Sample - Unit 2 / LA A

The Manufacturing Process of a Stator Shell

Materials:
Possible materials to use to use for the stator
shell are steel and aluminium. Each material
may be considered, depending on the purpose
the motor that houses the stator shell will be
used for. For example; aluminium will be more
suited to fractional horse power motors, which
will be on for short durations.
Steel and aluminium are generally used to
create stator shells due to their high robusticity,
meaning that although the shell is a hollow tube
(skeletal element), it has good structure and is very strong. This allows the tube to withstand
the high pressures within the motor without collapsing. Also, these materials have good
heat dissipation and aluminium in particular is the best for cooling, which will lower the
chances of the stator from overheating and reducing the functionality of the motor.

STEEL ALUMINIUM
MELTING POINT (degrees) 1,427 660.32
BOILING POINT (degrees) 3000+ 2470
TENSILE STRENGTH Low;380Mpa high;1760Mpa Low;90Mpa high;572Mpa
YEIELD STRENGTH Low; 210Mpa Low;34Mpa high;505Mpa
high;1620Mpa
LIFE SPAN 50-100 years 20-30 years

Both materials are quite cheap, making them easy to access and produce. However, steel
has a higher melting point than aluminium and is stronger, making it a more suitable
material for a stator shell. It also, has 3 times the lifespan, meaning that the stator motor in
all will have a longer lifespan and will require less maintenance.

Engineering Processes
These are a few of the processes that take place in order to create a stator shell;

Types of Welding;

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There are different types of welding that can be used, however they all have different
outcomes and methods. To choose the correct welding method you must first consider your
desired result of your project, the material it is made from as well as other factors. Welding
is a process that allows you to attach two pieces of metals together using heat. 
Metal Inertia Gas (MIG) Welding
This method of welding was originally industrialised for welding aluminium as well as other
non-ferrous metals. It is a semi-automatic or automatic process in which a wire acts as an
electrode by connecting to a source of direct current in order to join to pieces of metal
together. To prevent external particles from contaminating the welding pieces, a current of
inert gas, e.g. argon, is passed through the welding gun simultaneously with the wire
electrode.

https://sites.google.com/site/gobanengineeringnotes/welding/mags-mig-welding

Pros of MIG welding

1. The welding process is quick
2. The welder is easy to control which means improved accuracy
3. It is inexpensive
4. Produces a clean weld with minimal splatter 

Cons of MIG welding

1. Not very strong so not useful for denser metals
2. Cannot be used outside or in wind as it will disturb the gas shield
Tungsten Inertia Gas (TIG) Welding
This method of welding is similar to MIG, however it uses a tungsten electrode that does not
melt so doesn’t need to be replaced very often. To fuse the metals together and electric arc
is placed between the workpiece and the tungsten electrode. The welding zone is also
shielded by a flow of inert gas. TIG welding can also be semi- automatic or automatic.

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https://www.azom.com/article.aspx?ArticleID=2111

Pros of TIG welding

1. Has greater precision
2. Produces strong, high quality welds
3. Can weld a large range of alloys 

Cons of TIG welding

1. Expensive as it needs high quality machines
2. requires a lot of experience to use it accurately
3. welds materials very slowly

Welding Health and Safety

As welding requires the use of high temperatures, there must be precautions in place to
ensure the safety of the welder as well others in the workshop. Some safety precautions
include;
1. protecting eyes and face from UV light and flames - using a welding helmet
2. protect the skin from flames and corrosive substances - using a long sleeve
flameproof overall
3. remove all flammable objects from flames
4. ensure that a form of fire extinguisher is present and easily accessible for when there
is an uncontrolled fire
5. hands and feet must be protected from the flames 

Fire and smoke

Since welding creates sparks and drips of molten metal, it is possible that this may start a
fire, so materials such as wood, fabric and other flammable substances should be kept away
from the welding area. A form of fire extinguisher must be kept in the area at all times in
case of emergency.

Permits to work

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Where proposed work is identified as having a high risk, strict controls are required. The
work must be carried out against previously agreed safety procedures, a ‘permit-to-work'
system.
The permit-to-work is a documented procedure that authorises certain people to carry out
specific work within a specified time frame. It sets out the precautions required to complete
the work safely, based on a risk assessment. It describes what work will be done and how it
will be done; the latter can be detailed in a ‘method statement'.
The permit-to-work requires declarations from the people authorising the work and carrying
out the work. Where necessary it requires a declaration from those involved in shift
handover procedures or extensions to the work. Finally, before equipment or machinery is
put back into service, it will require a declaration from the permit originator that it is ready
for normal use. 

