manufacturing processes. categories of processing methods: – casting – forming and shaping –...

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Manufacturing Processes

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Page 1: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Manufacturing Processes

Page 2: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Manufacturing Processes

• Categories of processing methods:– Casting – Forming and shaping– Machining– Joining– Finishing

Page 3: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Casting

• Sand Casting: Engine blocks, cylinder heads, pump housings.

• Shell mold casting: Gear housings, connecting rods.

• Expandable pattern casting: Crankshafts, brake components, machine bases.

• Vacuum casting, Die casting, Slush casting……

Page 4: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Casting

• Plaster mold Casting: (High dimensional accuracy)

Locks, gears, valves, toolings.

• Ceramic mold Casting: (High dimensional accuracy) Impellers, cutters for machining, dies for metalworking.

• Investment Casting: (High dimensional accuracy) http://www.youtube.com/watch?v=BX8wGUPz1w&feature=related

Page 5: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Forming

• Rolling: plates ( 5 to 12 in thk), sheets (upto 6 mm thk) threads, seamless tubes and pipes.• Forging: Aircraft landing gear, jet engine shafts, structural components.

Changing the shape of an existing solid body

Page 6: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Forming

• Extrusion and Drawing: door and window frames, tubing, railings rods, shafts, wires. • Sheet metal forming: 1. Shearing 2. Bending metal desks, cabinets, car bodies, fuselage beverage cans.

Page 7: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

http://www.youtube.com/watch?v=qTUMbVNf1Xc&feature=related

http://www.youtube.com/watch?v=nA8y__BMl-o&feature=related

http://www.youtube.com/watch?v=q5Wlr6Co5SI

Sheet Metal

Page 8: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Machining

Cutting: Turning, Shaping, Milling, Drilling. http://www.youtube.com/watch?v=874DNEvCc-c

Abrasive: Grinding, Honing, Lapping, Buffing, Polishing.

Non-traditional: Electrochemical machining, laser beam machining.

Page 9: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Joining / FabricationWelding : Fusion welding: Plasma Arc, Electron beam.

Solid State: Resistance welding.http://www.youtube.com/watch?v=b2n_kpLXwY8

Brazing and Soldering

Adhesive bonding

Mechanical fastening

Page 10: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Manufacturing Processes

Selecting a Manufacturing Process depends on:

• Size• Thickness• Shape Complexity• Material• Cost

Page 11: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

DFM considerations

Page 12: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Save material in Stamping from stock sheet metal

DFM considerations

Page 13: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

DFM considerationsSave material in Stamping from stock sheet metal Uniform cooling when heat treating

Page 14: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

DFM considerationsSave material in Stamping from stock sheet metal Uniform cooling when heat treating

Overcome practical difficulty in grinding near a corner

Page 15: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

DFM considerationsSave material in Stamping from stock sheet metal Uniform cooling when heat treating

Eliminate expensive reinforced weldOvercome practical difficulty in grinding near a corner

Page 16: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

DFM considerations

Page 17: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

DFM considerationsAvoid flat bottom holes, give room for tool clearance and chips

Page 18: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

DFM considerationsAvoid flat bottom holes, give room for tool clearance and chips

Limit machining operations

Page 19: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

DFM considerationsAvoid flat bottom holes, give room for tool clearance and chips

Limit machining operations

Sharp corners decrease the strength

Page 20: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Sheet MetalFlat pattern Bend Final product

Compresses on the Inside, Stretches on the outside

Calculating length of Flattened pattern: Bend Allowance.

Empirical formula:BA = (0.017453 R + 0.0078 T) N

Where R = radius of bend T = metal thickness N = number of degrees of bend

Page 21: Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing

Sheet MetalCalculate Bend Allowance for

R = 0.075 inchThickness T = 0.125 inchAngle N = 90

BA = (0.017453 x 0.075 + 0.0078 x 0.125 ) 90 = 0.20555775 0.2056 in.