolithography machine (the SLA 1).
In 1992, Materialise began mapping human anatomy digitally in three dimensions, using sliced CT image data, which lead to the development of its medical image processing software: Mimics. Concurrently, the team was also developing its industrial software solution, Magics. Both of these software solutions were later commercialized to promote growth.
1995 was the year that Materialise became the first company to produce 3D printed parts in more than one colour, specifically at this time for anatomical models produced using the stereolithography process to delineate the complexities of the anatomy (such as nerves, blood vessels and tumours) and allow surgeons to more precisely plan for operations.
The company developed and produced the first customised 3D printed surgical guide for a dental operation in 1996. These personalised guides were utilised during surgery to show surgeons bone cutting and drilling locations to apply implants. This knowledge was used to develop Materialise SimPlant software, allowing the surgeon to virtually plan the surgery and minimize invasive exploratory surgery.
The company launched one of the first 3D printing online ordering systems in 1997, Materialise NextDay, which later became Materialise OnSite. This service allowed 3D printing service customers to send digital 3D data, which could be printed and shipped the next day.
Demand for prototypes grew, leading Materialise to develop its Mammoth Stereolithography systems, which are capable of printing single-piece models with dimensions of more than 2 meters in the Y axis.
2000s.
In the year 2000, hearing aid specialist Phonak approached Materialise to develop the Rapid Shell Modeling (RSM) software. This allowed the design process for customized, patient-specific hearing aid shells to become automated. The resulting designs could then be 3D printed to produce the customised hearing aids. This was the first high volume, end-use application of 3D printing, and today, 99% of the world's hearing aids are now produced using 3D printing.
Materialise acquired US company Columbia Scientific Inc, (CSI) in 2001, the creators of Sim/Plant and ImageMaster, which became the US headquarters for Materialise's dental division in that region.
In 2003 Materialise launched one of the first 3D printed consumer brands — .MGX by Materialise — for 3D printing end-use products as well as prototypes. In parallel, the company also acquired Fused Deposition Modelling (FDM) systems for industrial applications.
The following year, in 2004, Materialise introduced its 3-matic software, allowing 3D printer users to edit files directly in the STL format. Previously, if design changes were required in the digital model, designers had to make them in the CAD suite of choice before re-converting the entire file to STL again.
In 2006 Materialise launched RapidFit, developed as a 3D printed solution for shipping large parts with customized jigs and fixtures to prevent deformation or breakage while in transit.
In 2006 Materialise developed the first Titanium 3D printed skull implants, following the acquisition of OBL, which specialized in the creation of custom cranio-maxillfacial (CMF) implants, producing customized implants with intricate porous structures, that behave like natural bone and mimic its mechanical and thermal properties.
In 2008 Materialise introduced the e-Stage software which was the first software to automatically generate support structures for different geometries in Stereolitography. In the same year, the company launched i.materialise for the consumer market, making it possible for anyone to print their ideas using professional-quality equipment. Materialise also developed its first Build Processor to support running different 3D printing processes more efficiently within a single location.
2010s.
In 2012, Materialise introduced Streamics to provide traceable quality control to industrial 3D printer users producing end-use parts within regulated industries.
Materialise went public on June 25, 2014 to enable expansion of its services and software development. The same year the company acquired OrthoView, a market leader in orthopaedic digital pre-operative planning software and officially established a new office in China in December with a focus on 3D printing Software and R&D, namely Materialise Shanghai Co. Ltd.
In 2016, the company opened a new and dedicated metal production facility in Bremen, Germany. Materialise HQ, Leuven, also acquired and started testing the multi jet fusion (MJF) process from HP. Production of parts with MJF started in the following year, 2017.
With the expansion of the AM Metal market, Materialise acquired ACTech in Germany to extend the company's metal capabilities, with a specific emphasis on low-volume production of highly complex metal parts. The acquisition also enabled Materialise to develop and improve its software suite for metal 3D printing.


MADEI

MADEI has been assembling Japanese commercial vehicles in Myanmar for decades.
Recently, it was commissioned by the government to manufacture jeeps.
Manufactured at six industrial zones under government supervision, the models are Super Mandala Jeep from Mandalay Industrial Zone, Myay Latt Jeep from Myingyan Industrial Zone, Htila Jeep from Meikhtila Industrial zone, Chindwin Star Jeep from Monywa Industrial Zone, Shan Star Jeep from Ayethaya Industrial Zone in Taunggyi and PKU Jeep from Pakokku Industrial Zone. Body is made locally, while the mechanical parts are imported from Japan.
Production rate was approximately 100 annually.


Smart cut

Smart cut is a technological process that enables the transfer of very fine layers of crystalline silicon material onto a mechanical support. It was invented by Michel Bruel of , and was protected by US patent 5374564. The application of this technological procedure is mainly in the production of silicon-on-insulator (SOI) wafer substrates.
The role of SOI is to electronically insulate a fine layer of monocrystalline silicon from the rest of the silicon wafer; an ultra-thin silicon film is transferred to a mechanical support, thereby introducing an intermediate, insulating layer. Semiconductor manufacturers can then fabricate integrated circuits on the top layer of the SOI wafers using the same processes they would use on plain silicon wafers.
The sequence of illustrations pictorially describes the process involved in fabricating SOI wafers using the smart cut technology.


