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Casing & Compressor of Air Conditioner

The document discusses different components of an air conditioner's outdoor unit and compressor. It describes the casing of the outdoor unit, which uses die casting for its material and manufacturing process. It also discusses the compressor's piston, scroll, balance plate, and connecting tube. The piston uses hydrostatic extrusion and forging. The scroll and balance plate use flashless forging. And the connecting tube uses cold direct extrusion. The document analyzes the advantages and disadvantages of each manufacturing process and justifies their use for the particular component.

Uploaded by

Abdullah Zakirin Abdul 'Azam
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© Attribution Non-Commercial (BY-NC)
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109 views22 pages

Casing & Compressor of Air Conditioner

The document discusses different components of an air conditioner's outdoor unit and compressor. It describes the casing of the outdoor unit, which uses die casting for its material and manufacturing process. It also discusses the compressor's piston, scroll, balance plate, and connecting tube. The piston uses hydrostatic extrusion and forging. The scroll and balance plate use flashless forging. And the connecting tube uses cold direct extrusion. The document analyzes the advantages and disadvantages of each manufacturing process and justifies their use for the particular component.

Uploaded by

Abdullah Zakirin Abdul 'Azam
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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CASING

&
COMPRESSOR OF
AIR CONDITIONER
INTRODUCTION

CASING OF AIR CONDITIONER (OUTDOOR UNIT)


Protection to the electric components inside the outdoor
unit of an air conditioner

COMPRESSOR OF AIR CONDITIONER


Used to compress the refrigerant in the refrigerating cycle
and increases energy and temperature of refrigerant.
CASING OF AIR
CONDITIONER (OUTDOOR
UNIT)
1) CASING OF AN AIR CONDITIONER
(OUTDOOR UNIT)

MATERIAL SELECTION
Material chosen: Aluminium alloy
This material is corrosion resistant.
MANUFACTURING PROCESSES FOR CASING OF
AN AIR CONDITIONER
IDENTIFICATION
1) Die Casting
Is a permanent-mold casting in which the molten metal is
injected to the mold cavity under the high pressure.There are types
of die casting ; 1)Hot chamber 2)Cold chamber(more suitable)
2) Sheet metal working
Sheet-metal processing is performed at room temperature (cold working).
There are 3 majors categories of sheet-metal processes ; 1)Cutting 2)Bending
3)Drawing

Cutting Bending Drawing


DISCUSSION
1) The advantages and disadvantages die casting(cold chamber) are shown below:

Advantages of die casting (cold chamber) Disadvantages of die casting (cold


chamber)

1)Higher production rates 1)Part produced has lower strength than that
2)Economical for large production produced by sheet-metal working process
3)Reasonable to good surface finish 2)Poorer dimensional accuracy
4)Lower scrap
5)Lower tooling cost
2) The advantages and disadvantages of sheet metal working are shown below:

Advantages of sheet metal working Disadvantages of sheet metal working


1) Higher strength 1) Time consuming
2) Good dimensional accuracy 2) Higher tooling cost
3) Good surface finish 3) Wasteful of material
4) Need high labor skill
JUSTIFICATION
1) Die casting (cold chamber) is chosen to produced outdoor unit
casing of air conditioner.
2) Casing of an air conditioner is just a protecting shield which
very high strength is not required.
3) This process involves lower tooling cost and higher production
rate.
4) Die casting process involved less material waste which also
contributes lower production cost.
COMPRESSOR OF AIR
CONDITIONER

Example of compressor parts are:


1) Piston
2) Compressor Scroll
3) Balance Plate
4) Connecting Tube
1) PISTON OF AIR CONDITIONER
COMPRESSOR

MATERIAL SELECTION
Material chosen: SiCp or Al-Si ( types of metal matrix composites materials).
These materials have high strength, good wear resistance and light weight.
MANUFACTURING PROCESSES FOR PISTON OF
AIR CONDITIONER COMPRESSOR
IDENTIFICATION
1) Hydrostatic extrusion followed by impression-die forging
Bar is produced by hydrostatic extrusion.
The extruded bar is warm-forged at temperature of 400oC to final shape by
impression-die forging process.
Flash is trimmed off to get final product.
2) Sand casting
Molten alloy is poured into a sand mold having the shape of a piston.
When alloy had solidified, it is removed from the mold.

