Application of Mechanical Systems in Engineering - Assignment Example

APPLICATION OF MECHANICAL SYSTEMS IN ENGINEERING By Name Course Instructor Institution City/State Date Application of Mechanical Systems in Engineering Task 1a (P1) The purposes and applications of lubricants Lubricants key purpose involves friction reduction between moving surfaces as well as parts. Therefore, they are vital, principally with regard to the maintenance and functionality especially in various types of machinery and operations. Describe the difference between the following lubricant types: Mineral Mineral fluid lubricants are derived from mineral oils, which are products of crude oil that has been refined. Basically, there are three types of mineral oil: aromatic, naphtenic as well as paraffinic. In this case, Aromatic oils are refining process products in paraffinic oils manufacturing and are utilised for producing adhesives, seal compounds, as well as plasticizers in production of asphalt and rubber.1 Paraffinic oils are manufactured either through solvent extraction or hydrocracking process and are utilised for used for manufacturing industrial lubricants, engine oils, as well as processing oils in paper, textile, and rubber industries. Lastly, Naphtenic oils are generated from distillates of crude oil, and are used for manufacturing metal working fluids as well as transformer oils. Vegetable oils Vegetable-based oils are natural esters or triglycerides that are derived from agricultural crops and since the oils are from natural products, their chemical composition differs slightly from one crop to another. Vegetable lubricants are derived from palm oil, cotton seed, canola oil, corn, castor oil, soybean, as well as rape seed oils. Evidently, vegetable oils are eco-friendly substitute to mineral oils given that they are biodegradable, and they have lubrication properties similar to that of mineral oils. However, vegetable oils have low temperature as well as oxidation stabilities. Synthetic oils These are lubricants produced through chemical synthesis instead of through refinement or extraction of petroleum to generate a compound with predictable and planned properties. They can be divided into: Polyalphaolefins (PAO), Polyglycols (PAG), Ester oils, and Silicones. Importantly, synthetic lubricants can be utilised in higher temperatures as compared to refined lubricants devoid of breaking down.2 Besides that, synthetic lubricants are good chemical resistant; thus, allowing then to be used in hazardous applications like gas, nuclear or other industries, which need exceedingly high specification lubricants. Greases Greases are semi-fluid lubricants manufactured through emulsifying fats or oils with water and metallic soap at 204 to 316°C. Greases are used in machined that need infrequent lubrication as well as where a lubricating oil cannot hold. They seal to prevent entrance of incompressible materials and water. Its application includes; roller bearings lubrication in rolling mills and railway car wheels, spindles, steam turbines, and other different machinery bearings. Cutting fluids Cutting fluids are utilized in metal machining for various reasons like improving life of the cutting tool, lessening thermal deformation of the work piece, refining surface finish as well as washing away chips. Cutting fluids are very important because they reduce friction effects, carry away heat during the machining operations, and assist in improving dimensional accuracy as well as part quality. Task 1b (P2) Identify the following three lubrication systems found in the machine shop in Pembrokeshire College or in industry and describe the operation and maintenance of each one: Gravity feed Gravity feed lubrication systems offer reliable and constant lubrication, and perform effectively in numerous industrial lubrication applications. Gravity feed has a lightly covered cup placed on top of the bearing tasked with metering out oil at a certain set interval. The lubricant supply to the bearing is regulated by a conical valve or needle, and may be altered when needed. The reservoir of or pipes to a number of bearings, acknowledged as a multiple point system.3 It is suitable for low-to-moderate speeds and low loads that need small oil quantities, applied at consistent intervals. Fig 1: Gravity Feed Lubrication System (Source; techtransfer.com) Forced feed In Force Feed Lubrication, the system contains three unceasing phases of operation. First, the gear box oil is collected and conveyed to the oil reservoir; secondly, force from the reservoir is taken by the oil pump, which releases the oil by means of an oil cooler and then taken back to the gear box. When desirable, the oil pump takes the reservoir’s oil, where it is cleaned in the filter, and then returned to the reservoir.4 It is suitable for machine functioning at heavy loads as well as high speeds which produced high temperatures because of friction, so this system protects the machine from high temperatures through a high flow of oil. Fig 2: Force Feed Lubrication for Gear Box with Bearings (Source; techtransfer.com) Grease cups and nipples A grease cup can be described as a fitting that is utilised for supplying lubrication to bearings as well as other moving parts of the machine. Basically, grease cups are manufactured to offer a steady and constant supply of lubrication to machine’s moving parts. The grease cup as shown below is filled with grease then discharged as required, but the lubricant utilised in the grease cup relies on the system demands. Grease nipples function similarly as grease cup and are mainly used in lubrication equipment, cars, grease guns, machinery, bikes, trailers, and bearings. Fig 3; Grease Cup (source: myford.co.uk) Fig 4: Grease Nipple (Source; exportersindia.com) Task 1c (D1) Justify the use of fully synthetic oil and a force feed lubrication system such as a formula one car engine Incredible accelerations as well as decelerations that formula one cars’ piston experience over a short distance indicates the level of mechanical stresses that is acting on the engine components mostly, such restraints stresses are brought about by huge frictional forces between the piston cylinder wall and the piston rings, the bearing shells as well as the connecting rods, and the crankshaft. In this case, synthetic lubricants are more effective because they can be used in high temperatures, to reduce temperature prevent any metal-to-metal contact. The suitable lubrication system for formula one car is force feed, because it is suitable for heavy loads and high speeds. Task 2a (P3) Describe the operation of one seal, one type of packing and two different types of bearing with a typical application for each one: Seals: - Circular oil seals Circular oil seals are accessible in various forms including metal-cased, metal-cased leather, rubber-covered, double offers the