FRESH ELECTRIC COMPANY

Prepared For
Prof. Dr. Eman Ibrahim & Dr. Mona Ahmed
Ph.D. Lecturer in Mech. Eng. Department, H.T.I
Eng. Hossam Ramadan
Lecturer in mechatronics Department, H.T.I

BY
Salman Ali Mabed
ID: 20160395
Mechatronics department
2nd industrial training

August 3, 2019
 ACKNOWLEDGEMENTS

Thank you to Engineer Mahmoud Essam and Hossam Ramadan for following me with the

length of the training and his effort in the discussion.

Thanks to all workers and all engineers at ‘‘Fresh company’’ for helping me to improve the guide,

thank them very much for their important note that have given me about this report, I thank also

my institute that give me this chance to training and know more information about the outer

companies, very thank for our professors that provide us with the scientific subject that help us in

this training a lot. I thank all people in our institute and all engineers for giving more advices.

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 ABSRTRACT

Fresh electric company is a great place for training. I have spent the training period in this

company. I have learned the basic concepts of industrial engineering and how to implement them.

I knew how to manage the engineers. I also knew the role of the engineer, the technician, the

worker and all the officials in the factory and I learned how to deal with each of them.

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 TABLE OF CONTENTS

Contents Pages
ACKNOWLEDGEMENTS ............................................................................................................. i
ABSRTRACT ................................................................................................................................. ii
TABLE OF CONNTENT .............................................................................................................. iii
LIST OF FIGURES ........................................................................................................................ v
INTRODUCTION .......................................................................................................................... 1
1.1. METAL FORMING ............................................................................................................. 1
1.2. TYPES OF PRESSES ......................................................................................................... 2
1.3. PRESS SELECTION .......................................................................................................... 3
FRESH COMPANY ....................................................................................................................... 4
2.1. DEFINIATION OF FRESH COMPANY ............................................................................ 4
2.2. FRESH ELECTRIC PRODUCTS ...................................................................................... 6
THE SAFETY ................................................................................................................................. 7
3.1. Safety instructions for production ........................................................................................ 7
HYDRAULIC PRESS .................................................................................................................. 12
4.1. General description of the hydraulic press ........................................................................ 12
4.2. PRINCIPLE OF HYDRAULIC PRESS ........................................................................... 13
4.3. COMPONENT OF HYDRAULIC SYSTEM.................................................................... 14
4.3.1 HYDRAULIC FILTERS .............................................................................................. 14
4.3.2 HYDRAULIC PUMP ................................................................................................... 15
4.3.2.1 TYPES OF PUMPS ............................................................................................... 15
4.3.2.1.1 EXTERNAL GEAR PUMP ............................................................................ 16
4.3.3 PRESSURE REGULATOR ......................................................................................... 17
4.3.4 VALVES ...................................................................................................................... 18
2.3.4.1 MANUAL VALVE ............................................................................................... 18

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 4.3.4.2 VALVES WITH SOLENOID ............................................................................... 19
4.3.4.3 TYPES OF SOLENOIDS ...................................................................................... 21
4.3.4.3.1 SINGLE SOLENOID VALVE ....................................................................... 21
4.3.4.3.2 DOUBLE SOLENOID VALVE ..................................................................... 22
4.3.4.4 THRE POSITIONS VALVE ................................................................................. 23
4.4. GAP FRAM HYDRAULIC PRESS ................................................................................. 24
4.5. ADVANTAGES OF HYDRAULIC PRESS ................................................................... 25
MECHANICAL PRESS ............................................................................................................... 27
5.1. GNERAL DESCRIPTION IF MECHANICAL PRESS.................................................... 27
5.2 TYPES OF MECHANICAL PRESS DRIVE ..................................................................... 28
5.2.1 DIRECT DRIVE MECHANICAL PRESS .................................................................. 28
5.2.2 SINGLE GEAR REDUCTION SINGLE END DRIVE .............................................. 29
5.3. PRINCIPLE OF MECHANICAL PRESS MACHINE ..................................................... 30
5.4. COMPONENTS OF MECHANICAL PRESS .................................................................. 31
5.4.1 FLYWHEEL ................................................................................................................. 31
5.4.2 CLUTCHS AND BREAKS.......................................................................................... 32
5.4.3. CRANK SHAFTT ....................................................................................................... 33
ENAMEL PAINT ......................................................................................................................... 34
6.1. CRUNCHING PROCESS FOR ENAMEL ....................................................................... 34
6.2. THE TRATMENT PROCESS ........................................................................................... 34
6.3. PRODUCT SPRAYING AND IMMERSION PROCESS ................................................ 36
6.4. CLEANING AND BURN THE SHEETS ......................................................................... 37
6.5. EMBATTLING AND PACKAGING ................................................................................ 38
MATEEIAL OF STOVES ............................................................................................................ 39
7.1. TYPES OF MATERIAL .................................................................................................... 39
7.2. SOME COMPONENTS OF STOVE ................................................................................. 40
CONCLUSION ............................................................................................................................. 41
REFERENCES ............................................................................................................................. 42

