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Manufacturing Processes

Manufacturing Processes. Manufacturing Processes. Categories of processing methods: Casting Forming and shaping Machining Joining Finishing. Casting. Sand Casting : Engine blocks, cylinder heads, pump housings. Shell mold casting: Gear housings, connecting rods.

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Manufacturing Processes

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  1. Manufacturing Processes

  2. Manufacturing Processes • Categories of processing methods: • Casting • Forming and shaping • Machining • Joining • Finishing

  3. 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……

  4. Casting • 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) • http://www.youtube.com/watch?v=BX8wGUPz1w&feature=related

  5. 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.

  6. 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.

  7. Sheet Metal http://www.youtube.com/watch?v=nA8y__BMl-o&feature=related http://www.youtube.com/watch?v=q5Wlr6Co5SI http://www.youtube.com/watch?v=qTUMbVNf1Xc&feature=related

  8. Machining • Cutting: Turning, Shaping, Milling, Drilling. • http://www.youtube.com/watch?v=874DNEvCc-c • Abrasive: Grinding, Honing, Lapping, Buffing, • Polishing. • Non-traditional: Electrochemical machining, • laser beam machining.

  9. Joining / Fabrication • Welding : • Fusion welding: Plasma Arc, Electron beam. • Solid State: Resistance welding. • http://www.youtube.com/watch?v=b2n_kpLXwY8 • Brazing and Soldering • Adhesive bonding • Mechanical fastening

  10. Manufacturing Processes • Selecting a Manufacturing Process depends on: • Size • Thickness • Shape Complexity • Material • Cost

  11. DFM considerations

  12. DFM considerations Save material in Stamping from stock sheet metal

  13. DFM considerations Save material in Stamping from stock sheet metal Uniform cooling when heat treating

  14. DFM considerations Save material in Stamping from stock sheet metal Uniform cooling when heat treating Overcome practical difficulty in grinding near a corner

  15. 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

  16. DFM considerations

  17. DFM considerations Avoid flat bottom holes, give room for tool clearance and chips

  18. DFM considerations Avoid flat bottom holes, give room for tool clearance and chips Limit machining operations

  19. DFM considerations Avoid flat bottom holes, give room for tool clearance and chips Limit machining operations Sharp corners decrease the strength

  20. 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 = (0.017453 R + 0.0078 T) N Where R = radius of bend T = metal thickness N = number of degrees of bend

  21. Sheet Metal Calculate Bend Allowance for R = 0.075 inch Thickness T = 0.125 inch Angle N = 90 BA = (0.017453 x 0.075 + 0.0078 x 0.125 ) 90 = 0.20555775  0.2056 in.

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