group1_manufacturing process-class presentation

8/10/2019 Group1_Manufacturing Process-class Presentation

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Manufacturing process

Metal forming process

Metal removal process

Manufacturing systems and

Service Operations

By,

Sagar Bhore

Shenbagamoorthy M

Shubham Garg

Srajan Srivastava

Ratika Kapoor

Rahul Sarda1


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Manufacturing Process

Manufacture-derived from Latin Manu factuswhich means made by hand.

It is an industrial activity that changes the form of

raw material to create products.

Modern manufacturing includes all intermediate

processes required for the production and

integration of a product's components.

The production engineer should select themanufacturing process keeping in mind the needs

of the customer and at the same time with least

cost.

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Product Development

Parameters considered

while

designing

ManufacturabilityPerformance

Testability

Service

Quality

Cost

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Classification

ProcessedMaterial

Metallics

Polymers Ceramics

Glasses

Composites

Biomaterials

System ofOrganization

Discrete

Manufacturing Continuous

Manufacturing

Techniquesused

Solidification

Joining Plasticity

Cutting

Microstructurechange

CombinedProcess

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Casting

Casting, one of the oldest manufacturingprocesses, dates back to 4000 B.C. when copper

arrowheads were made.

Casting processes basically involve the

introduction of a molten metal into a mold cavity,

where upon solidification, the metal takes on the

shape of the mold cavity.

Sand CastingHigh Temperature Alloy,

Complex Geometry,

Rough Surface Finish

Investment CastingHigh Temperature Alloy,

Complex Geometry,Moderately Smooth Surface

Finish

Die CastingHigh Temperature Alloy,

Moderate Geometry,Smooth Surface

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Welding

Welding is a fabrication process that joinsmaterials, usually metals or thermoplastics, by

causing coalescence

Soldering and brazing involves melting a lower-

melting-point material between the workpieces to

form a bond between them, without melting the

workpieces.

Many different energy sources can be used for

welding, including a gas flame, an electric arc,

a laser, an electron beam, friction, and ultrasound.

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Metal Removal ProcessA part is created to its desired geometric

dimensions by the removal of excess materialfrom a work piece

A shearing force exerted through a certain cuttingtool

Qualities of a desirable manufacturing material

for this purpose would be:1) Lower Shear Strength (to make cutting easier)2) Shock Resistant (to withstand impact loading)3) Material must not have a tendency to stick tothe cutting tool

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Metal Removal Process

Machining can produce extreme dimensionalaccuracy, (tolerances of less than .001)

Machining accuracy allows it to produce surface

finish and smoothness that can't be achieved any

other way.

By combining different machining operations,

very complex parts can be made.

The removal process wastes material. Althougheconomical if the number of parts to be made is

small; labor, energy equipment, and scrap cost

are relatively high for large runs.

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The cutting tool is used to remove the materials from the work piece through t

The removed metal or the waste generated are called ChipsProper Tool Geometry should be selected for efficient operation and surface a

Oblique Cutting Orthogonal Cutting 2D Representation

Tool life is moreHeat generated will be more

Chip flows sideways

Tool life is lessHeat generated will be less

Chip coils in light flat spiral

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Speed (V)

-Relates velocity of the cutting tool to the work

piece

Feed (f)-Linear translation of tool per revolution with

respect to the work piece.

Depth of Cut (d)

-Distance the tool has plunged into the surface.

Material Removal Rate (MRR)

-Mass of material removed per unit machining time

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Material Removal Process

Conventionalmachining

Turning and related

operations

Drilling and related

operations

Milling

Other machining

operations (shaping,planing, broaching &

sawing)

Abrasiveprocesses

Nontraditional

machining

Grinding operations

Other abrasive

processes (honing,lapping & superfinishing)

Mechanical energy

process

Electrochemical

machining

Thermal energy

machining

Chemical machining11


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Turning

Facing:

Facing is the process of removing metal from the

end of a workpiece to produce a flat surface

Straight turning:

Work turned in a lathe so that the diameter is constant

over the length of the workpiece.

Taper turning :

An operation performed on a lathe that feeds a

tool at an angle to the length of the work piece in order

to create a conical shape

External grooving turning:

A method for removing the surface from a circular piece by bringing the cutting

edge of a tool against it while the piece is rotated.