Welding Use:
In relation to the stator shell, welding can be used to attach the separate elements if a
method of casting is used which requires the object to be created in parts, for example,
from sand casting and it wouldn’t be good to attach anything that is part of the stator shell
using semi-permanent methods as it will be vibrating constantly. If welding would be
necessary, TIG welding would be the best choice because it has a higher accuracy compared
to MIG welding. TIG welding also produces a stronger weld, which will reduce the risk of the
stator shell coming apart while in use, which is very important given that there will be a lot
of moving parts and this could be dangerous. MIG welding is usually used for non-ferrous
materials such as aluminium, however, the stator shell will be made out of steel. Therefore
TIG welding would be the most suitable welding method to use while making this stator
shell as it is also good for thin components and there are a lot of them on it. 

Human Factors in Welding:

Welding is a very slow process which will require the operator to have patience and a steady
hand. TIG welding is very expensive, so only an experienced welder should utilise this
engineering process to reduce the amount of wasted material and create and accurate weld
oft the stator shell in a timely manner. They should also be familiar with the safety
regulations of welding and work with other colleagues to watch the area for sparks as a fire
could be started. TIG welders have to be very careful to be professional as if they make
mistakes it could mean all the cost already in the product is lost and scrapped so they have
to act with care, and also not put themselves at risk by not using the correct PPE and putting
their mask down.

Types of Casting;
This is a manufacturing process that allows you to create a solid shape by pouring molten
metal into a mould or your desired shape and left to solidify, the shape can then be
removed from the cast. Different casting methods will have different effects on the surface
of the solid work piece.

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Sand Casting
Sand casting refers to a casting method in which the mould is made from sand. This is done
by placing a mock of the desired shape (pattern) into the sand and incorporating them both
in a gating system, so the sand will hold the shape, and then removing the pattern. This
results in a mould cavity which metal can be poured into in order to create your desired
solid shape. The stator shell will need a core in the mould for the cylinder shape. 
Pros of sand casting
1. Simple production process
2. Lower production costs
3. Higher production rate
Cons of sand casting
1. More casting defects
2. Rough surface quality
3. Bad casting dimensions
4. Unstable casting quality

Centrifugal Casting
In this casting process, molten metal is poured into
a die that can be spinning on a vertical or horizontal
axis. It is commonly used to cast tubes, cylinders
and rings. i.e.; symmetrical shapes that can be spun
on their axis. With this casting, when the metal
moves to the moulds walls, the impurities within
the metal will “float” to the centre of the shape,
which allows for easy machining when finishing the
project to obtain a smooth surface. 

Pros of Centrifugal Casting

1. Relatively very light impurities move inwards towards centre. So they can be removed
easily thus helping in producing sound castings.
2. Gates and risers are not needed.
3. Castings acquire high density, high mechanical strength and fine grained structure.
4. These castings have a directional solidification starting from outside to inside.

Cons of Centrifugal Casting

1. This process requires lots of experience
2. An inaccurate diameter of the inner surface of the casting could ruin the whole
process.
3. Only some shapes can be generated by this casting process (circular)
4. Not all alloys can be cast in this way.

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 5. Centrifugal castings are very expensive. 

Die Casting
This process uses a permanent die usually made out of steel
and machined to match the negative of the part that needs to
be produced. It is done by injecting molten metal into the die at
a high pressure into a mould cavity. Due to the fact that alloy
steel will be used, which contains iron, the hot chamber die
casting method will be used to make it, as it has a quick cycle
time (about 15 per min.) a pool of molten metal is required to
feed the die. 

Pros of Die Casting

1. Excellent dimensional accuracy (dependent on casting
material, but typically 0.1 mm for the first 2.5 cm (0.005 in. for the first inch) and
0.02 mm for each additional centimetre (0.002 in. for each additional inch).
2. Smooth cast surfaces (1—2.5 μm (40—100 μin.) rms).
3. Thinner walls can be cast as compared to sand and permanent mould casting
(approximately 0.75 mm (0.030 in.).
4. Inserts can be cast-in (such as threaded inserts, heating elements, and high strength
bearing surfaces).
5. Reduces or eliminates secondary machining operations.
6. Rapid production rates.
7. Casting tensile strength as high as 415 MPa.