Highly accelerated life test

A highly accelerated life test (HALT) is a stress testing methodology for enhancing product reliability in which prototypes are stressed to a much higher degree than expected from actual use in order to identify weaknesses in the design or manufacture of the product. Manufacturing and research and development organizations in the electronics, computer, medical, and military industries use HALT to improve product reliability.
HALT can be effectively used multiple times over a product's life time. During product development, it can find design weakness earlier in the product lifecycle when changes are much less costly to make. By finding weaknesses and making changes early, HALT can lower product development costs and compress time to market. When HALT is used at the time a product is being introduced into the market, it can expose problems caused by new manufacturing processes. When used after a product has been introduced into the market, HALT can be used to audit product reliability caused by changes in components, manufacturing processes, suppliers, etc.
Overview.
Highly accelerated life testing (HALT) techniques are important in uncovering many of the weak links of a new product. These discovery tests rapidly find weaknesses using accelerated stress conditions. The goal of HALT is to proactively find weaknesses and fix them, thereby increasing product reliability. Because of its accelerated nature, HALT is typically faster and less expensive than traditional testing techniques.
HALT is a test technique called test-to-fail, where a product is tested until failure. HALT does not help to determine or demonstrate the reliability value or failure probability in field. Many accelerated life tests are test-to-pass, meaning they are used to demonstrate the product life or reliability.
It is highly recommended to perform HALT in the initial phases of product development to uncover weak links in a product, so that there is better chance and more time to modify and improve the product.
HALT uses several stress factors (decided by a Reliability Test Engineer) and/or the combination of various factors. Commonly used stress factors are temperature, vibration, and humidity for electronics and mechanical products. Other factors can include voltage, current, power cycling and combinations of them.
Typical HALT procedures.
Environmental stresses are applied in a HALT procedure, eventually reaching a level significantly beyond that expected during use. The stresses used in HALT are typically hot and cold temperatures, temperature cycles, random vibration, power margining, and power cycling. The product under test is in operation during HALT and is continuously monitored for failures. As stress-induced failures occur, the cause should be determined, and if possible, the problem should be repaired so that the test can continue to find other weaknesses.
Output of the HALT gives you:
Test chambers.
A specialized environmental chamber is required for HALT. A suitable chamber also has to be capable of applying pseudo-random vibration with a suitable profile in relation to frequency. The HALT chamber should be capable of applying random vibration energy from 2 to 10,000 Hz in 6 degrees of freedom and temperatures from -100 to +200°C. Sometimes HALT chambers are called repetitive shock chambers because pneumatic air hammers are used to produce vibration. The chamber should also be capable of rapid changes in temperature, 50°C per minute should be considered a minimum rate of change. Usually high power resistive heating elements are used for heating and liquid nitrogen (LN2) is used for cooling.
Fixtures.
Test fixtures must transmit vibration to the item under test. They must also be open in design or use air circulation to produce rapid temperature change to internal components. Test fixtures can use simple channels to attach the product to the chamber table or more complicated fixtures sometimes are fabricated.
Monitoring and failure analysis.
The equipment under test must be monitored so that if the equipment fails under test, the failure is detected. Monitoring is typically performed with thermocouple sensors, vibration accelerometers, multimeters and data loggers. Common causes of failures during HALT are poor product design, workmanship, and poor manufacturing. Failures to individual components such as resistors, capacitors, diodes, printed circuit boards occur because of these issues. Failure types found during HALT testing are associated with the infant mortality region of the bathtub curve.
Military application.
HALT is conducted before qualification testing. By catching failures early, flaws are found earlier in the acceptance process, eliminating repetitive later-stage reviews.


Spicule (glass manufacture)

Spicules are tiny glass flakes which are formed during the manufacture of glass vials. A glass tube is extruded at a constant rate and a jet of water applied to the hot glass is used to cut the blank tube to length. The bottom and lip of the vial are formed by swagging or upset forming while the glass is still hot.
Spicules are formed in a cloud when the glass explodes from the contact of the cold jet. These are held to the glass blank during forming, and if the vial is not reheated or cleaned after manufacture, these spicules can drift off into the mixture subsequently placed in the vial. This is a serious problem in the manufacture of soft contact lenses or pharmaceutical products.