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 LIST OF FIGURES

Figures pages

1.1 metal forming……………………………………………………………………………….1

2.1 products of fresh company………………………………………………………………….6

3.1 Types of PPE……………………………………………………………………………….8

3.2 storages areas comply with applicable rules………………………………………………..9

3.3 correct posture when lifting………………………………………………………...………10

3.4 Break time……………………………………………………………………………….…11

4.1 hydraulic press…………………………………………………………………….………..12

4.2 principles of hydraulic system…………………………………...…………………………13

4.3 hydraulic filter…………………………………………………………….……………….14

4.4 types of pumps…………………………………………………………….……………….15

4.5 operating of external pump…………………………………………………………………16

4.6 pressure regulator………………………………………………………….……………….17

4.7 manual valve…………………………………………………………………….…………18

4.8 direct operated valve……………………………………………………….……………….19

4.9 steps of a pilot operated valve…………………………….………………………...………20

4.10 operation of single solenoid valve………………………………………….……………..21

4.11 operation of double solenoid valve…………………………………………..……………22

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4.12 operation of 3-position valve…………………………………………..………………….23

4.13 typical hydraulic press featuring gap-frame construction……………….………………..24

4.14 the full force in hydraulic press delivered at any point compare with mechanical press…25

5.1 mechanical press………………………………………………………………..…………..27

5.2 direct single end drive………………………………………………………………………28

5.3 single gear reduction single end drive press………………………………..………...…….29

5.4 principles of mechanical press machine……………………….……………...……………30

5.5 flywheel mechanism…………………………………………………….………………….31

5.6 clutch mechanism………………………………………………………….…….………….32

5.7 crank shaft element……………………………………………………….……..………….33

6.1 Steps of treatment process…………………………………………………..………….…..35

6.2 steps of sheets spraying process ………………………………….………………………..36

6.3 Burn the sheets…………………………………………………………………….………..37

6.4 Embattling and packaging of sheets…………………………………………………..……38

7.1 sheets iron rollers…………………………………………………………………….……..39

7.2 Gas pipes and burner………………………………………………………………………..40

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 CHAPTER 1

INTRODUCTION

1.1. METAL FORMING

Metal forming is one of the manufacturing processes which are almost chips. These operations
are mainly carried out by the help of presses and press tools. These operations include deformation
of metal work pieces to the desired size and size by applying pressure or force. Presses and press
tools facilitate mass production work. These are considered fastest and most efficient way to form
a sheet metal into finished product

Figure 1.1 metal forming

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1.2. TYPES OF PRESSES

The Presses having a stationary bed and a slide (Ram) which has controlled reciprocating motion
towards and away from the bed surface and at right angle to it. The slide being guided in the frame
of the machine to give a definite path of the motion.

• According to the Power Source

These power sources are categorized as:

Manually Operated or Power Driven1.2. TYPES OF PRESSES

➢
➢

These presses are used to process thin sheet metal working operations where less pressure or
force is required. These are operated by manual power.
Most of manually operated presses are hand press, ball press or fly press.

➢ Power Presses

Power presses are normally driven by mechanical mechanism or hydraulic system. Power
source of these presses may be electric motor or engine.

• According to the Type and Design of Frame

The type and design of frame depending on the design of frame these are classified as
inclinable, straight side, adjustable bed, gap frame, horning and open end.

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1.3. PRESS SELECTION

Proper selection of a press is essential for successful and economical operation. The purchase
of a press represents a substantial capital investments, and return on investment depends upon how
well the press performs the job required.

No general purposes press exists that can provide maximum productivity and economy for all
applications.

Compromises are usually have to be made to permit a press to be employed for more than one job.
Careful consideration should be given to both present and future production requirements.

Important factors influencing the selection of a press include size, force, energy and speed
requirements. The press must be capable of exerting force in the amount location, direction as well
as for the length of time needed to perform the specified operations.

