We Failed in The Delv

 NAME: MAZEN MOHAMED MOHAMED
SALEH.
 TO: ENG/MOHAMED MOHSIN
 SUBJECT: delivery of engineering processes

safely as a team.
 ABOUT: THE FIRST EXAM
 GROUP: B_201.
The content:
1- the three engineering processes are used safely
when a manufacturing
2- The best way manufacturing to make the 5 samples.
3- The best way when you will manufacture large batch
of the product.
4-how to manufacture the spanner by machining or by
forging
5- How human factor effect the performance of
engineering processes.
References:
Dokumen.teps
En.wikipidea.org
www.iqsdirectory.com
www.wonkeedonkeetools.co.uk
www.sciencedirect.com
3 engineering processes for the spanner
1-forging (used in large batches) : The forging process has existed for several
thousand years in different forms as a means for shaping metal. Once the metal has
reached a point where it is pliable, it is formed, shaped, configured, and manipulated to
achieve the desired formation. This part of the process can include hammering,
grinding, molding, compressing, and bending; this is dependent on the chosen method.
Regardless of the forging process, the metal is put through a set of stressing steps
designed to transform it into the planned design
Different Types of Forging

1-Open Die Forging
Open die forging, sometimes referred to as drop forging, transforms a

workpiece without completely enclosing the metal material within the die.
Open die forging is done by pounding the workpiece with the die until the
workpiece takes the shape and form of the die. Prior to being placed in
the anvil type process, the workpiece is heated and then hammered until
it takes the desired shape.
 2-Closed Die Forging

Closed die forging, also known as impression forging, is a
process where two halves of a die move toward each other
to enclose the workpiece or billet. The heated billet is
placed in the bottom die and is approximately the size of
the part to be completed. The force provided by the
meeting of the dies compresses the billet to form the
required forged part. Though this process is initially more expensive than other forms of
forging, the investment is recovered by the accuracy, quality, and strength of the
completed parts.
3-Roll Forging
Roll forging is a heated metal process that uses opposing rolls to

shape and deform the workpiece. The shape and dimensions of
the part are determined by geometric shapes that have been cut
into the rolls. The part is produced by a partial turning of the rolls
as the workpiece passes between them. The shape on the rolls is
one fourth to three fourths of the two rolls. The grooves in the
rollers give the workpiece a variable cross section for secondary
finishing.
2-casting (small batches): Casting is a manufacturing process in which a
liquid material is usually poured into a mold, which contains a hollow cavity of the
desired shape, and then allowed to solidify.
Different Types of casting
1-Sand Casting Process

Sand casting is a versatile casting process that can be
used to cast any metal alloy, ferrous or non-ferrous. It is
widely used for mass production in industrial units, such
as automotive metal casting parts, like engine blocks,
cylinder heads, crankshafts
2-Centrifugal Casting
Centrifugal casting, also known as roto casting, is a process
for industrially manufacturing cylindrical parts with centrifugal
forces. This type of metal casting uses a preheated spinning
die in which the molten metal is poured. The centrifugal forces
help to distribute the molten metal within the die at high
pressure.
 3- Gravity Casting
Gravity die casting, also typically known as permanent
mold casting, uses reusable molds made of metal, like
steel, graphite etc. to fabricate metal and metal alloys. This
type of metal casting can manufacture various parts like
gears, gear housing, pipe fittings, wheels, engine pistons
3-machinhng (used in on-off & continuous): Machining is a process in
which a material (often metal) is cut to a desired final shape and size by a controlled
3-Machining processes explained
1-Turning
Turning is a process that rotates the workpiece as the primary method
of moving metal against the cutting tool. Lathes are the principal
machine tool used in turning.
2-Milling
Milling uses a rotating cutting tool to bring cutting edges to bear
against the workpiece. This is the most versatile tool and technique
used in a machine shop.
3-Drilling
Drilling creates a new hole or refines an existing hole using a rotating

cutter. Drilling is most commonly done using drill presses, but
sometimes drilling tools will be attached to compatible lathes or mills
to create holes.
o The best way to manufacture the 5 samples of the

spanner is the machining because this process
gives you more accuracy by decreases the
tolerance in the manufacturing and the surface
will be more soft and shining too.
Comparing between those 3 types:
The face of
comparison forging casting machining
cost Low cost High cost High cost
time Taking little Taking little Taking long