Plate rolling machine

A plate rolling machine is a machine that will roll different kinds of sheet metal into a round or conical shape.
It can be also called a “roll bending machine”, “plate bending machine” or “rolling machine”.
There are different kinds of technology to roll the metal plate:
The flat metal plate is placed in the machine on either side and "pre-bent" on the same side.
The side rolls do the work of bending. The pinching roll holds the plate.
The three-roll variable pitch works by having all three rolls able to move and tilt. The top roll moves in the vertical plane and the side rolls move on the horizontal plane.
When rolling, the top roll presses the metal plate between the two side rolls. The advantage of having the variable three roll is the ability to roll many thicknesses and diameters of cylinders.
For example;
The side-rolls are what produce the mechanical advantage. With the side rolls all the way open, one has the maximum mechanical advantage. With the side rolls all the way in, you have the least mechanical advantage.
So, a machine has the capability of rolling 2-inch-thick material with the maximum mechanical advantage, but a job is only 1/2 inch thick. Reduce the mechanical advantage and one has a machine that can roll from 1/2 to 2 inches thick.
Plate rollers can be powered and controlled in multiple ways. Older plate mills are driven by electric motors and newer ones are directed by programs that are loaded into the CNC controller. When thinking about plate roll acquisition, industrial machinery companies like Provetco Technology will ask about the working length of the roller, the maximum thickness of the material, top roll diameter size as well as the minimum thickness of the material. Furthermore, the material yield is another critical component to disclose to machinery companies when looking for a plate roller.
References.
Provetco Technology: www.provetco.com


Chemical Engineering and Biotechnology Abstracts (CEABA-VTB) is an abstracting and indexing service that is published by DECHEMA, BASF, and Bayer Technology Services, all based in Germany. This is a bibliographic database that covers multiple disciplines.
Subject coverage.
Subject coverage includes engineering, management, manufacturing plants, equipment, production, and processing pertaining to various disciplines. The fields of interest are bio-process engineering, chemical engineering, process engineering, environmental protection (including safety), fermentation, enzymology, bio-transformation, information technology, technology and testing of materials (including corrosion), mathematical methods (including modeling), measurement (including control of processes), utilities (including services). Also covered are production processes and process development. CAS registry numbers are also part of this database.


SolarPark Korea

SolarPark Korea Co., Ltd. is a South Korean crystalline silicon module manufacturer. Founded in 2008 as a German-Korean joint venture, the company combines German and Korean machinery and engineering in its automated module fabrication lines. In June 2011, SolarPark Korea became a 100% subsidiary of the SolarPark Co., Ltd.
History.
April 1981
The automated machinery company INMAC is established in Sogong-dong, Joong-gu, Seoul, Korea
July 1990
A new factory is established in Songne-dong, Soda-gu, Bucheon-si, Gyeonggi-do, Korea
The headquarters is relocated to the same location
March 1997
INMAC is selected as a prospective medium & small enterprise of Gyeonggi-do
April 1999
INMAC is selected as a prospective medium & small exporting enterprise
April 2007
Establishment of SolarPark Co., Ltd.
November 2007
SolarPark is awarded the 3 Million Dollar Export Tower Award and presidential citation during the 44th Trade day
April 2008
Establishment of SolarPark Korea Co., Ltd.(Previously SolarWorl Korea Co., Ltd)
Established as a 50/50 JV with SolarWorld AG
September 2008
Construction of Gochang Solar Park(15MWp) completed
November 2008
SolarPark Korea completes the first stage construction of its module production factory (annual capacity 60 MW)
September 2009
Solarpark Korea completes the second stage construction of its module production factory (annual capacity 90 MW)
February 2010
Construction of the Inline Mechanics Co., Ltd. factory completed
April 2010
SolarPark Korea completes the third stage construction of its module production factory (annual capacity 100 MW)
'Total capacity : 250 MW'
October 2010
IEC 61215, 61730-1, 61730-2 certifications received
November 2010
SolarPark Korea is awarded the Ston Tower Industrial Medal for achieving 300 million dollars in exports during the 47th Trade Day
June 2011
SolarWorld AG's 50% share of SolarPark Korea is acquired by SolarPark Korea.
SolarPark Korea now owns 100% of shares
September 2011
ISO 9001 & ISO 14001 certifications received
April 2012
Construction of second module production factory (annual capacity : 300 MW + 50 MW) completed
'Total capacity : 600 MW, 5th largest production capacity in Asia (excluding Chinese manufacturers)'
'July 2012
Merger of the 3 companies; SolarPark Korea Co., Ltd., SolarPark Co., Ltd., and Inline Mechanics Co., Ltd, completed.
Oct 2012
Passed PID test by TUV-SUD
Automation in production.
SolarPark Korea espouses automation in production to achieve consistent high-quality, high-volume and cost-competitive output. Its module production lines achieve a capacity-per-employee of 0.83 MW.
SolarPark Korea's production lines comprise machines from equipment makers such as Somont, 3S, Berger Lichttechnik, Pasan and Schleich. Equipment integration is provided by affiliate Inline Mechanics.


Yiyang High-Tech Industrial Development Zone (; abbr: YYHTZ) is a national high-tech industrial zone in Yiyang, Hunan, China. Its area is . It traces its origins to the former "Chaoyang Economic Development Zone" , founded in 1994. It was renamed to the present name, meanwhile the zone was upgraded to one of first batch of provincial HTZs. In 2011, it became a national HTZs approved by the State Council of China. Its four major industries are new materials, new energy, advanced manufacturing and biomedicine.