Other considerations must include the size and geometry of the workpieces. Operations to be
performed, no of workpieces to be produced, production rate needed, accuracy and finish
requirements, equipment costs and other factors.

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 CHAPTER 2

FRESH COMPANY

2.1. DEFINIATION OF FRESH COMPANY

Fresh Electric Company for Home Appliances was founded in Egypt in 1987 with a dream
of introducing MODERN and affordable quality products to enhance customers’ lives.

Covering an area of 310920 m² between manufacturing HUBS, WAREHOUSES and SERVICE

CENTERS, Fresh currently runs 16 INDEPENDENT factories located in Egypt at 10th of
Ramadan City industrial zone, Badr City.

Fresh extended ITS OPERATIONS IN 2015 in Ethiopia

Fresh currently produces over 980 varied models of products manufactured and assembled in its
own facilities to exceed not only local, but global expectations.

More than 5,500 trained dedicated employees invest in both research and development to
constantly ensure compliance with its well – earned CE Mark, SASO, G.mark, SONCAP & ISO
9001/2000 TO always guarantee that its products meet international quality & safety standards

FRESH OPERATES a 24/7 operating Call Center, TO sufficiently attend all customers’ inquiries
& needs with the mindset of being “partners to depend on”.

Driven by 30 years of expertise in the market and a passion to always innovate, Fresh currently
exports to over 52 countries serving more than 150 million customers in Europe, Africa, the Middle
East and Asia while maintaining its position as a leader in the local market.

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Vision

“Fresh Ideas to exceed your every expectation.” Fresh Electric Company for Home
Appliances’ vision is to be able to constantly anticipate customers’ ever-changing needs and fulfill
them through innovative, affordable & environmental friendly appliances that not only exceed
customers’ expectations through increased reliability but also transcend local boundaries to
continue to expand globally.

Mission

“A local mindset with a global reach..” Our mission is to provide simple & affordable every day
solutions that make our customers’ life more enjoyable. Our brand’s core values rest in providing
cutting-edge modernity that is also user-friendly supported for life by the mutual partnership we
establish with our customers once they purchase our products.

Value

“Fresh values are at the heart of our brand” We strive to achieve:

Modernity – we look for trends and innovation so that our products associate our products with
vitality and creativity and to provide you with up to date durable products. Facilitation’ we want
our home appliances to make your life more comfortable. It’s the reason why fresh focuses on
ergonomic and easy to use products that are associated with a high level of service. Positivity –
We have a loyal and focused relationship with our clients. We aim to tackle all obstacles with a
positive attitude, dedicated to finding solutions.

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2.2. FRESH ELECTRIC PRODUCTS

Figure 2.1 products of fresh company

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 CHAPTER 3

THE SAFETY

3.1. Safety instructions for production

1. Inform Supervisors of Unsafe Conditions

If you see something that could potentially hurt someone, remove the object or clean the
area if you can do so safely. Otherwise, inform your supervisor. Since your supervisor is legally
obligated to keep you and your fellow employees’ working environment safe, they must take
action.

2. Use Equipment, Machines, and Tools Properly

Misusing tools and machines is the most prevalent cause of workplace injuries. When using
equipment, make sure that you are using each piece of equipment for its intended purpose and
are using it correctly. Furthermore, regularly clean and inspect equipment to ensure that it is safe.

3. Prevent Slips and Trips

As the second most prevalent cause of nonfatal occupational injuries, it is vital to ensure that
aisles are clear and spills are cleaned to prevent employees from tripping or slipping. If you are
dealing with a liquid, use drip pans and guards. Clean up any spills immediately to keep
conditions safe. Also, check your workplace to make sure there are no holes, loose boards, or
nails projecting from the floor. If any of these characteristics exist, replace the damaged flooring.
In areas that cannot easily be cleaned, consider installing anti-slip flooring.

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4. Wear Safety Equipment (PPE)

When cleaning up messes and using equipment, make sure you wear the proper safety
equipment. Making sure you wear the proper safety equipment and checking that your safety
equipment is undamaged significantly lowers your likelihood of getting injured.

Figure 3.1 Types of PPE

5. Keep Work Areas and Emergency Exits Clear

Make sure to remove any clutter blocking emergency exits, equipment shutoffs, and areas that
you are working. A cluttered work area can lead to not having enough space to use tools and pick
up heavy objects properly. Furthermore, if an exit is obstructed, you may not be able to quickly
escape if an emergency occurs. Placing equipment in proper storage areas after use will help
keep the work area and emergency exits clear.

