PRECISION ENGINEERING PROCESS (PEMILIHAN ALAT POTONG, ALAT PEMEGANG DAN MESIN DALAM PROCES MANUFAKTUR)

Persoalan yang akan di hadapi yaitu proces yang akan dilakukan untuk pembuatan ball bearing baik itu dari pemilihan mesin, alat potong dan alat cekam material yang akan dibuat menjadi bagian dari ball bearing.

Question: 

Please select one major product from one major company in the world and have a good discussion according to Table1.1 on Page 5 of TEXTBOOK – production terms for manufacturing production systems.

(The answer should include sentences and figures)

Table1.1 on Page 5 of TEXTBOOK [1]

Term	Meaning
Production system	All aspects of workers, machines, and information, considered collectively, needed to manufacture parts or products; integration of all units of the system is critical.
Manufacturing system (sequence of operations, collection of processes)	The collection of manufacturing processes and operations resulting in specific end products; an arrangement or layout of many processes, materials-handling equipment, and operators.
Machine or machine tool or manufacturing process	A specific piece of equipment designed to accomplish specific processes, often called a machine tool; machine tools linked together to make a manufacturing system.
Job (sometimes called a station; a collection of tasks)	A collection of operations done on machines or a collection of tasks performed by one worker at one location on the assembly line
Operation (sometimes called a process)	A specific action or treatment, often done on a machine, the collection of which makes up the job of a worker
Tools or tooling	Refers to the implements used to hold, cut, shape, or deform the work materials; called cutting tools if referring to machining; can refer to jigs and   work holding and punches and dies in metal forming

Answer:

Introduction:

             I am interested in discussed about Company which is produce bearing. It’s name is NTN. NTN quickly opened overseas production facilities in response to this shift in manufacturing. Since then, we have enhanced our global production system. To provide the needed parts and quantities at the specified locations more promptly anywhere in the world is the objective of NTN's production division.

NTN will continue self-assessment with a critical eye to assure stable production at the highest level.

NTN was early to systematize production lines to strengthen production technology. Now, most of NTN production lines are automated, contributing to standardized quality and reduced costs. NTN Control its product used quality control efforts have received ISO 9001 certification. With this production control system NTN's superior quality products are earning the high acclaim and trust of customers everywhere.

We will discuss according to Table1.1 on Page 5 of TEXTBOOK 

1.  Production system

NTN is a company which is produce and sales of mechanical parts and equipment, such as bearings, constant velocity joints, and precision equipment.

It has become increasingly apparent that manufacturers of automobiles, electric equipment, and parts are forming ties with international companies to produce products in suitable regions for use worldwide.

Figure 1. Balls Bearings That are Produce by NTN

2.  Manufacturing system

Manufacturing process for ball bearing

  

Figure 2. A manufacturing system for making Ball Bearing in NTN

3.    Machines or machine tools

Annotation : 1. Press Machine 2. Forging Machine 3. Turning Machine 4. Gringding Machine

5. Lapping Machine 6. Heat treatment 

Jobs

-  Cutting
-  Forging
-  Boring
-  Surface treatment
-  Flushing
-   Turning

-  Grinding
-   Lapping
-   Assembling

-  Testing

 Operations

a.       Cutting/Pressing:

The cutting is the beginning process of making cage. It is used to change form sheet metal plate to be certain form (Fig. 9). This process is known by blanking and punching.

                    

b.      Forging:

The Forging is process making certain form by using jix and fixture. This process is used to making cage, rolling element, inner ring and out ring.

  

c.      Boring
     This process is used in making hole for cage. After processing of finishing forging is made hole this process use drilling machine.

  

d.       Surface treatment
This process is needed to make the product surface harder than before. This process can be seen in processing make of cage of ball bearing.

Another process of surface treatment is heat treatment. It is used in process in making inner and outer ring.

Figure 3. Surface Treatment in Making Ball Bearing

e.      Flashing
This flashing process is needed to reduce of excess material after material of ball forged in cold header.

 

Figure 4. Flashing process in making ball material

f.       Turning

Turning is needed in making inner and outer ring of ball bearing.

  

g.      Grinding

The grinding process is happen in making ball materials, inner and outer ring.

   

h.       Lapping

This process is run after grinding for ball material. the balls are moved to a lapping machine, which has cast iron wheels and uses the same abrasive lapping compound as is used on the races. Here, they will be lapped for 8-10 hours, depending on the four parts of a finished ball bearing: inner race, outer race, cage, and ball, how precise a bearing they are being made for. Once again, the result is steel that is extremely smooth

  

i.        Assembling

Assembling process is final process for making ball bearings. In this process all aprt of bearing is united, namely; cage, ball, inner ring and outer ring. First, the inner race is put inside the outer race, only off to one side as far as possible. This makes a space between them on the opposite side large enough to insert balls between them. The required number of balls is put in, then the races are moved so that they are both centered, and the balls distributed evenly around the bearing. At this point, the cage is installed to hold the balls apart from each other.

j.        Testing

Bearing making is a very precise business. Tests are run on samples of the steel coming to the factory to make sure that it has the right amounts of the alloy metals in it. Hardness and toughness tests are also done at several stages of the heat treating process. There are also many inspections along the way to make sure that sizes and shapes are correct. The surface of the balls and where they roll on the races must be exceptionally smooth. The balls can't be out of round more than 25 millionths of an inch, even for an inexpensive bearing. High-speed or precision bearings are allowed only five-millionths of an inch.

 Tools or toolings

 A.  Jigs and fixture

 

Figure 5 . Special Holder

B.  Forming Tools

  This the tool which are used in the forming such as drill, grinding wheel and turning cutter.

Annotation 1. Drill cutter, 2. Wheel Grinding 3. Turning Chisel 

Figure 6 Cutter/Tools

References:

1.      J T. Black, Ronald A, 2008, Kohser Materials and Processes in Manufacturing, John Wiley & Sons, Inc

2.      ……., http://www.madehow.com/Volume-1/Ball-Bearing.html, retrieved on October 29, 2013.

3.      ……., The manufacturing of ball bearings.

4.      ……., Handbook of Rolling Bearing, NTN, CAT.No.9012/E