Cons of Die Casting

1. Casting weight must be between 30 grams (1 oz) and 10 kg (20 lb).
2. Casting must be smaller than 600 mm (24 in.).
3. High initial cost.
4. Limited to high-fluidity metals.
5. A certain amount of porosity is common.
6. Thickest section should be less than 13 mm (0.5 in.).
7. A large production volume is needed to make this an
economical alternative to other processes. 

Casting Health and safety

Safety Equipment:
1. Visor
2. Leather gloves
3. Leather leggings
4. Leather apron

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Dust
Dust from sand, fettling and kiln relining contains silica and, when dry, this produces dust
known as respirable crystalline silica (RCS). Inhaling RCS can cause silicosis. Silicosis is a
serious and irreversible lung disease that causes permanent disablement and early death.

Fume
Molten metal fume (foundry fume) is hazardous to health. Ferrous foundry fume can cause
lung cancer. Other foundry fume and spray mists can cause lung diseases including asthma.
This will be necessary as the material for the stator shell is a ferrous material. The Control of
Substances Hazardous to Health (COSHH) Regulations 2002 require that employers protect
their workers from the hazards of dust and fume.

Casting Use:
Casting can be used to create the stator shell as a whole element, for this process, die
casting may be the preferred method as it will create the stator shell as one component.
This will make a stronger stator shell, due to the fact there will be no weaker parts created
due to two halves being created separately and welded together for example during sand
casting. This means that the stator shell is able to withstand the strong energy flowing
through the stator motor. Die casting allows for more accurate castings than centrifugal
casting, which will allow the cast to be more detailed. Also, even though the main
component of the shell is a circle, there is a square carriage at the top, which disrupts the
rotational symmetry. This would mean that it may have to be welded on at the end.
Therefore die casting is the best method to use as it creates a near perfect cast which does
not require much machining at the end. The other thing is that a stator shell would be made
in quantity and die casting is much quicker once set up. 

Human Factors in Casting:

Casting is a very dangerous process which involves high heat and loud machines. Operators
must be very familiar with the health and safety regulations within the foundry as failure to
comply may result in death or injury. This means that operators must be very experienced
when using the machines, as even though they may be careful, due to lack of experience,
they may be slower in setting up the dies and operating the machines, which will increase
the production time of the stator shell. Die casting is fast, so operators must be alert and
free from distractions, motivated and well-trained so they don’t take risks to meet targets.

Types of Drills/ Drilling Methods

Drilling is a cutting process that uses a drill bit to create a hole in a solid piece. The drill bit is
usually a spinning cutting tool that is pressed against the work-piece and rotated to remove
the material in its path. This manufacturing process is usually used so can be fitted inside
the hole that is created.

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Hand Drill
This is a manual method of drilling and can be in two formats electric and non electric. They
both are used to bore holes into materials. However, the non electric drill relies on man
power, which may not be enough to bore through tougher materials such as metal. 

Pros of Using a Hand Drill

1. It is compact and portable
2. Is inexpensive

Cons of using a hand drill

1. It cant drill a wide range of metals
2. Doesn’t have a wide range of speeds

Pillar Drill
This is an automatic or semi-automatic method or drilling a hole. A pillar drill is freestanding
machine that’s can drill a range or materials such as; wood, plastic and metals. In order to
drill with this machine, the workpiece must be clamped onto the table of the drill to prevent
it from spinning. Once the bit has been fitted and the speed set, the drill can then be
lowered onto and through the workpiece to create a hole.

Pros of Using a Pillar Drill

1. can drill a wide variety of materials
2. Has a wider range of speeds
3. More accurate

Cons of Using a Pillar Drill

1. Not portable 

Reaming
This is a finishing process that enlarges holes using a reamer, which is a metal tool that can
be attached to a milling machine or pillar drill, or it can even be used by hand. This can be
used to accurately enlarge the holes on the stator shell, for example the fixing holes, if they
have been inaccurately cast, or have impurities. Therefore, by using the reamer to finish the
stator shell holes you can have smooth flush holes.