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6. Eliminate Fire Hazards

If you are using combustible materials in the work environment, only keep the amount you need
for the task at hand. When you are not using the flammable material, store the chemical in an
assigned safe storage area away from sources of ignition. Also, store combustible waste in metal
receptacles and dispose of it daily.

Figure 3.2 storages areas comply with applicable rules

7. Avoid Tracking Hazardous Materials

To ensure that hazardous materials are not accidentally tracked into other areas, make sure that
work area mats are maintained and kept clean. Prevent cross-contamination by using different
cleaning materials—such as mops—for various spills, and change clothes if you spill toxic
materials on them. Also, if you work with toxic materials, do not wear your work clothes home.

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8. Prevent Objects from Falling

To keep objects from falling, use protections such as nets, toe boards, and toe rails. In addition,
stack boxes straight up and down, and place heavy objects on lower shelves. Furthermore, keep
stacked objects out of the way of aisles and work areas.

9. Use Correct Posture when Lifting

To avoid injuring your back when you are trying to pick up an item, keep your back straight, use
your legs to lift, and pick up the item without stooping or twisting. Whenever possible, use
mechanical aids such as a conveyor belt, wheelbarrow, or forklift.

Figure 3.3 correct posture when lifting

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10. Take Work Breaks from Time to Time

Many work-related injuries occur when a worker is tired and cannot adequately observe dangers
in their surroundings. By taking regular breaks, you are able to stay more alert when working.

Figure 3.4 Break time

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 CHAPTER 4

HYDRAULIC PRESS

4.1. General description of the hydraulic press

A hydraulic press is a machine press using a hydraulic cylinder to generate a compressive

force. It uses the hydraulic equivalent of a mechanical lever.

Figure 4.1 hydraulic press

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4.2. PRINCIPLE OF HYDRAULIC PRESS

The hydraulic press is one of the oldest of the basic machine tools. In its modern form, is well
adapted to presswork ranging from coining jewelry to forging aircraft parts. Modern hydraulic
presses are, in some cases, better suited to applications where the mechanical press has been
traditionally more popular.

A hydraulic press works on the principle of Pascal’s law, which states that when pressure is applied
to a confined fluid, the pressure change occurs throughout the entire fluid. Within the hydraulic
press, there is a piston that works as a pump, that provides a modest mechanical force to a small
area of the sample. There is also a piston with a larger area, which produces a larger mechanical
force.

Figure 4.2 principles of hydraulic system

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4.3. COMPONENT OF HYDRAULIC SYSTEM

4.3.1 HYDRAULIC FILTERS

Hydraulic filters protect your hydraulic system components from damage due to contamination
of oils or other hydraulic fluid in use caused by particles.

Every minute, approximately one million particles larger than 1 micron (0.001 mm or 1 μm) enter a
hydraulic system. These particles can cause damage to hydraulic system components because hydraulic
oil is easily contaminated.

Thus, maintaining a good hydraulic filtration system will increase hydraulic component lifetime.

Figure 4.3 hydraulic filter

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4.3.2 HYDRAULIC PUMP

Hydraulic pumps are used in hydraulic drive systems. A hydraulic pump is a mechanical
source of power that converts mechanical power into hydraulic energy.

It generates flow with enough power to overcome pressure induced by the load at the pump outlet.
When a hydraulic pump operates, it creates a vacuum at the pump inlet, which forces liquid from
the reservoir into the inlet line to the pump and by mechanical action delivers this liquid to the
pump outlet and forces it into the hydraulic systems.

4.3.2.1 TYPES OF PUMPS

Many different of pumps exist to assist fluid movements in a variety of systems, I will just explain
the External gear pump.

Figure 4.4 types of pumps

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4.3.2.1.1 EXTERNAL GEAR PUMP

It uses two gears rotating against each other to provide fluid movement, one gear is driven
by motor connected to a shaft this called " the drive gear " and it meshes with other gear then, it
drives the movement of the other gear.

As two gears rotate away from each other, they create an expanding volume on inlet side of the
pump, this creates a vacuum at the inlet port allowing fluid to flow into the pump then, fluid flows
into the cavities and is trapped by the gear teeth.

As the gear rotate a flow path is created around the outside of each one then, fluid trapped in the
slots between teeth is discharged into the cavity with outlet port.

Meshing of the teeth in the center of the pump don’t allow for fluid passes between the gears.