Thermoplastic vulcanizates

Thermoplastic vulcanizates (TPV) are dynamically vulcanized alloys consisting mostly of fully cured EPDM rubber particles encapsulated in a polypropylene (PP) matrix. They are part of the thermoplastic elastomer (TPE) family of polymers but are closest in elastomeric properties to EPDM thermoset rubber, combining the characteristics of vulcanized rubber with the processing properties of thermoplastics. There are almost 100 grades in the S portfolio that are used globally in the automotive, household appliance, electrical, construction, and healthcare markets. The name Santoprene was trademarked in 1977 by Monsanto, and the trademark is now owned by Celanese. Similar material is available from Elastron and others.
Overview.
TPV was created after several years of research and development aimed at finding new materials for injection-molded tires. Although the search for a new tire material was unsuccessful, it resulted in the development of TPV, which combines the characteristics of vulcanized rubber with the processing properties of thermoplastics. The first sales of developmental products began in 1977, the same year it was registered by Monsanto, and it was fully commercialized in 1981.
Part of the TPE family of polymers, TPV is the closest in elastomeric properties to EPDM thermoset rubber. TPVs have a combination of elastomeric properties, like compression and tension sets, coupled with aging performance and chemical resistance.
Early successes.
Santoprene TPV had early application successes in the automotive sector, including rack and pinion boots, due to its flex life, fluid resistance, and sealability. In the appliance sector, a dishwasher sump boot made with Santoprene TPV provided good sealing and resistance to heat and fluids. Due to its sealing properties, Santoprene TPV was also successful in the domestic and high-rise construction sectors in applications such as window seals, caster wheels, tubing, and small hose parts, electrical connectors, and coatings for wire and cables. It was also used in the medical industry as a gasket on syringe plungers.
Chemistry.
Santoprene TPV is a dynamically vulcanized alloy consisting mostly of fully cured EPDM rubber particles encapsulated in a polypropylene (PP) matrix.
Photographs made using an atomic force microscope and a scanning electron microscope show a multitude of very small particles, typically no bigger than a couple of microns in diameter. These particles are fully vulcanized rubber (typically EPDM rubber for most Santoprene TPV grades) in a thermoplastic phase (most often PP in the case of Santoprene TPV grades). Fully cross-linked or vulcanized means 98% or above, and because the morphology is "locked-in," it provides stable physical properties.
Properties.
Designed for specific engineered applications, Santoprene TPV grades range from the hardness of 35 Shore A up to 50 Shore D.
Santoprene TPV grades offer the following:
Applications.
Santoprene TPV grades are designed for a broad range of specific engineered applications.
Automotive components.
Santoprene TPV (thermoplastic vulcanization) is used in weather seals, underhood and under-car applications, and interior components. In weather seals, TPV is used as a lightweight alternative to thermoset rubber materials in semi-dynamic and static parts, while in underhood and under-car applications it is well-suited for air ducts, tubing, molded seals, grommets, suspension bellows, cable jacketing, plugs, bumpers, and many other parts. This is due to its sealing performance and resistance to extreme temperatures, chemical exposure, and harsh environments.
Building and construction products.
In commercial glazing seals, Santoprene TPV is used for curtain walls, storefronts, architectural windows, and skylight weather seal applications. It is also commonly used in residential glazing seals due to its low air and water infiltration ratings for the life of window and door systems.
For road and rail construction projects, Santoprene TPV is used for bridge and parking decks, water stops, rail pads, and other applications.
In plumbing, Santoprene TPV is used to create long-term seals, gaskets, and grommets that are resistant to flex fatigue, harsh temperatures, and chemicals. It can be used in a variety of sealing applications including pipe seals, bridge expansion joints and curtain walls, parts for potable water, and pipe seals for sewer and drainage.
Household appliance parts.
Santoprene TPV is used in washing machines, dryers, dishwashers, refrigerators, small appliances, and floor care. Its properties enable it to be used in a range of parts including pump seals, hoses, couplings, vibration dampeners, drum rollers, knobs, and controls.
Electrical components.
Santoprene TPV is used in wiring connectors to make watertight seals with electrical and thermal resistance, insulation for high voltage applications, and flexibility even at low temperatures to −60 °C.
It is used in industrial wire and cable connectors and low-voltage industrial cable applications that include insulation and jackets, in addition to consumer wire and cable use.
For electrical components, Santoprene TPV can be used for watertight seals, enabling connectors to be insert-molded to cable jacketing, producing a single integral part.
Processing.
Santoprene TPV can be processed using conventional thermoplastic processes such as injection molding, blow molding, and extrusion. Manufacturing a part using Santoprene TPV, in contrast to rubber, is less complex. Santoprene TPV is ready to use and does not need to be compounded with different ingredients such as reinforcing fillers (carbon black, mineral fillers), stabilizers, plasticizing oils, and curing systems.
Compared to processing rubber, thermoplastic processing of Santoprene TPV can deliver shorter cycle times, a higher part output per hour, and the reuse of scrap produced during processing. This can result in part cost reduction, less tooling/machinery, lower scrap costs, and optimization of material logistic costs compared to rubber.
After a short drying period, TPV pellets are automatically transferred to the molding machine or extrusion line. Cycle times can be significantly faster because the parts do not have to cure in the mold, which is typically two to three minutes for rubber. The TPV part only has to cool, typically about 30 seconds, and then it can be removed from the mold or cooled in water.
Processing options.
Injection molding: Santoprene TPV grades can be processed using conventional thermoplastics injection-molding equipment at reduced cycle times compared to thermoset rubber. TPV flexibility allows for greater freedom of mold design where undercuts are employed.
Insert molding: Insert molding consists of placing a preformed substrate into the mold and injecting TPV around or over it. If the insert and the TPV are compatible materials, a melt bond occurs at the interface between the two materials. The strength of this bond is affected by several factors, including interface temperature, cleanliness of the insert, and melt temperature of the TPV.
Two-shot injection molding: TPV can be combined with polymers through several types of multi-shot injection molding processes. By combining multiple materials, a wide variety of parts applications, such as a hard/soft combination, can be achieved. The process produces both a finished part and a substrate during each cycle. Two-shot molding is more efficient than insert molding because no handling of the substrate is required.
Blow molding: Santoprene TPV can be blow molded in a single layer, multi-layer, exchange blow, sequential 3D, suction blow, flashless extrusion blow, injection blow, and press-blow molding processes.
Extrusion: Santoprene TPV is easy to extrude into single and complex profiles. These materials can also be coextruded to yield a part with both rigid and soft components.
Thermoforming: The thermoforming properties of Santoprene TPV are similar to acrylonitrile butadiene styrene (ABS) and exhibit good melt strength, which provides uniform and predictable sag characteristics during heating. When producing a sheet for thermoformed parts, key attributes of Santoprene TPV are maintained, including colorability, impact resistance, weatherability, chemical resistance, non-skid, and matte surface in appearance and feel.
Recycling.
Santoprene TPV can contribute to a reduction in overall waste in the manufacturing process as scrap produced during processing can be recycled. Material that has been recycled – even from old parts – exhibits properties almost as good as virgin material as an article in “Design News” magazine reported on May 5, 2003.
According to the article:


