1. Introduction to Manufacturing Processes Pt. 2 © 2012 Project Lead The Way, Inc.Principles Of Engineering

2. Heat Treating Processes Controlled heating and cooling of a material to alter its properties while maintaining its shape Properties include: Strength, toughness, machinability, wear resistance, and corrosion resistance 90% of heat treating is preformed on steel and other ferrous metals

3. Heat Treating Processes To aid in the manufacturing process, materials can be treated to be weak and ductile and then can be re-treated to provide high strength. Can also occur incidentally during the manufacturing process

4. Joining and Assembly Processes Mechanical Fastening Use physical force to hold parts together Mechanical fasteners or part design Screws, bolts, nails, rivets, cotter pins, retaining clips, and edge design ©iStockphoto.com

5. Joining and Assembly Processes Welding Operations that use heat, pressure, or both to permanently join parts Gas, arc, stud, spot, forge, roll laminating, resistance, and induction welding ©iStockphoto.com

6. Joining and Assembly Processes Adhesive bonding Bonding of adjoining surfaces by filling the gap between each surface with a bonding material Glue, cement, thermoplastic, thermosetting, and elastomers ©iStockphoto.com

7. Joining and Assembly Processes Soldering and Brazing Operation in which metal surfaces are bonded together by an alloy Heated molten alloy flows between the adjoining surfaces When the heat is removed, the molten metal solidifies and the metal surfaces are bonded ©iStockphoto.com

8. Rapid Prototyping Additive process Parts are produced directly from software applications Common rapid prototyping systems include: stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), laminated object manufacturing (LOM), digital light processing (DLP)

9. Rapid Prototyping Finished parts can be field tested depending upon building material Created parts can be used to create a mold Modifications to design can be implemented quickly

10. Other Manufacturing Processes Testing Transportation Material handling Packaging ©iStockphoto.com

11. Material-Specific Manufacturing Processes Plastic Processes Ceramic Processes ©iStockphoto.com

12. Plastics Manufacturing Processes A rotating screw forces plastic through a heating chamber and then through a heated die Produces long plastic parts with uniform cross sections Extrusion

13. Heated plastic is forced by a movable plunger through a nozzle and then into a mold. The material fills the mold and then is cooled. Most widely used high-volume production process Plastics Manufacturing Processes Injection Molding

14. Plastic is melted and poured into a mold – No pressure or fillers are required. Plastics Manufacturing Processes Casting A closed mold is filled with a predetermined amount of plastic. The mold is heated, rotated, and then cooled to create a hollow plastic object with uniform wall thickness. Rotational Molding

15. Plastics Manufacturing Processes A solid bottom hollow tube is placed between two mold halves and heated. The heated tube is then expanded into the sides of the mold with compressed air. Blow Molding

16. Plastics Manufacturing Processes Liquid reactants are mixed and then pressurized into a mold. No heat is needed. Curing time is typically less than 1 minute. Reaction Molding Plastic sheets are heated over an open mold to a working temperature. Once workable, a vacuum is applied to the mold, forcing the plastic sheet to take the shape of the mold. Thermoforming

17. Ceramic Manufacturing Processes Two distinct classes of materials and processes exist. Glass is heated to a molten state, shaped by viscous flow, and then cooled to produce a solid. Crystalline Ceramics Material is shaped and then heated to produce a permanent solid.