DISCUSSION
1) The advantages and disadvantages of both hydrostatic extrusion and
impression-die forging are shown below:

Advantages of hydrostatic extrusion disadvantages of hydrostatic extrusion


and impression-die forging and impression-die forging

1) Part produced is more ductile 1) Higher tooling cost


2) Higher strength
3) Higher production rate
2) The advantages and disadvantages of sand casting are shown below:

Advantages of sand casting Disadvantages of sand casting


1) Low tooling and production cost 1) Rough surface produced
2) Part produced is in net shape 2) Close tolerances are difficult to
achieve
3) Poor dimensional accuracy
4) Low strength
5) Time consuming
JUSTIFICATION
1) Hydrostatic extrusion followed impression-die forging are chosen as the
manufacturing process for air conditioner compressor piston.
2) Piston of an air conditioner compressor required high ductility, strength to
function without failure and both processes will increase the ductility and
strength of the part produced.
3) These processes provide higher production rate and lead to reduction of
production cost.
2) AIR COMPRESSOR SCROLL & BALANCE
PLATE

MATERIAL SELECTION
Air compressor scroll
Material chosen: Aluminium alloy
This material is light and corrosion resistant.
Balance plate
Material chosen: No magnet stainless steel.
This material is high strength.
MANUFACTURING PROCESSES FOR AIR
COMPRESSOR SCROLL AND BALANCE PLATE
IDENTIFICATION
1) Flashless forging
Carried out in an elevated temperature which in between cold and hot forging.
Warmed work piece is compressed between a punch and a die having the shape
of the compressor scroll or balance plate until deformation occurs.
2) Sand casting
Molten metal alloy is poured into the mold which has pattern of compressor
scroll or balance plate and let to solidify.
Casting is removed from the sand mold after solidified.

DISCUSSION
1) The advantages and disadvantages of flashless forging are shown below:

Advantages of flashless forging Disadvantages of flashless forging

1)Part produced is more ductile 1) Higher tooling cost due to complex


2)Higher strength die shape
3)Higher production rate
4)Little or no material is wasted
5)Produced part are in net shape
2) The advantages and disadvantages of sand casting are shown below:

Advantages of sand casting Disadvantages of sand casting


1) Low tooling and production cost 1) Rougher surface produced
2) Part produced is in net shape 2) Close tolerances are difficult to
achieve
3) Poor dimensional accuracy
4) Low strength
5) Time consuming

JUSTIFICATION
1) Flashless forging is chosen as the manufacturing process for air
compressor scroll and balance plate.
2) High strength and ductility are important for these parts. This process will
increase the ductility and strength of the part produced.
3) This process is also more economical due to higher production rate and
less waste of material.
3) CONNECTING TUBE

MATERIAL SELECTION
Material chosen: stainless steel
This material have very high corrosion and strength which needed
for connecting tube production.
MANUFACTURING PROCESS FOR CONNECTING
TUBE OF AIR CONDITIONER COMPRESSOR
IDENTIFICATION
1) Cold direct extrusion followed by machining
The billet is place in the container
The ram will push the billet
The shape of the final work is determine by the mandrel
2. Sand casting
Molten alloy poured into sand mold
After the casting had solidified, it is removed from the mold

DISCUSSION
1) The advantages and disadvantages of cold direct extrusion are shown below:

Advantages of cold direct extrusion Disadvantages of cold direct extrusion

1) Higher strength 1) Higher tooling and processing cost


2) Close tolerances
3) Less material waste
4) Good surface finish
5) Higher production rate
2) The advantages and disadvantages of sand casting are shown below:

Advantage of sand casting Disadvantage of sand casting


1) Lower production cost 1) Lower strength
2) Part produced is in net shape 2) Poor dimensional accuracy
3) Produced low surface quality
4) Lower production rate

JUSTIFICATION
1) Cold direct extrusion is chosen as manufacturing process for connecting tube of
air conditioner
2) Connecting tube require high strength to function
3) Cold direct extrusion more economical with less waste material and high
production rate
CONCLUSION

1) Outdoor unit casing of an air conditioner - die casting process


2) Air conditioner compressor piston - hydrostatic extrusion followed by impressed-
die forging.
3) Compressor scroll and balance plate - flashless forging
4) Connecting tube - cold direct extrusion.
 

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