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Manufacturing Materials and Processes
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Learning Objectives Define and describe given manufacturing materials, material terminology, numbering systems, and material treatment Describe steel and aluminum material selection characteristics Explain sustainability applications for steel and aluminum processing and manufacturing
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Learning Objectives Identify a variety of manufacturing processes used to create plastic products Explain sustainability applications for plastics processing and manufacturing Discuss casting processes and terminology Explain the forging process and terminology
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Learning Objectives Describe manufacturing processes
Define the representation of various machined features Explain tool design practices Discuss the statistical process quality control assurance system
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Learning Objectives Evaluate the results of an engineering and manufacturing problem Explain the use of computer-aided manufacturing (CAM) in industry Discuss robotics in industry
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Ferrous Metals Contain iron Cast iron Steel
Alloy containing 1.7% to 4.5% carbon Varying amounts of silicon, manganese, phosphorus, and sulfur Steel Alloy containing 0.8% to 1.5% carbon
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Gray Cast Iron 1.7% to 4.5% carbon 1% to 3% silicon
Easy to cast and machine Popular for: Automotive cylinder blocks Machine tools Agricultural implements Cast iron pipe
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White Cast Iron Extremely hard and brittle Almost no ductility
Highly resistant to wear
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Chilled Gray Cast Iron Creates outer surface of white cast iron
Internal characteristics of gray cast iron Surface advantage of white cast iron
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Alloy Cast Iron Nickel, chromium, molybdenum, copper, or manganese alloy Increased: Strength Wear resistance Corrosion resistance Heat resistance
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Malleable Cast Iron Heat-treated white cast iron Strong Ductile
Shock-resistant Easy to machine
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Nodular Cast Iron Special casting process Magnesium or cerium alloy
Strong Ductile Can be chilled
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Mild steel (MS) Less than 0.3% carbon Cannot be hardened
Common for forged and machined parts
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Medium Carbon Steel 0.3% to 0.6% carbon Harder than mild steel
Easy to forge and machine
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High Carbon Steel 0.6% to 1.50% carbon
Can be hardened by heat treating Difficult to forge, machine, or weld
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Hot-Rolled Steel (HRS)
Formed between rollers or forged when red-hot Consistent grain structure Strong Ductile
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Cold-Rolled Steel (CRS)
Additional forming after initial hot rolling Smooth, clean surface Ensures dimensional accuracy Increases tensile strength
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Steel Alloys Chromium Manganese Molybdenum Tungsten Carbon Vanadium
Corrosion resistant Wear resistant Manganese Strong Molybdenum Heat resistance Non-brittle Tungsten Hard for cutting tools Carbon Vanadium Tough Strong Non-brittle
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Steel Castings Generally stronger and tougher than cast iron
Common for machine parts
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Stainless Steel Generally at least 10.5% chromium
Excellent corrosion resistance Oxidation resistant Heat resistant Strong
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Stainless Steel Applications
Restaurant and hospital equipment Architectural and marine applications Some aircraft applications Consumer products
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Steel Numbering Systems
American Iron and Steel Institute (AISI) Society of Automotive Engineers (SAE) Example: SAE 1020 10: type of steel 20: approximate amount of carbon (0.20% carbon) Added letter between the first and second pair of numbers
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Heat Treating Steel Heating followed by quenching hardens steel
Case hardening Hardens the surface layer by carburization, often followed by quenching Tempering Annealing
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Hardness Testing Brinell test Rockwell hardness test
Brinell Hardness Number (BHN) Rockwell hardness test Example note: CASE HARDEN 58 PER ROCKWELL āCā SCALE.