Gas-assisted injection molding

Gas-assisted injection molding is a molding process where an inert gas is injected into the melted plastic pushing it further into the mold and resulting in hollow parts.
Basic concept.
The basic concept of the gas-assisted molding process is quite similar to the regular injection molding process. In gas-assisted molding, the plastic material is injected into the mold cavities like the regular injection molding process but only up to 70%~80% of the mold volume. The melted plastic in contact with the mold walls begins to solidify, then nitrogen gas is injected into the mold through strategically designed and placed gas inlets, providing pressure that pushes the plastic into the mold extremities. The path of the bubble is controlled by taking the path of least resistance through the hottest, least viscous plastic, which keeps it centered from the colder walls of the mold. Finally the molded part is ejected like the regular injection molding process.
Advantages.
This process forms hollow parts that are cheaper than traditionally injection molded equivalents. Molded parts also cool faster in this process. There is also usually less shrinkage as the thicker wall sections are hollow.
Some of the benefits of this process are:
Disadvantages.
This molding technique is very difficult to apply to multi-cavity molds, especially if the cavity sizes are dissimilar. Clear or transparent plastic materials are an inappropriate option for this technique as the cosmetic-appearance can deteriorate.


Deep hole drilling

In the field of manufacturing technology, deep hole drilling refers to the drilling of bore holes with high length-to-diameter ratios.
Definition of deep hole drilling.
According to the VDI Standard 3210, deep hole drilling processes are manufacturing processes for the machining of bore holes with diameters between D = 0.2...2000 mm and whose drilling depth is usually greater than three times the diameter. For small diameters, length-to-diameter ratios of up to l/D ≤ 100 can be achieved, in special cases even up to l/D = 900. With large diameters, the l/D ratio is usually limited by the travel or the bed length of the deep hole drilling machine.
Deep hole drilling.
Deep hole drilling also differs from normal drilling in that, depending on the drilling process and the drilling diameter, cooling lubricant must be pumped to the cutting edges in large quantities and under high pressure. This ensures good cooling and at the same time good lubrication of the contact areas between the workpiece and the cutting edge of the tool on the one hand and the workpiece and guide pads of the tool on the other. In addition, the cooling lubricant leads to the constant removal of chips from the cutting zone, which makes surface-damaging and time-consuming chip removal strokes unnecessary and therefore improves the quality of the borehole and the productivity of the processes. For the production of deep holes, two different tool types are distinguished. On the one hand, there are tools with an asymmetrical single cutting-edge design. These deep hole drilling tools include single-lip deep hole drills, the single-tube system (BTA deep-hole drilling) and the double-tube system (ejector deep-hole drilling), which are referred to as the "classic" deep hole drilling processes. On the other hand, there are tools with symmetrically arranged cutting edges. These include spiral deep hole drilling tools and double-lip deep hole drilling tools, which can also be assigned to the deep drilling processes due to the drilling depths to be achieved with them. Deep Hole drilling was made originally in china.
The mentioned tool types differ with regard to the realizable diameter range, the achievable l/D ratios, the surface quality and they're productivity. Symmetrical tools can only be used in the small diameter range of D = 0.2 ... 32  mm to produce holes with an l/D ratio up to a maximum of l/D = 85, the standard is an l/D ratio of l/D = 30. With asymmetrical tools, holes in the diameter range of D = 0.5...2000  mm can be produced and the upper limit of the l/D ratio is usually limited by the machine dimensions. The figure shows selected deep hole drilling methods with their usual application diameters, whereby it becomes clear that deep hole drilling methods do not compete with each other in all diameter ranges. The advantage of the symmetrically designed tools compared to the "classical" deep hole drilling tools in the small diameter range is the feasibility of significantly higher feeds f, which can be 6 times higher compared to the usual values for single-lip deep hole drilling.
In addition to the high l/D ratio, the "classic" deep hole drilling methods are characterized by high productivity and high surface quality compared to the conventional drilling methods with twist drills. The high drilling quality is characterized by low surface roughness, small diameter deviations and a high geometrical accuracy. Important for the good surface quality is the asymmetrical design of the deep hole drilling tools. The "classical" tools for single-lip deep hole drilling, BTA deep hole drilling and ejector deep hole drilling are, with a few exceptions, designed asymmetrically and have a secondary cutting edge (circular grinding chamfer) and guide pads. Due to this design features, a certain amount of the cutting forces during the process is transferred via the guide pads to the bore hole wall. These force components at the tool head are supported at the produced borehole wall and thus guide the tool in the bore hole itself. The distribution of the process forces during deep hole drilling is therefore different from conventional drilling, where the forces are largely absorbed by the tool shank and thus by the machine spindle. Due to the process force distribution to bore hole wall in deep hole drilling, the drill guides itself and thus the process benefits from a comparatively low straightness deviation. The "support" of the guide pads on the borehole wall also results in a forming process that (ideally) smooths the bore hole wall. Due to this forming process the surface roughness caused by the engagement of the cutting edges during drilling can be decreases by about 70%. Thus very high surface qualities with bore hole tolerances of IT 9 to IT 7 can be achieved by deep hole drilling processes. Subsequent steps to improve the surface quality of the bore hole can often be reduced or eliminated completely. A further advantage is the low burr formation for trough holes and for over-drilling cross holes. Due to the high surface quality combined with a high productivity, the use of deep hole drilling methods can be economical even at low drilling depths.