Step 1 step 2 step 3

Figure 4.5 operating of external pump

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Advantages of external gear pump:

1. High speed and pressure

2. Relatively quiet operation
3. Variety of build material options

Disadvantages of external gear pump:

1. Bushings wear in liquid area

2. Fixed end clearance

4.3.3 PRESSURE REGULATOR

A pressure regulator is a device which controls the pressure of liquids or gases (medium) by
reducing a high input pressure to a controlled lower output pressure. They also work to maintain a
constant output pressure even when there are fluctuations in the inlet pressure.

Figure 4.6 pressure regulator

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4.3.4 VALVES

A hydraulic valve properly directs the flow of a liquid, usually oil, through your hydraulic
system. The direction of the oil flow is determined by the position of a spool.

The required size is determined by the maximum flow of the hydraulic system through the valve
and the maximum system pressure.

Valves are used to control the direction rate and pressure in fluid lines, control valves for these
functions can be purchased with either manual or solenoid actuators.

2.3.4.1 MANUAL VALVE

In manually actuated valve the internal cylinder is shifted by hand using a lever push-button
plunger or other manual actuated device.

Figure 4.7 manual valve

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4.3.4.2 VALVES WITH SOLENOID

Valves with a solenoid actuator respond to an electrical signal for shifting with electrical
control machine cycles can be set up for automatic sequencing and operator control can be
exercised from a remote location.

Solenoid valves are said to be either direct or pilot operated, a direct operated valve is shown
in this figure.

Figure 4.8 direct operated valve

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A pilot operated valve has a pilot and bleed orifice and utilizes line pressure for operation, this is
a pilot operated relief valve.

when the solenoid is energized, the core opens the pilot orifice and relieves pressure from the top
of the valve piston to the outlet side of the valve. This results in an unbalanced pressure then,
lifting the piston off the main orifice.

When the solenoid is de-energized, the pilot orifice is closed and full line pressure is applied to the
top of the piston then, closing the valve.

Figure 4.9 steps of a pilot operated valve

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4.3.4.3 TYPES OF SOLENOIDS

4.3.4.3.1 SINGLE SOLENOID VALVE

A single solenoid valve has one solenoid to assist in valve operation, the valve spool shifts
when the solenoid receives an electrical signal and is energized.

The valve will remain shifted as long as electrical current is applied to the solenoid, once the
electrical current is removed and the solenoid is de-energized, the valve returns to its normal
position by spring force.

Fluid circuits designed to use single solenoid valve must maintain electrical current in order to
keep the valve in its shifted position.

Figure 4.10 operation of single solenoid valve

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4.3.4.3.2 DOUBLE SOLENOID VALVE
A double solenoid valve has two solenoids typically mounted on opposite ends of the valve
body, this type of to position double solenoid valve doesn’t have a spring return.

When the first solenoid is energized, the valve spool shifts into first position. even if the first
solenoid is de-energized, the spool remained shifted. This because there is no spring to return the
spool to its original position.

Energizing the second solenoid will send the valve to the second position. Even if the second
solenoid is de0energized, the valve will remain shifted until the first solenoid is re-energized.

Since there is nothing holding the valve in the shifted position other than friction, the types of
valves should be mounted horizontally to avoid self shift due to excessive airflow or vibration.

If both solenoids are energized at the same time, the solenoids will work against each other and
may cause the spool to become stuck electrical burnout of solenoid or overload of inrushing current
to the circuit. Any of which will cause severe damage to the system or valve.

Figure 4.11 operation of double solenoid valve

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4.3.4.4 THRE POSITIONS VALVE

A three positions valve has a spring centered neutral position for its internal spool because
of the centering spring it’s necessary to hold current on one solenoid or the other to keep the
spool in one of its side positions.

When each solenoid is energized, the valve shifts to the appropriate position. Anytime both
solenoids are de-energized, the valve spool will spring to center and stop the fluid flow. There
fore a three positions valve requires a maintained electrical signal for its operation.

As before energizing both solenoids at once may cause damage to the valve or to the system. To
prevent this from occurring, electrical circuits should be designed to make it impossible to have
current on both solenoids at the same times.

Figure 4.12 operation of 3-position valve

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4.4. GAP FRAM HYDRAULIC PRESS

hydraulic presses deliver a controlled force to accomplish work. The style of the press frame
and the hydraulic components vary depending on the intended use. Figure 1 illustrates a gap-frame
or C-frame hydraulic press.

