1. Manufacturing Products
Chapter 16
Manufacturing Products
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2. Learning Objectives
List the basic steps involved with casting and molding.
Identify methods used in casting and molding processes.
Name safety rules involved with casting processes.
Identify the basic concepts of forming actions.
Name the types of separating processes.
Identify methods used in separating processes.
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3. Learning Objectives
Name safety rules involved with using machine tools.
List the three types of conditioning processes.
Identify methods used in conditioning processes.
Identify methods used in assembling processes.
Identify methods used in finishing processes.
Name safety rules involved in finishing processes.
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4. Secondary Manufacturing Processes
Six groups:
casting and molding
forming
Separating
conditioning
assembling
finishing.
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5. Casting and Molding
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6. Producing a Mold Two types of molds:
Expendable molds are made in two steps: a pattern slightly larger than the product is made and then, is surrounded with an inexpensive material and dried.
Permanent molds are often made from steel, aluminum, or plaster and are used for die casting, injection molding, and slip casting.
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7. Preparing the Material
Three types of liquids are used in casting processes:
Solutions
Suspensions are mixtures in which the particles will settle out, like slip.
Molten materials are solids in hot, liquid states.
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8. Introducing the Material
expendable molding processes use gravity to fill the mold.
Permanent molds, use force to fill the mold.
Die casting with metals and injection molding (shown to the right) are very similar processes.
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9. Solidifying the Material
Once the liquid material is introduced into the mold cavity, it must become a solid through one of three ways:
Cooling: sending cool water through the mold or actually freezing the product.
Drying is used in slip casting.
Chemical action, like polymerization, allows liquid plastic to change into a solid.
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10. Extracting the Product
Expendable molds are destroyed to remove the product.
Permanent molds are designed to easily eject the product after it is solidified.
(Stahl)
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11. Forming Processes Forming processes.
All materials have an elastic range, which, includes a yield point.
A material’s plastic range goes to the fracture point of the object.
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12. Forming Devices
Two forming devices are used to ensure a consistent shape is attained during forming:
Dies.
Rolls.
Smooth and shaped rolls are used to make curved shapes from sheets, shapes of metal, piping, tubing, and corrugated metal.
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13. Dies Dies can be used to form anything that is softer than they are.
Dies depend on pressure to actually shape the material.
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14. Material Temperature
All materials have a temperature at which their properties change.
The internal structure of any material changes when heated.
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15. Separating Processes- remove excess material by machining or shearing.
machining methods:
Chip removal.
Flame cutting.
Nontraditional machining.
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16. Chip Removal Machines
Chip removal machines are based on their cutting motion and feed motion:
Milling machines like table saws and routers.
Drilling machines like the drill press.
Turning machines like wood and metal lathes.
Shaping machines like metal-working shapers and hacksaws.
Planing machines like metal shapers and planers.
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17. Flame Cutting
Flame cutting is used to melt away excess metal on workpieces.
The fuel gas is either acetylene or natural gas.
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18. Nontraditional Machining
Three common nontraditional processes:
Electrical discharge machining (EDM) is used to create cavities on metals.
Laser machining uses intense light to melt material.
Chemical machining uses chemical reactions to remove excess.
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19. Shearing- The second group of separating processes
Shearing can be used to:
cut material to length
produce an external shape
generate an internal feature
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20. Conditioning Processes
The three types: mechanical, chemical, and thermal conditioning.
Mechanical conditioning works on the principle that most metals become harder when squeezed, stretched, pounded, or bent.
Chemical conditioning can be used to make glass more shatterproof or even change fiberglass resins.
Thermal Conditioning– most common conditioning processes
Include heat treating, firing, and drying.
Hardening, annealing, and tempering is used on metals
Firing: is used on ceramics.
Drying: is used for both ceramics and wood materials.
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21. Assembling Processes Brings parts together through: Bonding Agents:
Bonding-uses cohesive or adhesive forces to hold parts together.
Cohesive forces hold molecules of one material together
Adhesive forces occur between different kinds of molecules.
Bonding Agents:
The same material—steel melted together or steel welding rod used to strengthen the bond.
Similar material—metal (solder) bonds metallic parts.
Different material—white glue holds wood together.
Mechanical fastening - uses friction and seams to join parts.
Mechanical Fasteners:
Permanent fasteners - nails, rivets, wood screws.
Semi-permanent fasteners- Bolts, nuts
Temporary fastener - wing nut
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22. Types of Joints Joints can occur at the ends, sides, and faces.
They are used to add length, width, or thickness and to make corners.
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23. Finishing Processes - Finishing processes involve cleaning the surface, selecting the finish, and applying the finish.
Two types:
A group to change the surface of the product.
A converted surface finish is applied to some metals to prevent rapid corrosion.
A group that applies a coating.
Films are applied to products to protect the surface and add color, as well.
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24. Selecting the Finish Either inorganic or organic.
Metal and ceramic coatings are mostly inorganic.
Paints, varnish, enamels, and lacquers are organic finishes.
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25. Applying the Finish
Metallic coatings are often applied through dipping or plating.
Organic materials can be applied through brushing, rolling, spraying, flow coating, and dip coating.
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26. Automating and Controlling Processes
New machines can load materials, adjust tool feeds and speeds, and do many other tasks humans once did.
These machines make up systems called automation.
Automation includes robots, programmable logic controllers (PLCs), computer-controlled machines, and artificial intelligence (AI) systems.
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27. Automation Parts
Industrial robots are commonly used for welding, painting, assembling, moving materials and parts, and inspecting products.
Programmable logic controllers (PLCs) have three basic functions: input, control, and output, all programmed by a technician.
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28. Automation Parts
Computer-controlled machining uses computer numerical control (CNC) to produce automatic, precise motion of a machine’s tools or the material being processed.
Artificial intelligence (AI) uses digital cameras or sensors for automatically controlling various tasks.
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29. Review
What are the five basic steps followed when casting and molding?
Producing a mold, preparing the material, introducing the material to the mold, solidifying the material, and extracting the product from the mold.
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30. Review What two general kinds of molds are made?
Expendable and permanent molds.
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31. Review What four things are to be considered when forming a product?
The yield point, elastic range, plastic range, and fracture point of the material being formed.
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32. Review What are the two major separating processes?
Machining and shearing.
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33. Review Name three safety rules to be obeyed when using machine tools.
Wear eye protection, wear hearing protection when loud or high-pitched noises are present, and do not talk to anyone while running a machine.
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34. Review
What are some types of machining used in the separation processes?
Chip removal, flame cutting, and non- traditional machining.
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35. Review What are the three types of conditioning processes?
Mechanical, chemical, and thermal conditioning.
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36. Review What do some thermal conditioning processes include?
Hardening, annealing, and tempering.
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37. Review What are the two assembling processes?
Bonding and mechanical fastening.
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38. Review What two groups can finishing processes be separated into?
Changing the surface of the product and applying a coating.
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39. Review List three safety rules considered during finishing processes.
Wear eye and face protection and protective clothing, use a spray booth to remove toxic fumes, and never apply a finish near an open flame.
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