Deep hole drilling methods.
Single-lip deep hole drilling.
Single-lip deep hole drilling is usually used to produce holes in the diameter range of D = 0.5...40 mm. This range of application is currently limited at the lower end by the manufacturing technology to realize the coolant channels inside the tool and the increasing challenges in grinding technology with decreasing tool diameters. The upper limit results from the more economical use of alternative deep hole drilling methods. Characteristic for single-lip deep hole drilling is the internal coolant supply through one kidney-shaped or two circular cooling channels. The chip/coolant mixture is discharged in a v-shaped longitudinal groove on the tool, the so-called gullet. The coolant mass flow is the only transport mechanism for removing the chips. For this reason, a diameter-dependent high-pressure coolant supply is necessary. The general structure of single-lip tools is divided into three parts: the drill head, the shank and the clamping sleeve. Usually the drill head is joined to the shank by brazing. The clamping sleeve is the clamping element of the tool and forms the interface to the tool holder and thus to the machine tool. Solid carbide tools are often used for smaller tool diameters and tools with a high-performance design. With these more powerful tools, the drill head and the shank are made of a single carbide rod. The drill head is usually made of carbides of the ISO cutting application group K 10 to K 20 and is coated if required. In special applications, PCD, cermets, ceramics or high-speed steels are also used. The choice of the drill head geometry is made depending on the existing machining situation. In this respect, a distinction is made between different cutting edge angles and the circumferential shape of the guide pads. With the usual standard grinding for single-lip drills, the main cutting edge is divided into an outer and an inner cutting edge, which differ in different cutting edge angles depending on the bore hole diameter. The choice of the circumferential shape, i.e. the number and arrangement of the guide pads on the circumference of the single-lip drill, is also important. Compared to conventional drilling with twist drills, single-lip drilling is characterized by its suitability and high process reliability with large length-to-diameter ratios. In addition, single-lip drilling achieves comparatively high bore hole qualities, which can reduce the need for post-processing.
Tools
As can be seen in the pictures, a single-lip deep hole drill consists of a tool holder, a shank and the drill head (usually carbide). As far as the design is concerned, it can be generally said that the shank is a few 1/10th of a millimeter to 1 millimeter smaller than the drill head. It can also be seen that approximately 1/4 of the shank consists of a grove, in which the coolant flow flushes the chips out of the bore hole. The cutting head itself carries guide surfaces which are in contact with the bore hole wall and guide the drill. Conventional twist drill on the other hand are usually guided by the axis of the machine tool.
The actual cutting edge is asymmetrically arranged and runs from the cutting edge corner via the tip to the centre of the drill. The tool thus works with a single cutting edge. The cutting forces, which are not cancelled out because of the asymmetrical design, are supported on the bore hole wall. The chips produced at the cutting edge are surrounded by coolant from the outside and then flushed away from the cutting zone through the grove in the shank. Up to a diameter of approx. 10 mm the tools have one cooling channel, for larger diameters two or more channels are used.
BTA deep hole drilling.
The disadvantages of single-lip deep hole drilling, such as the contact of the chips with the generated bore hole surface or the low torsional moment, were the motivation to develop a modified deep hole drilling method that avoids these problems and retains the good properties. As a result of the above, a new deep hole drilling method was developed around 1940, which was given the name BTA deep hole drilling in the early 1950s.
BTA stands for "Boring and Trepanning Association" which was dominated by the now liquidated company Gebrüder Heller in Bremen Germany. Under their leadership, the new process was created during the Second World War by combining their own developments with those of Burgsmüller and Beisner. Burgsmüller replaced the grooved drill shaft used until then by a tube with a closed cross-section, which was more torsionally rigid, and for the first time conveyed the chips through the inside of the tube. Burgsmüller used a double-edged tool and an air-oil mixture, which is nowadays used in production with minimum quantity lubrication. Beisner improved the tool design and introduced oil as cooling lubricant. Heller, which was the first company to introduce carbide-tipped single-lip deep hole drilling tools, had the patent for the cutting edge/guide pad constellation which was then also used for the BTA tools.
During the machining process, the coolant is fed to the cutting zone, as shown in the figure, through the ring gap between the hole produced and the drill tube with the aid of the drilling oil supply unit (BOZA). The BOZA also seals between the workpiece and the drill tube. For this purpose, it has a conical rotating workpiece holder which is directed towards the workpiece and is pressed against the workpiece with high pressure. This centres the workpiece and creates a sealing contact surface. In most cases, the rear side of the BOZA is sealed by a stuffing box, which also guides the drill tube. In the BOZA, the tapping bush is usually integrated, which means that working with a pilot bore hole in the BTA process is rarely necessary.
Tools
The chips are removed through the openings integrated in the drilling head with the aid of the cutting oil flow. Therefore, the openings are called "chip mouth". In this way, the chips can be removed without contact to the bore hole wall. Due to the circular cross section of the tool and the drill tube, the process has a higher torsional resistance moment compared to single-lip deep hole drilling, which allows a significantly higher cutting performance to be achieved. The BTA process is used for bore hole diameters of D = 6...2000 mm. For industrial processes it is used in a range from approx. D = 16 mm. It is possible to manufacture BTA drill heads with a diameter of D ≤ 6 mm, but there is no known application case until today.
