1. Manufacturing Processes Punching A metal forming process that uses a press to force a tool through the workpiece to create a hole via shearing. Used to make bicycle chains, bolts, and various metal rings Die Casting Forces molten metal under high pressure into a mold cavity Used to make gearbox housing, oil pans, cylinder head covers Hot Pressing Simultaneous application of heat and pressure to powder creates hard, brittle material Used to make cutting tools, brake pads, clutch discs 2/3/20141 Keith Lee – kmlee@clemson.edukmlee@clemson.edu

2. Patents 2/3/20142 Punching Die CastingHot Pressing Keith Lee – kmlee@clemson.edukmlee@clemson.edu

3. 2/3/20143 Punching http://en.wikipedia.org/wiki/Punchinghttp://en.wikipedia.org/wiki/Punching 2/3/2014 - Most cost effective process of making holes in strip or sheet metal for average to high fabrication - Very quick process http://www.thefabricator.com/article/punching/the-formula-for-successful-punchinghttp://www.thefabricator.com/article/punching/the-formula-for-successful-punching 2/3/2014 - Four essential components: punch, stripper, die, and tool holder system - Optimizing the die clearance is a very important part of punching success http://www.manufacturelink.com.au/processes/fabrication-punching.aspxhttp://www.manufacturelink.com.au/processes/fabrication-punching.aspx 2/3/2014 - Punched material is most normally in sheets, but rolled material can also be punched - Some machines are able to change punches during the operation to punch different sized holes in the same piece Die Casting http://en.wikipedia.org/wiki/Die_castinghttp://en.wikipedia.org/wiki/Die_casting 2/3/2014 - Excellent dimensional accuracy (between.1 and.02 mm) - Casting tensile strength as high as 60 ksi http://diecasting.org/faqhttp://diecasting.org/faq 2/3/2014 - High speed production - Multiple finishing techniques available http://www.custompartnet.com/wu/die-castinghttp://www.custompartnet.com/wu/die-casting 2/3/2014 - Can produce geometrically complex parts - Reusable molds help reduce production costs Hot Pressing http://en.wikipedia.org/wiki/Hot_pressinghttp://en.wikipedia.org/wiki/Hot_pressing 2/3/2014 - Heats metal powder into a mold - Largely used to create diamond-metal composite cutting tools and technical ceramics http://www.bodycote.com/services/hot-isostatic-pressing/isostatic-pressing-services/hot-isostatic-pressing.aspxhttp://www.bodycote.com/services/hot-isostatic-pressing/isostatic-pressing-services/hot-isostatic-pressing.aspx 2/3/2014 - Enables blends of metal powder to be combined into solids that other processes can not achieve - Eliminates all internal voids in castings http://technoman.hubpages.com/hub/Isostatic-Pressinghttp://technoman.hubpages.com/hub/Isostatic-Pressing 2/3/2014 - Heat and pressure are applied simultaneously - The process must be closed from the atmosphere so that oxide films can be avoided Keith Lee – kmlee@clemson.edukmlee@clemson.edu

4. Summary Punching is the most cost effective way to make holes Die casting is fast and has high dimensional accuracy Hot pressing easily combines different types of metals 2/3/20144 Keith Lee – kmlee@clemson.edukmlee@clemson.edu