Pros of Reaming
1. Geometrically more accurate than drilling
2. Gives a smoother finish to the inside of the
hole

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Limitations of Reaming
1. The hole must be close in diameter to the reamer so it must be drilled first
2. May be difficult to find the exact size reamer for the diameter you need

Drilling health and safety

Drilling machines are one of the most dangerous hand operated pieces of equipment in the
shop area. Following safety procedures during drilling operations will help eliminate
accidents, loss of time, and materials. Listed below are safety procedures common to most
types of drilling machines found in the machine shop.
1. Do not support the workplaces by hand. Use a holding device to prevent the
workpiece from being tom from the operator's hand.
2. Never make any adjustments while the machine is operating.
3. Never clean away chips with your hand. Use a brush.
4. Keep all loose clothing away from turning tools.
5. Make sure that the cutting tools are running straight before starting the operation.
6. Never place tools or equipment on the drilling tables.
7. Keep all guards in place while operating.
8. Ease up on the feed as the drill breaks through the work to avoid damaged tools or
workplaces.
9. Remove all chuck keys and wrenches before operating.
10. Always wear eye protection while operating any drilling machines. 

Safety Equipment;
1. Earplugs or earmuffs to avoid hearing loss.
2. Safety glasses provide eye protection from flying chips, debris and other eye hazards.
3. Gloves protect your hands from chemicals, rough or sharp parts and a wide range of
other skin irritants.
4. Respirators can protect you against a wide r of dust, fumes, gases, vapours and many
other health hazards.
5. Boiler suits, chemical gloves and pants protect you from chemical burns.
6. Boots and shoes can provide a degree of protection from chemical splashes,
petroleum products, small cuts, bruises, and abrasions.

Drilling Use:
In this case, the stator shell will need to be drilled to create the fixing holes and the holes for
the wires. Using a pillar drill would be the best option because it is the fastest and more
accurate, as opposed to the hand drill. This is because the pillar drill will have machine
accuracy, and is less likely to make a mistake, from the operator’s hand slipping for example.
You can also set up pillar drills for making things in quantity by putting all the right clamping
equipment on the machine bed so each shell can just be placed in it. The hand drill will also
take much longer due to fatigue from the operator or lack of skill, as they will not be able to
work as quickly as the machine with the same accuracy. Reaming is more of a finishing

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process and would not be considered for creating holes but this is also easier to do using a
pillar drill if any of the holes need to be really accurate as you could ream straight after
drilling by just changing the tool. 

Human factors in Drilling:

Drilling is a repetitive activity that does not offer many variations, this may cause the
operator to have reduced concentration and work ethic, which may cause more mistakes
and lower the production of perfect stator shells. Therefore, operators must make sure that
they are qualified with the correct experience and attitude to be able to use the drilling
machines for long periods of time without making any errors. Operators should only use the
machine if they know they are experienced not just with the use of the machines but also
with its set up and safety precautions. For example, setting the correct speed on the drill
depending on the size hole that they need, or knowing when to change or sharpen the drill
bit so that the next operator can carry out the proceeding process (eg. Reaming) without
any problems. If any operator realises that they cannot carry out their process for example
due to a faulty or unsafe machine, they must report this to the rest of the team, so that the
production line does not have to be forcibly halted because of damage to a machine, this
would also mean that less materials would be wasted and other workers won’t get hurt.

Human Factors within the Workshop

While in the workshop, workers are expected to treat others with respect as this allows for a
safer and more productive time in the workshop. For example, if workers were not agreeing
with each other, or treating others in a discriminatory fashion, time would be wasted and
workers would become distracted. This could cause hazards such as fires, if the workers is
welding, or trips, if they worker is carrying a heavy load. 

Fatigue
Working in this environment can be very stressful as it is full of noise pollution and requires
long periods on manual labour. This could mean that a worker may have a reduced
productivity after a few hours of working as opposed to when they first start their shift.
Therefore, fewer stator shells could be produced by workers as they cannot have a high
output for the whole day.

Injury
If a worker is injured within the workshop, all process will have to be stopped in order for
the injured worker to be safe. This would cause a reduction of the production of the stator
shell for a period of time, if not the rest of the day if it is a serious injury. It would have to be
reported due to RIDDOR and put into the accident book and the employer and the working
area may be investigated to see if the environment was made as safe as possible for the
workers there. This will take some time and result in having the stator shell production
halted until further notice. 

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Sources:
http://www.hse.gov.uk/coshh/basics/permits.htm
http://www.hse.gov.uk/welding/fire-explosion.htm
https://en.wikipedia.org/wiki/Centrifugal_casting_(industrial)
http://www.hse.gov.uk/moltenmetals/health-topics.htm#dust
https://www.firstratemold.com/advantages-and-disadvantages-of-die-casting/comment-
page-3/
https://smithy.com/machining-handbook/chapter-6/page/2
https://en.wikipedia.org/wiki/Die_casting

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