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

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

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Manufacturing Processes Slide 2 Categories of processing methods: Casting Forming and shaping Machining Joining Finishing Slide 3 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 Slide 4 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 Slide 5 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 Slide 6 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. Slide 7 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 Slide 8 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. Slide 9 Joining / Fabrication Welding : 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 Slide 10 Manufacturing Processes Selecting a Manufacturing Process depends on: Size Thickness Shape Complexity Material Cost Slide 11 DFM considerations Slide 12 Save material in Stamping from stock sheet metal DFM considerations Slide 13 Save material in Stamping from stock sheet metalUniform cooling when heat treating Slide 14 DFM considerations Save material in Stamping from stock sheet metalUniform cooling when heat treating Overcome practical difficulty in grinding near a corner Slide 15 DFM considerations Save material in Stamping from stock sheet metalUniform cooling when heat treating Eliminate expensive reinforced weldOvercome practical difficulty in grinding near a corner Slide 16 DFM considerations Slide 17 Avoid flat bottom holes, give room for tool clearance and chips Slide 18 DFM considerations Avoid flat bottom holes, give room for tool clearance and chips Limit machining operations Slide 19 DFM considerations Avoid flat bottom holes, give room for tool clearance and chips Limit machining operations Sharp corners decrease the strength Slide 20 Sheet Metal Flat 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 Slide 21 Sheet Metal Calculate Bend Allowance for R = 0.075 inch Thickness T = 0.125 inch Angle N = 90 BA = (0.017453 x 0.075 + 0.0078 x 0.125 ) 90 = 0.20555775 0.2056 in.

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