common medium for sealing, but Viton appears suitable for chemical-handling and high temperatures applications. Majority of circular oils seals are produced to handle 0.5 bar pressure; still, Polytetrafluoroethylene seals have the ability to hold pressures equal to 10 bar. Circular oil seals are used to close spaces between moving and stationary components in machines; thus, assisting in preventing escape of the lubricants. They as well stop dangerous pollutants from going into the machinery, especially in severe settings. Important components of almost every type of all types of machines as well as in operation of vehicle, circular oil seals safeguard every from of precision-manufactured, sleeve, close-fitting ball, as well as roller bearings.5 Circular oil seals in precision bearings assist in preventing lubricants from escaping areas such as the bearing. Besides that, in machine components, they assist in preventing corrosive moisture, abrasives, as well as other dangerous pollutants from entering machinery. The circular oil seals can be used in a full range of machines like automotive, oil refineries, manufacturing, and power transmission industry. Packing: - Gaskets Gaskets are constructed by soft materials like rubber or cork, or metals and soft alloys, and majority of them are produced to be applied only once. Gaskets create a seal when is compressed between stationary parts where gas or liquids can pass. Various materials are utilised to produce gaskets they include; elastomeric materials (butyl rubber, ethylene propylenediene, ethylene propylenediene, fluoroelastomer, chlorosulphonated polyethylene), fibrous materials (asbestos, aramid, cellulose, glass, carbon fibre), metallic materials, and other materials such as mica, flexible graphite, and cork. Relying on construction, gaskets may be grouped: soft, semi-metallic, and metallic.6 Gaskets can be used in for industrial and commercial use on wood, pipes, in addition to other applications. Bearings: - Ball bearings and tapered roller bearings Ball bearings are form of rolling-element bearing, which utilises balls so as to maintain the gap between the bearing moving parts. Ball bearing purpose is to utilise rotating friction as well as support axial and radial loads. Ball bearings are categorized into three groups, which rely on the loads’ direction they are made to encounter (axial, radial, or combination of both): thrust ball bearings mainly for axial loads; radial ball bearings mainly for radial loads; and, angular contact ball bearings an integration of axial and radial loads. Ball bearings are applied in door hinges, oven racks, aircrafts in cargo rollers and fairlead pulleys, among others. On the other hand, tapered roller bearings use conical rollers as well as raceways, set in order that the raceways as well as rollers meet at a common point. In this case, the rollers are steered by contact between the inner ring rib and the roller large end. This offers high capability for single thrust and radial loads. In majority of applications, tapered roller bearings are used in the end-to-end pairs such that axial forces may be equally supported in both ends. Pairs of tapered roller bearings are commonly used in automobiles’ in heavy duty applications where robustness is vital, and in mining, construction, and agriculture equipment, gear box, axle systems, among others. Task 3a (P4) Describe two different types of screwed fastening and two different types of rivet giving a typical application for each one: Screwed fastenings: - Metric Bolts and Self-Tapping Screws Metric bolts are bolts that are either completely or partially threaded, and are used with washers and nuts. The bolts are made according to ISO standard and metric standards. Metric bolts can be used to attach steel purlins to steel frames, in industrial and building applications where materials joining are needed, to fasten applications like furniture, timber frames, fencing, and so forth. Self-tapping screws are screws that drill their own holes by cutting accurate threads when screwed into the metal, plastic, or wood: Application of self-tapping screws range from surgery (dental Implants), carpentry, to installation of air conditioning machines. Rivets: - Snap Head, Pan Head, Countersunk Heads and Pop Rivets Rivets are used for joining plates together, snap head are rounded pr hemispherical headed rivet or bolt; also, a swaging tool with a cavity in its face for forming such a rounded head used for joining metal, plastic or wood plates together. The pan rivet has a head shaped like a cooking pan that is inverted, and its application is akin to that of span head rivet. A countersunk head rivet has a flat head and may have a solid shank or tubular rivet, and are used to join together work-piece materials where the assembled rivet head will be flush with work piece top. Lastly, POP rivets are utilised in a number of applications to fasten two or more plates together.  Fig 5: Types of Rivet (source: bbc.co.uk) Task 3b (D2) Identify a piece of engineering equipment such as a lathe within the college and justify the choice of engineering components used. (Import a minimum of ten pictures taken from the machine shop) Lathe Machine consists of a bed that offers a heavy, rigid frame wherein all the key components are mounted; it has a gearbox: within the headstock, offering various speeds; tool post where the tool is mounted; lead screw for thread cutting; and carriage for mounting and moving the cutting tool. Other crucial parts of the lathe machine include; Spindle, Feed Rod, Quick Change Gearbox, stead and follow rest, apron, ways, among others.7 There are various types of lathe machine; Engine Lathe, Wood Lathe, Toolroom Lathe, Turret Lathe, and CNC Lathe. Lathe machines can be used for woodturning, metal spinning, metalworking, acrylic spinning, thermal spraying, and pottery. Fig 6: lathe Machine (Source: americanmachinetools.com) Fig 7: Wood Lathe (Source; antiqueroses.org) Fig 8: Engine lathe (Source: hr-tool.com) Fig 9: Toolroom Lathe (source; machinerycanada.com) Fig 10: Turret Lathe (Source; southwestdynamics.com) Fig 11: CNC Lathe (Source; skcnc.com) Fig 12: Drilling in Lathe Machine (Source: mini-lathe.com) Fig 13: Basic Operations of Lathe (Source; nmri.go.jp) Fig 14: lathe Work (source: dir.indiamart.com) Fig 15: Turning Operations (source; mmsonline.com) Bibliography Automotive, C. South African Automotive Light Vehicle Level 3. Pritoria: Jones & Bartlett Learning, 2013. Conover, E. The Lathe Book: A Complete Guide to the Machine and Its Accessories. Connecticut: Taunton Press, 2001.. Rudnick, L.R. Synthetics, Mineral Oils, and Bio-Based Lubricants: Chemistry and Technology. 2nd ed., New Jersey, CRC Press, 2008. TechTransfer. Oil and Grease Application Methods. 2014. http://www.techtransfer.com/blog/oil-and-grease-application-methods/ (Accessed 19 March 2015). Read More