time time time
used in on-off
Mass continuous small batches & large batches
production
Numbers of 2 1 7
stages
Extremely High
accuracy High quality High quality quality
 Now when we go into a large numbers for the production of

the spanners we should to change the way of the production
to save the time and the cost too so, we will use the forging
because it benefits and advantages :
 Increased Strength
 great accuracy
 low cost
 taking little time
The steps of the manufacturing of the spanner
(for the 5 samples)
1- We cut the sheet metal to get the dimensions that we will work on it.
2- We face the surface by milling machine.
3-We shape the material and cut the extras to make the shape of the
spanner.
4- We make a hole by the drilling machine and we make the thread too.
5- Sawing stage to remove the extra part.
6- After that we do the finish of the surface by filing.
7-We punch on the spanner to print the data of it on it.
The steps of the manufacturing of the spanner

by forging
1-we make the material in the fluid case to be easier when shaping, after
that we punch it many times to take the shape by the closed die forging.
2-we clod it until it be solid metal again.
Health and safety: we must make sure that we follow health and safety
instructions in all the engineering processes but every process have its special
(PPE) following its dangers like when will you make a large batches of the product
by using (forging & casting) we must to wear the gloves to protect our hands from
the very high temperature and we must to wear the glasses too to save our eyes.
And when making a one –off batch by the machining you must wear the glasses to
save your eyes from the reverse iron when the cutting and you must wear the
overall to save you all body.
how human factor as an individual or as a team affect
the performance of engineering processes?
In essence, human factors engineering focuses on how systems work in actual
practice, with real and reasonable human beings at the controls, and attempts to
design systems that optimize safety and minimize the risk of error in complex
environments.
Human factors engineering has long been used to improve safety in many
industries outside of health care—it has been employed to analyze errors in
aviation, automobiles, and the Three Mile Island nuclear power plant accident. Its
application to health care is relatively recent; pioneering studies of human factors
in anesthesia were integral to the redesign of anesthesia equipment, significantly
reducing the risk of injury or death in the operating room.
Applications of Human Factors Engineering to Improving Safety:
Usability testing—Human factors engineers test new systems and equipment

under real-world conditions as much as possible, in order to identify potential
problems and unintended consequences of new technology.
Forcing functions—An aspect of a design that prevents an unintended or
undesirable action from being performed or allows its performance only if another
specific action is performed first. For example, automobiles are now designed so
that the driver cannot shift into reverse without first putting his or her foot on the
brake pedal. Forcing functions need not involve device design. One of the first
forcing functions identified in health care was the removal of concentrated
potassium from general hospital wards.
Standardization—An axiom of human factors engineering is that equipment and
processes should be standardized whenever possible, in order to increase
reliability, improve information flow, and minimize cross-training needs.
Standardizing equipment across clinical settings.
Resiliency efforts—Given that unexpected events are likely to occur, attention
needs to be given to their detection and mitigation before they worsen. Rather than
focus on error and design efforts to preclude it, resiliency approaches tap into the
dynamic aspects of risk management, exploring how organizations anticipate and
adapt to changing conditions and recover from system anomalies. Building on
insights from high-reliability organizations, complex adaptive systems, and
resourceful providers at the point of care, resilience is viewed as a critical system

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 NAME: MAZEN MOHAMED MOHAMED

 TO: ENG/MOHAMED MOHSIN

 SUBJECT: delivery of engineering processes

 ABOUT: THE FIRST EXAM

Different Types of Forging

Open die forging, sometimes referred to as drop forging, transforms a

 2-Closed Die Forging

Roll forging is a heated metal process that uses opposing rolls to

Different Types of casting

1-Sand Casting Process

3-Machining processes explained

Drilling creates a new hole or refines an existing hole using a rotating

o The best way to manufacture the 5 samples of the

cost Low cost High cost High cost

time Taking little Taking little Taking long

 Now when we go into a large numbers for the production of

2- We face the surface by milling machine.

5- Sawing stage to remove the extra part.

6- After that we do the finish of the surface by filing.

7-We punch on the spanner to print the data of it on it.

The steps of the manufacturing of the spanner

2-we clod it until it be solid metal again.

Applications of Human Factors Engineering to Improving Safety:

Usability testing—Human factors engineers test new systems and equipment

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