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 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)

5. 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.

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

8. Machining Cutting: Turning, Shaping, Milling, Drilling.
Abrasive: Grinding, Honing, Lapping, Buffing,
Polishing.
Non-traditional: Electrochemical machining,
laser beam machining.

9. 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

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 = ( R 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 = inch
Angle N = 90
BA = ( x x ) 90 =
 in.