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Turning

Roughing, or rough turning Finish turning13


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Drilling

Drillingis a cutting process that uses a drill bit to cut or enlarge a

hole of circular cross-section in solid materials.

The drill bit is a rotary cutting tool, often multipoint

The bit is pressed against the workpiece and rotated at rates from

hundreds to thousands of revolutions per minute

Drilling may affect the mechanical properties of the workpiece by

creating low residual stresses around the hole opening and a very

thin layer of highly stressed and disturbed material on the newly

formed surface

This causes the workpiece to become more susceptible to

corrosion at the stressed surface

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Drilling Operations

Reaming Tapping Counter Boring

Counter Sinking Centering Spot facing

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Boring In machining, boring is the process of enlarging a hole that has

already been drilled (or cast), by means of a single-point cutting

tool

Boring is used to achieve greater accuracy of the diameter of a

hole, and can be used to cut a tapered hole.

Boring can be viewed as the internal-diameter counterpart to

turning, which cuts external diameters

The boring bar may be supported on both ends (which only works if

the existing hole is a through hole), or it may be supported at one

end

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Milling

Milling is the most common form of machining, a material removal

process, which can create a variety of features on a part by

cutting away the unwanted material.

The cutting action of the many teeth around the milling cutter

provides a fast method of machining.

The machined surface may be flat, angular or curved. Thesurface may also be milled to any combination of shapes.

Milling machines are basically classified as Vertical or Horizontal.

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Types of Milling

Peripheral Milling Face

Milling This operation is also called plain millingoperation.

In this operation axis of rotating tool is

always kept parallel to the surface being

machined.

This operation is done by the cuttingedges on outside periphery of the milling

In the operation of face milling,axis of the milling cutter remains

perpendicular to the surface

being milled.

In this case cutting action is

done by end and outside of the

periphery18


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Peripheral Milling

Face Milling

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Other forms of milling

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Broaching

Broaching is a machining process for removal of a

layer of material of desired width and depth usually in

one stroke by a slender rod or bar type cutter having a

series of cutting edges with gradually increased

protrusion.

Broaching enables remove the whole material in one

stroke only by the gradually rising teeth of the cutter

called broach.

Commonly machined surfaces include circular and

non-circular holes, splines, keyways, and flat

surfaces.21


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Broaching

There are two main types of broaching: linear and rotary

In linear broaching, which is the more common process, the broach is

run linearly against a surface of the workpiece to effect the cut.

Linear broaches are used in a broaching machine, which is also

sometimes shortened to broach.

In rotary broaching, the broach is rotated and pressed into the

workpiece to cut an axis symmetric shape.

A rotary broach is used in a lathe or screw machine.22
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Broaching

Major advantages

Very high production rate (much higher than milling, planing, boring

etc.)

High dimensional and form accuracy and surface finish of the product

Roughing and finishing in single stroke of the same cutter

Needs only one motion (cutting), so design, construction, operationand control are simpler

Extremely suitable and economic for mass production

Limitations

Only through holes and surfaces can be machined

Usable only for light cuts, i.e. low chip load and unhard materials

Cutting speed cannot be high

Design, manufacture and restoration of the broaches are difficult and

expensive

Separate broach has to be procured and used whenever size, shapeand geometry of the job changes23


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SawingSawing is used to cut the correct sized work piece from a large

raw material stock and it is the first operation in manufacturing

There are several types of saws :

Hacksaws: straight blade, moving in a reciprocating motion;

Bandsaws: straight blade, ends welded together to make a loop,

moving continuously in one direction

Circular saws: blade in the shape of a circular disk, rotatingcontinuously.

Types of saws24


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Sawing Actions

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chip

slidetool-postpivot

chip

tool-post rotates as

slide returns;

workpiece shifted;

next stroke

(a) (b) (c)

chipchip

slidetool-postpivot

slidetool-postpivot

chip


slide returns;

workpiece shifted;

next stroke

chip


slide returns;

workpiece shifted;

next stroke

(a) (b) (c)

Shaping uses a single-point tool that is moved horizontally in a reciprocating

motion along a slide.

The ram holding the tool gets the reciprocating movement.

It is used to create a planar surface, usually to prepare rectangular blocks

that can later be used as workpieces for machining on a milling machine etc.

Shaping machine and shaping operation

Shaping

The planer like a shaper is a machine tool primarily intended to produce plane

and fiat surfaces by a single point cutting tool.