Ejector deep hole drilling.
The ejector deep hole drilling is used in a diameter range of approx. D = 18 ... 250 mm. It is a variant of the BTA process in which the drill heads used are structurally comparable to the BTA tool system. The only difference are additional coolant outlets on the circumference of the tool. The coolant is supplied through the ring space between the drill tube and the inner tube, which also gives the process the name two-tube process. The coolant emerges laterally from the already mentioned coolant outlets, flows around the drill head and flows back into the inner tube transporting the produced chips. Part of the coolant is fed directly into the inner tube via a ring nozzle. This creates a negative pressure (ejector effect) at the chip mouth, which facilitates the backflow in the inner tube. The system can be operated via an external high-pressure pump or the internal coolant supply of the machine. Since, in contrast to the BTA process, no sealing against escaping coolant is required, the ejector process can also be used on conventional lathes and machining centres. As the pipe cross-section through which the chips are to be removed is reduced by the double tube system, the cutting capacity is lower than with the BTA process. For this reason, lower cutting speeds are usually selected for ejector deep hole drilling. In addition, the lower rigidity is accompanied by poorer concentricity properties (IT9 to IT11).
A prerequisite for the implementation of the process is the use of a connecting piece which is inserted into the turret holder of the lathe or the spindle of the machining centre. Through this connection piece, the coolant is fed from the connected pump unit into the ring gap between the inner and outer tube. To enable this function, two different versions are available. A rotating connection piece is required for machining centres, and a non-rotating connection piece for lathes. The required installation space must be taken into account when selecting the machine tool.
Tools
The design of the tools for ejector deep hole drilling is almost identical to that of the BTA deep hole drilling tools. The additional coolant discharge outlets are shown in the illustrations.
Methods associated with deep hole drilling.
In addition to the classical deep hole drilling methods, there are a number of other methods for the final processing of deep holes. The hole can be post-processed with regard to their surface finish or can serve as a basis for machining complex and non-cylindrical contours.
Internal profiling.
For various reasons, there are components with deep holes whose inner contours are rotationally symmetrical but not uniformly cylindrical. Such components can have contours without undercuts, e.g. for centrifugal casting moulds or conical bores in extruder cylinders, and with undercuts, e.g. for propeller shafts or landing gears. To produce such chamber pockets, high quality pre-drilling is required. If the radially extendable cutting tool holder is controlled via an NC axis and connected to the NC bore slide of the deep hole drilling machine, it is almost possible to produce any bore hole wall contour in one cut over the entire contour length. The position of the cutting edge can be modified by an axial displacement, e.g. by using an internal thrust tube. In addition, the guide pads can also be adjusted hydraulically. Since the guide bore has already been maschined after the first cutting step for the so-called long chamber method, the guide pads must also be radially adjustable to support the tool for larger chambers. As an alternative to this method, the so-called short-chamber method does not require extendable guide pads, as the tool is only seated in the pre-drilled guide hole.
Skiving and smooth rolling.
Skiving improves the roundness and the dimensional accuracy of the bore hole diameter. The process creates an open surface profile, which is particularly suitable for subsequent machining processes such as smooth rolling or honing. In the field of machining hydraulic cylinders and cylinder liners, skiving and smooth rolling is considered a manufacturing process related to deep hole drilling, although it has a cutting and also a forming component. The reason for this is the wide use of combined skiving and smooth rolling tools.
Single edge reaming.
Another machining process to increase the surface quality and dimensional accuracy of a bore hole is the use of single-bladed reamers. Reaming is the ountersinking of a pre-drilled hole, where the tool is supported by the guide pads themselves. Therefore, the tool geometry of these reamers is very similar to single-lip drills. The difference to single-lip deep hole drilling with low cutting depth is the usually missing circumferential chamfer, a long side cutting edge parallel to the milling axis and the low coolant volumes and pressures.
Deep hole drilling machines.
For machining with deep hole drilling processes or processes associated with deep hole drilling, deep hole drilling machines are mainly used as standard (multi-purpose) or special machines. Gun drills are an archetypal example. Often single-lip deep hole drills are used on machining centres for the production of holes with smaller drilling depths (up to approx. 40 × D).
Ejector drilling is mainly used on conventional machine tools. Since deep hole drilling has a high productivity, only comparatively powerful machines are used. Basically, a coolant system is required that provides coolant with (compared to other drilling methods) above-average volume flow at higher pressures.
A deep hole drilling system consists of the deep drilling machine and the coolant tank with further peripheral equipment for coolant preparation and chip handling.
The ejector drilling process was developed as deep hole drilling technology which can be used on conventional machine tools. The use of single-lip deep hole drilling is particularly common on machining centres in series production.
On the right you can see schematic drawings of conventional deep hole drilling machines.
Literature.
VDI – The Association of German Engineers guidelines