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Nonferrous metals No iron content Copper Aluminum
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Aluminum Corrosion resistant Lightweight Easily cast
Conducts heat and electricity Easily extruded Very malleable
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Aluminum Alloy Numbering
Various designations Example: 1030 1: 99% pure 0: no control of specific impurities 30: 99.30% aluminum
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Copper Alloys Easily rolled and drawn into wire
Excellent corrosion resistance Great electrical conductor Better ductility than any metal except for silver and gold
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Brass Alloy of copper (about 90%) and zinc (about 10% zinc)
Corrosion resistant Strong Ductile
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Bronze Alloy of copper and tin Phosphor bronze Tin increases: Hardness
Wear resistance Phosphor bronze
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Precious and Other Specialty Metals
Gold Silver Platinum Columbium Titanium Tungsten
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Metallurgy Practical use of metals and metalworking
Production of metal components for use in products Alloy development Material shaping Heat treatment Surface treatment
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Plastics and Polymers Polymerization Often molded into shape
Machined for tight tolerance situations or when holes or other features are required Gears Pinions Society of the Plastics Industry, Inc. (SPI) identification coding system
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Thermoplastics Heated and formed by pressure to a desired shape
Reheating changes the shape Used for most plastic products
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Thermoplastics Thousands of different thermoplastic combinations for specific applications Common examples: Acrylic Acrylonitrile-butadiene-styrene (ABS) Polyamide (nylon) Polyethylene Polypropylene Polyesters
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Thermosets Heated and formed by pressure to a permanent shape
Cannot be altered by heating after curing Used when heat exists More rigid and harder than thermoplastics About 15% of plastics Expensive Brittle Cannot be reformed
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Common Thermosets Alkyds Melamine formaldehyde Phenolics
Unsaturated polyesters Urea formaldehyde
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Elastomers Stretch at least equal to their original length and return to their original length Rubber Occurs naturally in a number of plants Produced synthetically Almost twice as many products as natural rubber
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Common Elastomers Many different elastomers for specific applications
Butyl rubber Chloroprene rubber (Neoprene) Nitrile rubber Polyurethane Silicones
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Inorganic Materials Carbon Graphite Can be molded by pressure
Low tensile strength High compressive strength
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Inorganic Materials Ceramics Hard Brittle
Resistant to heat, chemicals, and corrosion
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Inorganic Materials Clay Glass Refractory Inorganic cements
Used for high-temperature applications Inorganic cements
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Composites Reinforced plastics
Polymers combined with reinforcing material Glass Graphite Thermoplastic fibers Cotton Paper Metal
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Material Selection Typically occurs during initial design or redesign
Requires knowledge of: Material properties, characteristics, cost, and availability Manufacturing processes and costs Part geometry External and internal forces applied to the parts and the assembly Product use and appearance Environmental considerations and sustainability
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Castings The result of founding
A pattern is constructed that is the same shape as the desired finished product A mold is made by packing sand or other material around the pattern The pattern is removed from the mold and molten metal is poured into the hollow cavity
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Sand Casting Most commonly used method of making castings
Two general types: Green sand Dry sand
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Cores Baked clean sand mixed with binders, or Ceramic products
Reduce casting weight Save on machining costs
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Centrifugal Casting No cores needed
Objects with circular or cylindrical shapes Tubing Pipes Wheels
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Die Casting Nonferrous metal castings Quick and economic
Zinc alloy Brass Bronze Aluminum Quick and economic Fine detail and smooth finish
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Permanent Casting Similar to sand casting and die casting
The mold can be used many times Good finished qualities
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Investment Casting
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Forgings Hot or cold materials
Material retains original grain structure Strong and ductile
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Forging Methods Hand forging Machine forging Smithing Blacksmithing
Upset Swaging Bending Punching Cutting Welding
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Metal Stamping Uses a punch press
Holes created by punching through material Mass production Example: Automobile body panels
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Hydroforming Tube hydroforming Sheet hydroforming
High strength-to-weight ratios Can be more economical than metal stamping
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Powder Metallurgy (PM)
Uses metal-alloyed powders Compacted under pressure in a die Sintered Metal Injection Molding (MIM) Powder Forging (PF) Quality, precision parts Mass production
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Machine Processes Machining Machine tools Machinist
Used to manufacture metal and some plastic products Machine tools Machinist
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Drilling Machine (Drill Press)
Machine-drill holes Reaming Boring Counterboring Countersinking Tapping