The press shown in Figure 1 has a frame and bolster. The frame is of robust construction and made
of cast iron to limit both angular and total deflection. The bolster and ram provide a surface to
mount tooling.

The ram is actuated by a large hydraulic cylinder in the center of the upper part of the frame.
Additional alignment is provided by two round guide-rods.

The motor drives a rotary pump, which draws oil out of the reservoir housed in the machine frame.
The control system has electrically-actuated valves which respond to commands to advance and
retract the slide or ram. A pressure regulator is either manually or automatically adjusted to apply
the desired amount of force.

Figure 4.13 typical hydraulic press featuring gap-frame construction

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4.5. ADVANTAGES OF HYDRAULIC PRESS

1. Full power stroke

The full power of a hydraulic press can be delivered at any point in the stroke. Not
only at the very bottom, but the rated capacity of mechanical press is available only at the
bottom of the stroke. No allowances for reduced tonnage at the top of the stroke.

In drawing operations, for example, you have the full power of the press available at the
top of the stroke. You don't have to buy a 200-ton press to get 100 tons throughout the
stroke.

Figure 4.14 the full force in hydraulic press delivered at any point compare with mechanical press

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 2. overload protection

A 100-ton hydraulic press will exert only 100 tons of pressure (or less, if you have
set it for less) no matter what mistakes you make in set-up. You needn't worry about
overloading or breaking the press or smashing a die. When a hydraulic press reaches its set
pressure, that's all the pressure there is. The relief valve opens at that limit and there is no
danger of overload.

3. Greater versatility

A single hydraulic press can do a wide variety of jobs within its tonnage range.
Commonly seen are deep draws, shell reductions, urethane bulging, forming, blank and
pierce, stake, punch, press fits, straightening, and assembly. They are also used for powered
metal forming, abrasive wheel forming, bonding, broaching, ball sizing, plastic and rubber
compression, and transfer molding.

4. Quiet

Fewer moving parts and the elimination of a flywheel reduce the overall noise level
of hydraulic presses compared to mechanical presses. Properly sized and properly
mounted pumping units meet and exceed current Federal standards for noise, even with
the pump under full pressure.

Because each phase of the ram movement can be controlled, noise levels can also be
controlled. A hydraulic ram can be controlled to pass through the work slowly and
quietly.

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 CHAPTER 5

MECHANICAL PRESS

5.1. GNERAL DESCRIPTION IF MECHANICAL PRESS

The mechanical press transforms the rotational force of a motor into a translational force
vector that performs the pressing action. Therefore, the energy in a mechanical press comes from
the motor. These types of presses are generally faster than hydraulic or screw presses.

Figure 5.1 mechanical press

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5.2 TYPES OF MECHANICAL PRESS DRIVE

5.2.1 DIRECT DRIVE MECHANICAL PRESS

In direct drive presses, the flywheel is mounted on the end of the crank shaft and Energy is
transferred from the motor to the flywheel by several V-belts.

Directly driven press are capable of much higher operating than geared types. Speed rang from
under 100 strokes per minutes to 1800 for short stroke high speed operation.

The application of direct drive mechanical press:

The application of direct press in blanking, high speed production and shallow forming
operation.

The advantages:

1) The design is simple.

2) There are few a bearing and no gear wear out.
3) Frictional losses are lower than of mechanical geared and hydraulic presses.
4) The high operating speeds provide much greater productivity than geared presses.

The disadvantages:

1) The full rated force of the machine is available very close to the bottom of the stroke;
typically (1.524 mm) from bottom dead center.
2) The ability to deliver rated force is substantially reduced if the press is operated at less
than full speed.

Figure 5.2 direct single end drive

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5.2.2 SINGLE GEAR REDUCTION SINGLE END DRIVE

In single gear reduction presses, the flywheel is mounted on the back shaft and the power is
transmitted through a pinion to a main gear mounted on a crankshaft.

Single gear reduction presses typically operate in the speed range of 16 to 200 SPM, because
these presses utilize a gear reduction, with the flywheel on the high-speed back shaft.

The application of single gear drive:

The application of single gear drive in drawing and heavy forming operation.

The advantages:

1) More flywheel energy can be provided for a given flywheel weight than in a direct drive
press.
2) greater amount of flywheel energy provides greater torque capacity.

The disadvantages:

1) the low operating speeds.

2) Single gear drive presses are often built in larger sizes than direct presses.