Pressure bag moulding

Pressure bag moulding is a process for moulding reinforced plastics. This process is related to vacuum bag molding.
Procedure.
A solid female mold is used along with a flexible male mold. The reinforcement is placed inside the female mold with just enough resin to permit the fabric to stick in place (wet lay-up). A measured amount of resin is then liberally brushed indiscriminately into the mold and the mold is then clamped to a machine that includes the male flexible mold. Then, the flexible male membrane is inflated with heated compressed air or possibly steam. The female mold can also be heated. Excess resin is forced out along with trapped air. Due to the lower cost of unskilled labor, this method is used extensively in the production of composite helmets. For a helmet bag moulding machine, cycle times vary from 20 to 45 minutes, but if the molds are heated, the finished shells require no further curing.


Autoclave moulding

Autoclave moulding is an advanced composite manufacturing process.
Procedure.
It is a process that uses a two-sided mould set that forms both surfaces of the panel. On the upper side is a flexible membrane made from silicone or an extruded polymer film such as nylon and on the lower side is a rigid mould. Reinforcement materials can be placed manually or robotically. They involve continuous fibre forms fashioned into textile constructions. Usually, they are pre-impregnated with the resin in the form of prepreg fabrics or unidirectional tapes. In some situations, a film of resin is placed upon the lower mould, and dry reinforcement is placed above. The upper mould is installed, and the vacuum is applied to the mould cavity. The assembly is placed into an autoclave. This process is generally performed at both elevated pressure and elevated temperature. The use of elevated pressure facilitates a high fibre volume fraction and low void content for maximum structural efficiency.


Tellurium copper

Tellurium copper is an alloy of copper and tellurium. Tellurium improves the machinability of copper.
Overview.
Tellurium is usually added to copper to improve machinability ("free cutting"). ASTM specification B301 has 0.5% tellurium; at concentrations of up to 0.75% machinability is improved while electrical conductivity and hot working behavior is maintained. Mechanical properties are similar to "tough pitch copper", while machinability is similar to brass - the hardness of the alloy is increased by precipitation of the copper telluride: weissite.
Tellurium copper is not suited to welding, but it can be welded with gas shielded arc welding or resistance welding. It can be readily soft soldered, silver soldered, or brazed.
Tellurium copper can be used as the electrode in electrical discharge machining (EDM) - the alloy is used to replace copper when grinding wheel loading occurs during fine finishing of the electrode - the alloy retains the properties of copper in the EDM process.
Phase diagram.
Copper forms tellurides. These include Cu4Te, Cu2Te (m.p. 1125 °C), and CuTe. A eutectic forms at 71% (mol) Te, (m.p. 340 °C). Between 4.3 and 30% (mol) Te there is stratification between Cu and Cu2Te.