A planer is very large and massive compared to a shaper and capable of

machining heavy workpieces which cannot be accommodated on a shaper

Planing

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Grinding

The grinding operation involvesforcing a rotating abrasive Grinding

Wheel into a Workpiece.

This has proven to be the best

method for removing material in amanner which leaves a precision

surface.

The grinding operation is the final

machining process used to produce

precision Workpieces.Because of its high cost, the

grinding operation should be done as

efficiently as possible.Centreless Grinding

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Honing

Honing is a surface finishing operation based onabrasive action performed by a set of bonded

abrasive sticks.

It is generally used to finish bores of cylinders of

IC engine, hydraulic cylinders, gas barrels,bearings, etc.

It can reduce the level of surface roughness

below 32 m.

It produces a characteristics surface pattern

ascross hatched which is a fit case to retain

lubrication layer to facilitate motion to moving

parts28


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Metal Forming process

A group of manufacturing processes in which thematerial is shaped to a certain geometry by

applying external forces large enough to cause a

permanent deformation.

The deformed material experienced plasticdeformation, i.e. it will not return to its original

shape after the forces are released.

The external forces can be in the the form of

compression, tension, torsion, shearing,

bending,drawing or a combination of the various

forces.

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Hot Working and Cold Working

Hot working refers to theprocess where metals aredefromed above theirrecrystallizatontempereture and strainhardening does not

occur. Lower working forces to

produce a given shape,which means themachines involved don'thave to be as strong,which means they can bebuilt more cheaply

Hot working can removesome kinds of defectsthat occur in cast metals

Plastic deformationwhich is carried out ina temperature regionand over a timeinterval such that the

strain hardening is notrelieved is called coldworking.

A better surface finishmaybe achieved

Dimensional accuracycan be excellentbecause the work isnot hot so it doesn'tshrink on cooling

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Metal Forming process

Sheet

Sheet metal forming

Vacuum forming

Blow moulding

Drawing

Bulk

Powder

Forging

Rolling

Slip Casting

Pressing and

sintering

Isostatic pressing

Extrusion

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Metal RollingBasic Principle

The work material isplastically deformed bycompressive forces betweentwo constantly spinning rolls

Reduction in thicknesscalled draft

Shape changes but volumeremains constant

Point in the roll zone where

the surface velocity of therolls and that of the materialare exactly the same iscalled the no slip point

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Direction of spin of the rolls can be

reversed

Enables the work to travel throughin one direction, then back through

in the other direction

Disadvantage - mechanical

requirements and power to

constantly overcome and reversethe angular momentum of the rolls

Three rolls that

always spin in thesame direction

An elevatormechanism lifts andlowers the work sothat it can be

passed back andforth through the

Roll force isreduced with asmaller radius ofthe rolls

Smaller radiusrolls deflecteasier and mustbe supported by

other rolls

Two High Rolling Millree g o ng

Millour g o ng

Mill

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Uses a small work roll backedup by many other rolls

Often used for cold rolling high

strength material to a very thin

width

Consists of several stands that the

work material constantly passesthrough

The total reduction between the

first and last stand is significant

Technical problems caused by the

speed of the work material

increasing as it passes through

Cluster Milling Tandem Rolling Mill

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Rotary Tube Piercing

Hot forming process

Compressive forcesapplied to a cylindercreate internal stresses

at the center The mandrel shaped

rolls rotate in the samedirection and are

oriented at an axis thatis at a slightly skewedangle to the axis of thepart causing the stockto be pulled through therolls forcing it against36


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Forging is a manufacturing process that involves

applying compressive forces to a work piece to

deform it, and create a desired geometric change

to the material.

Forging, similar to other forming processes,

effects the properties of the material of the forgedproduct.

Specifically, forging can strengthen the material by

eliminating cracks and empty spaces within the

metal. Forging a metal will also alter the metal's grain

structure with respect to the flow of the material

during its deformation.

Forging

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Open Die Forging

In an upsetting process the

work is placed between two

flat die and its height is

decreased by compressive

forces exerted between the

two die.

Since the volume of a metal

will remain constant

throughout its deformation, a

reduction in height will be

accompanied by an increase

Flat or slightly contoured die

are used to compress a work

piece, reducing its thickness

and increasing its length.