Figure 5.3 single gear reduction single end drive press

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5.3. PRINCIPLE OF MECHANICAL PRESS MACHINE

• The clutch which transmits energy from the flywheel to the crankshaft or eccentric drive,
in some cases, through reduction gearing.
• The brake used to stop the press and hold the slide and attached mechanism in place.
• The flywheel, which stores the energy, supplied by the motor.
• The motor which furnishes energy to the flywheel.
• Gears where used to reduce the speed and increase the torque delivered by the flywheel
through the clutch.
• The pitman(s) or eccentric strap(s), which transmits the motion of the crankshaft or
eccentric drive to the slide by means of the connection.
• The connection, which connects the pitman to the slide (Ram) through a bearing.
• The slide or ram to which the upper die is fastened: it is guided by gibs attached to the
machine frame or housing.
• The adjusting screw located at each slide connection point.

Figure 5.4 principles of mechanical press machine

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5.4. COMPONENTS OF MECHANICAL PRESS

5.4.1 FLYWHEEL

the motor furnishes energy to the flywheel. Once the flywheel is up to speed and
not being cycled, the motor need only supply enough energy to make up for frictional
losses. The flywheel stores the energy until some is used to perform work

Torque Capacity

The press must have the ability to take the energy of the flywheel, and transmit it through
the clutch, gears (if a geared press), crankshaft, connection and slide to perform the
required work without exceeding the safe working capacity of any component. The
energy stored in the flywheel increases as the square of the flywheel rotational speed.
Thus, presses having variable speed drives vary greatly in the amount of flywheel
energy available depending upon the speed adjustment setting.

Reducing the flywheel speed reduces the total energy available. However, this does
not reduce the press tonnage capacity. The tonnage capacity is based on the strength of
the machine component parts.

When the flywheel speed is reduced below its standard rating, the flywheel energy is
reduced by the square of the speed reduction. Likewise, if the speed is increased, the
flywheel energy is increased by the square of the speed increase.

Figure 5.5 flywheel mechanism

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5.4.2 CLUTCHS AND BREAKS

Virtually all mechanical presses have a means to transmit the energy stored in the flywheel to
the press by means of a clutch mechanism. Otherwise, the press would cycle continuously
whenever power was applied to the flywheel. When the clutch is not engaged, the press is stopped
and held by a brake.

The clutch is a mechanism used to control the coupling of the flywheel (or gear on a geared press)
with the press crankshaft. Many older presses utilize a mechanical clutch, which is a full revolution
type. When a full revolution clutch is activated, it cannot be disengaged until the crankshaft has
made one complete revolution.

Most modern presses are equipped with an air friction clutch and brake arrangement that is
commonly called a partial revolution clutch. The partial revolution clutch can be disengaged at
any point in the stroke before the crankshaft has completed a full revolution.

A brake serves to stop and hold the press crankshaft or eccentric drive stationary when the clutch
is not engaged.

Figure 5.6 clutch mechanism

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5.4.3. CRANK SHAFTT

The force of the crank press is created by the torque transmitted to the crankshaft by the electric
drive, which consists of an electric motor, a flywheel, an insert coupling, a brake, and a reduction
gear through which the rotation is transmitted to the crankshaft. The electric motor turns the
flywheel and a torque moment is generated on the crankshaft because of the inertial force of the
flywheel.

Figure 5.7 crankshaft element

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 CHAPTER 6

ENAMEL PAINT

6.1. CRUNCHING PROCESS FOR ENAMEL

The duration of the stage ranges from 4 to 6 hours, the components of the single process of
the mill are weighed according to the weights set by the operations engineer, these components
are discharged into the mill and added to the water by a specific quantity by the process engineer.

The mill operates for a specific time according to the required roughness, Finally, roughness and
density are measured before unloading the enamel in their designated containers.

When measuring the roughness if it is greater than the limit allowed, the mill is run again and
added water gradually until the roughness reaches the limit allowed.

➢ Characteristics of enamel

• Enamel is assigned to spray process:

Density: 1.66 to 1.72

Roughness: 0.5 to 1

• Enamel is assigned to dousing:

Density: 1.66 to 1.72

Roughness: 2 to 5

6.2. THE TRATMENT PROCESS

Duration 35 minutes per box. First, the products are inspected from the defects of the sheet
then, Fill the products inside the treatment boxes that are entered on the three abrasive basins to
remove grease, oil and rust.

