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

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Presentation on theme: "Manufacturing Processes. Categories of processing methods: – Casting – Forming and shaping – Machining – Joining – Finishing."— Presentation transcript:

1 Manufacturing Processes

2 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)

5 Forming 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. Changing the shape of an existing solid body

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

8 Machining Cutting: Turning, Shaping, Milling, Drilling. 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. 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 Save material in Stamping from stock sheet metal DFM considerations

13 Save material in Stamping from stock sheet metalUniform cooling when heat treating

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

15 DFM considerations Save material in Stamping from stock sheet metalUniform cooling when heat treating Eliminate expensive reinforced weldOvercome practical difficulty in grinding near a corner

16 DFM considerations

17 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 = inch Thickness T = inch Angle N = 90 BA = ( x x ) 90 = in.


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