 Besides that, synthetic lubricants are good chemical resistant; thus, allowing then to be used in hazardous applications like gas, nuclear or other industries, which need exceedingly high specification lubricants. Greases Greases are semi-fluid lubricants manufactured through emulsifying fats or oils with water and metallic soap at 204 to 316°C. Greases are used in machined that need infrequent lubrication as well as where a lubricating oil cannot hold. They seal to prevent entrance of incompressible materials and water.

Its application includes; roller bearings lubrication in rolling mills and railway car wheels, spindles, steam turbines, and other different machinery bearings. Cutting fluids Cutting fluids are utilized in metal machining for various reasons like improving life of the cutting tool, lessening thermal deformation of the work piece, refining surface finish as well as washing away chips. Cutting fluids are very important because they reduce friction effects, carry away heat during the machining operations, and assist in improving dimensional accuracy as well as part quality.

Task 1b (P2) Identify the following three lubrication systems found in the machine shop in Pembrokeshire College or in industry and describe the operation and maintenance of each one: Gravity feed Gravity feed lubrication systems offer reliable and constant lubrication, and perform effectively in numerous industrial lubrication applications. Gravity feed has a lightly covered cup placed on top of the bearing tasked with metering out oil at a certain set interval. The lubricant supply to the bearing is regulated by a conical valve or needle, and may be altered when needed.

The reservoir of or pipes to a number of bearings, acknowledged as a multiple point system.3 It is suitable for low-to-moderate speeds and low loads that need small oil quantities, applied at consistent intervals. Fig 1: Gravity Feed Lubrication System (Source; techtransfer.com) Forced feed In Force Feed Lubrication, the system contains three unceasing phases of operation. First, the gear box oil is collected and conveyed to the oil reservoir; secondly, force from the reservoir is taken by the oil pump, which releases the oil by means of an oil cooler and then taken back to the gear box.

When desirable, the oil pump takes the reservoir’s oil, where it is cleaned in the filter, and then returned to the reservoir.4 It is suitable for machine functioning at heavy loads as well as high speeds which produced high temperatures because of friction, so this system protects the machine from high temperatures through a high flow of oil. Fig 2: Force Feed Lubrication for Gear Box with Bearings (Source; techtransfer.com) Grease cups and nipples A grease cup can be described as a fitting that is utilised for supplying lubrication to bearings as well as other moving parts of the machine.

Basically, grease cups are manufactured to offer a steady and constant supply of lubrication to machine’s moving parts. The grease cup as shown below is filled with grease then discharged as required, but the lubricant utilised in the grease cup relies on the system demands. Grease nipples function similarly as grease cup and are mainly used in lubrication equipment, cars, grease guns, machinery, bikes, trailers, and bearings. Fig 3; Grease Cup (source: myford.co.uk) Fig 4: Grease Nipple (Source; exportersindia.com) Task 1c (D1) Justify the use of fully synthetic oil and a force feed lubrication system such as a formula one car engine Incredible accelerations as well as decelerations that formula one cars’ piston experience over a short distance indicates the level of mechanical stresses that is acting on the engine components mostly, such restraints stresses are brought about by huge frictional forces between the piston cylinder wall and the piston rings, the bearing shells as well as the connecting rods, and the crankshaft.

In this case, synthetic lubricants are more effective because they can be used in high temperatures, to reduce temperature prevent any metal-to-metal contact.

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