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 1. Hot rinsing basin at temperatures ranging from 70 to 90 degree.
2. Cold rinsing basin at temperature ranging from 20 to 25 degree.
3. A rust removal basin that contains on sulfuric acid diluted " H₂SO₄" at a temperature
ranging from 60-70 ° C, concentration of 6-10% and a concentration of 10% in case of high
rust.

Then, the treatment box is entered on two cold rinsing basins and has the same conditions as the
previous cold rinsing basin. Finally enter the box in the dryer basin at a temperature of 80-90
degree. After draying, the box is transferred to the paint stage.

Figure 6.1 Steps of treatment process

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6.3. PRODUCT SPRAYING AND IMMERSION PROCESS

Spraying process

Duration of the stage is 30 second, the components of the stove that are sprayed are the oven and
the surface of the stove.
There is more than one way to spray the sheet, one of them Installation of the sheet on the shelf
and after the spray of the sheet, the shelf enters to the dryer at a temperature of 150 to 200 co

Immersion process

The stage is 60 seconds, the shelf is immersed on enamel box then, the shelf is attached with
the chandler. Finally, the shelf enters to the dryer at a temperature of 150 to 200 co

Figure 6.2 steps of sheets spraying process

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6.4. CLEANING AND BURN THE SHEETS

Cleaning the sheets

The worker removes the extra enamel found in the form of a dot using a slate, taking care not to
touch the shelf completely so as not to deform the shelf before drying.

Burn the sheets

After the painted part of the dryer is released, the worker is transported by wire and placed on the
oven hanger, oven temperature 860 co and the belt speed is set at 2 to 2.2 m / s.

Figure 6.3 Burn the sheets

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6.5. EMBATTLING AND PACKAGING

Download the sheet from the oven hanger with the left wire suspension on the hanger as it
is, Check the sheet after the download and accept in case of defects

Finally, Fill the sheet inside the boxes and put the cardboard dividers between each sheet

Figure 6.4 Embattling and packaging of sheets

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 CHAPTER 7

MATERIAL OF STOVES

7.1. TYPES OF MATERIAL

There are three types of materials involved in the manufacture of the stove, they are sheet iron,
stainless steel and AK4

1. Sheet iron

Iron sheet is imported into the factory in the form of rollers, it is applied to the cutter
machine to cut the required size, and then take the sheet that has been cut into the presses for
the formation process.

After forming the sheet, the exposed parts for temperature, such as the oven box, are painted
with enamels on one side, the inside of the oven and the outside covered with thermal wool,
and also of the parts that can be made of the sheet is top facade.

Because the characteristics of enamel endure high temperatures and did not paint the sheet
from both sides to allow the exit of part of the heat in order to does not break enamel.

Figure 7.1 sheets iron rollers

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 2. Stainless

The stainless steel comes in the factory cut to the required measurements because there is no
scissor for cutting stainless steel.

If used in the sides of the pot is epoxy paint either when used in the upper interface is painted
enamel.

3. AK4 material

This materiel accepts enamel paint from both sides so it is used in internal oven components.

7.2. SOME COMPONENTS OF STOVE

• Gas Pipes

It is manufactured in another factory within Fresh factories, made of stainless steel.

• Gas Burner

It is manufactured from Brass or aluminium

Figure 7.2 Gas pipes and burner

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 CONCLUSION

I have benefited from this training in a lot of things, including the scientific things, I know

how to operate the mechanical press machine, hydraulic press machine, and I know a steps of the

enamel process and knew the types of materials used in the industry, I also knew how to treat the

workers in the factory and engineers and technicians and knew how to manage the factory.

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 REFERENCES

• http://www.employ.law/rest-breaks/

• N. Fisher. “Principles of Mechanical Power Presses”, SME Technical Paper MS76-285,

The Society of Manufacturing Engineers, Dearborn, Michigan, © 1976. The author, N.

Fisher, updates the material for public presentations

• Press, retrieved 2009-11-24.

• ^ Press Brake Tonnage Table, American Machine Tools Co. Web site

(http://www.americanmachinetools.com/pressure_table.htm). Retrieved 7-26-14.

• ^ Press Brakes, Pacific Press Technologies Web site (http://www.pacific-

press.com/brakes.html). Retrieved 7-26-14.

• https://www.journals.elsevier.com/process-safety-and-environmental-protection

• https://www.fresh.com.eg/

• Parr, Andrew (2011). "Hydraulics and Pneumatics a technician's and engineer's guide", p. 38.

Elsevier.

• https://en.wikipedia.org/wiki/Hydraulic_pump

• https://hardhatengineer.com/different-types-valves-used-piping/

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