After each compression of

the material the open die

advance along the length of

the work piece and perform

another forging compression.

UPSETTING COGGING

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O Di F i


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Open die with convex

surfaces are used to deform

the work piece.

The result is to causematerial to flow out of one

area and to both sides.

In edging, open die with

concave surfaces plastically

deform the work material.

Edging acts to causematerial to flow into an area

from both sides.

Edging and fullering both are

used to redistribute bulk

quantities of the forging'smaterial.

Open Die ForgingFULLERING EDGING

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Impression die forging Impression die forging manufacture involves

compression of a work piece by the use of

impression die, (molds), that contain cavities that actto restrict the flow of metal within the die during thedeformation of the work

The material will fill the space within the die cavity asit is plastically compressed into the molds.

Closing of the molds completes the deformation,hence impression forging is also referred to asclosed die forging.

The forged metal part will now have the geometricdimensions of the mold, provided a complete filling ofthe die cavity occurred during the process.

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Heading

A process by which

stock is upset at its

end in order to

increase the cross

section of the materialin this area

Used for producing

fasteners that include

nails, screws, nuts

and bolts

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Roll Forging

Roll forging is a forming technique that

utilizes opposing rolls to shape a metalpart.

Even though roll forging uses rolls in

order to accomplish the deformation of

the material it is classified as a forging

process and not a rolling process. Moresimilarly to forging than rolling, it is a

discrete process and not a continuous

one.

Roll forging is usually performed hot.

Applications : Majorly used in

automotive industry

Products : Shaft of various geometrics,

knives, hand tools, leaf springs

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Sizing

Sizing is a forging process thatis used mainly to finish work thathas already been manufactured.

It is a cold forming process.

Sizing uses a lot of force over a

short distance producing veryaccurate dimensions in thefinishing of these parts. Thismanufacturing technique canalso be used to create work withexcellent surface quality.

Sizing is characteristic in thatduring the operation, the flow ofwork material is unrestricted inall directions except that overwhich the force is applied.

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Piercing

Piercing is a forming technique that isoften performed as an auxiliary

process in conjunction with other

forging processes, in the

manufacture of a part.

It can be used to create a cavity orhole in the work piece. Piercing does

not break through the material's

surface, like a drilling operation but

cavity is pressed into the work thats

why it is a forging operation.

Piercing will effect the properties ofthe work material, and change the

grain structure of the part.

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Swaging

Swaging is a forming method of reducing aregular or irregular cross section area of tube, bar

or wire using two or more dies which surround the

outside of the work-piece completely or partially,

to a round predetermined diameter. It is usually cold working process but sometimes

may done as a hot working process

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Hobbing Hobbing is a cold working, forging process in which a punch

with an exact geometry at its end is pressed into a workpiece.

The special punch, called a hob, will create a cavity with theprecise dimensions desired.

Due to the high tolerances of the hob, the high pressuresapplied during the manufacturing process, and the fact that

the operation is performed cold, very accurate dimensionsand surface quality are obtained within the cavity.

A common application of hobbing in modern industry is toproduce molds or die cavities for other manufacturingoperations

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Skew Rolling

A process typically used formaking ball bearings

A round wire or rod stock is

fed into the roll gap and

spherical blanks are formedby the continuous rotating

rolls

The balls are then ground

and polished

This process is hot metal

process

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Drawing
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Drawing is an operation in which the cross-section of solid rod, wire ortubing is reduced or changed in shape by pulling it through a die.

The principle of this procedure consist of reducing the thickness of apointed ,tapered wire by drawing it through a conical opening in a toolmade of a hard material.The wire will take shape of the hole.

Drawing

This process is widely used for the production of thicker walled

seamless tubes and cylinders therefore; shafts, spindles, and small

pistons and as the raw material for fasteners such as rivets, bolts,

screws.

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E t i


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Extrusion

In extrusion, the workpiece is placed in a container andcompressed until pressure inside the metal reaches

flowstress levels.

The workpiece completely fills the container and additional

pressure causes it to travel through an orifice and form the

extruded product.

Extrusion can be forward (direct) or backward (reverse),

depending on the direction of motion between ram and

extruded product.

Extruded product can be solid or hollow.

Tube extrusion is typical of forward extrusion of hollow

shapes, and backward extrusion is used for mass

production of containers.50
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