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Grinding Machine Grinding Honing Lapping
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Lathe Cut material by turning cylindrically shaped objects
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Screw Machine Type of lathe Mass-production
Variety of small turned parts Screws Threaded parts
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Milling Machines Horizontal mill Vertical mill
Work fastened to a table Rotary cutting tool removes material Large variety of milling cutters End milling cutters
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Milling Machines
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Milling Machines Universal Milling Machine Multiaxis Milling Machines
Table action includes x-, y-, and z-axis movement plus angular rotation Multiaxis Milling Machines CNC tools that move in four or more directions
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Saw Machines Power hacksaw Band saw
Circular abrasive or metal cutting wheels Cut material to length Machining operations Kerf
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Water-Jet Cutting Cut almost any material
Cut material as thick as 12 in. (305 mm) or more Hold fine tolerances Do not produce a heat-affected zone
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Shaper Horizontal, vertical, or angular flat surfaces
Being replaced by milling machines Slow Cuts only in one direction
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Chemical Machining Uses chemicals to remove material accurately
Electrochemical machining (ECM) Electrodischarge machining (EDM) Electron beam (EB) cutting and machining Ultrasonic machining Laser machining
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Drill Features on a Drawing
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Ream Features on a Drawing
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Bore Features on a Drawing
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Counterbore Features on a Drawing
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Countersink Features on a Drawing
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Counterdrill Features on a Drawing
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Spotface Features on a Drawing
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Chamfer Features on a Drawing
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Fillet and Round Features on a Drawing
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Key, Keyseat, Keyway on a Drawing
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Threads on a Drawing Many different forms of threads
Fasteners to hold parts together Adjust parts in alignment Transmit power
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Knurl on a Drawing
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Surface Texture (Surface Finish)
Roughness Waviness Lay Flaws
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Additional Features Boss Lug Pad Dovetail Kerf Neck Spline T-slot
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Injection Molding Process
Most common process for creating thermoplastic products
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Extrusion Process Continuous shapes: moldings, tubing, bars, angles
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Blow Molding Process Hollow products: bottles, containers
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Calendering Process Thermoplastic or thermoset plastics pass through a series of heated rollers Sheet products Vinyl flooring Gaskets
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Rotational Molding Process
Polymer pellets in a heated, rotating metal mold Rotation forms a thin coating against the sides of the mold Large hollow objects Tanks Containers Floats
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Solid Phase Forming Process
Detailed shapes: containers, electrical housings, automotive parts
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Thermoforming of Plastic
Similar to solid phase forming, but does not use a die Thin-walled shapes Containers Guards Fenders
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Free-Form Fabrication (FFF) of Plastic
Rapid prototyping Stereolithography 3-D Printing
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Casting Thermoset Plastics
Similar to permanent casting of metals
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Compression Molding and Transfer Molding
Common for thermosets Uses a mold, specific amount of heated material, additional heat, and pressure
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Foam Molding and Reaction Injection Molding
Similar to casting, but uses an expanding foam material
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Vulcanization Process
Rubber products such as tires
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Manufacturing Composites
Layering process Compression molding of composites Resin transfer molding Vacuum bag forming
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Rapid Prototyping (RP)
Stereolithography (SLA) Computer controlled ultraviolet laser beam hardens a photo-curable liquid resin Fused deposition modeling (FDM) CNC extruder-head squeezes a fine filament of melted thermoplastic through a nozzle 3-D printing Print head dispenses a thermoplastic material in layers
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Jig and Fixture Prints Machining operations require special tools to hold the workpiece or guide the machine tool Kinematics
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Computer-Integrated Manufacturing (CIM)
Computer and software controls most, if not all, portions of manufacturing Brings together: Computer-Aided Design and Drafting (CADD) Computer-Aided Engineering (CAE) Computer Numerical Control (CNC) Computer-Aided Manufacturing (CAM) Computer-Aided Quality Control (CAQC) Robotics
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CAD/CAM integration A direct link between the design and manufacture of a product CAD used to create product geometry 2-D multiview drawings 3-D models CAM generates instructions for CNC machine tools Stamping Cutting Burning Bending Other operations
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Statistical Process Control (SPC)
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