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Manufacturing Processes
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Manufacturing Processes
Categories of processing methods: Casting Forming and shaping Machining Joining Finishing
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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……
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Casting Locks, gears, valves, toolings.
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)
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Changing the shape of an existing solid body
Forming Changing the shape of an existing solid body 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.
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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.
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Sheet Metal http://www.youtube.com/watch?v=nA8y__BMl-o&feature=related
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Machining Cutting: Turning, Shaping, Milling, Drilling.
Abrasive: Grinding, Honing, Lapping, Buffing, Polishing. Non-traditional: Electrochemical machining, laser beam machining.
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Joining / Fabrication Welding : Brazing and Soldering Adhesive bonding
Fusion welding: Plasma Arc, Electron beam. Solid State: Resistance welding. Brazing and Soldering Adhesive bonding Mechanical fastening
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Manufacturing Processes
Selecting a Manufacturing Process depends on: Size Thickness Shape Complexity Material Cost
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DFM considerations
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DFM considerations Save material in Stamping from stock sheet metal
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DFM considerations Save material in Stamping from stock sheet metal
Uniform cooling when heat treating
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DFM considerations Save material in Stamping from stock sheet metal
Uniform cooling when heat treating Overcome practical difficulty in grinding near a corner
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DFM considerations Save material in Stamping from stock sheet metal
Uniform cooling when heat treating Overcome practical difficulty in grinding near a corner Eliminate expensive reinforced weld
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DFM considerations
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DFM considerations Avoid flat bottom holes, give room for tool clearance and chips
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DFM considerations Avoid flat bottom holes, give room for tool clearance and chips Limit machining operations
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DFM considerations Avoid flat bottom holes, give room for tool clearance and chips Limit machining operations Sharp corners decrease the strength
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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 = ( R T) N Where R = radius of bend T = metal thickness N = number of degrees of bend
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Sheet Metal Calculate Bend Allowance for R = 0.075 inch
Thickness T = inch Angle N = 90 BA = ( x x ) 90 = in.
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