Manufacturing Processes

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Sheet metal processing

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Presentation transcript:

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. Expandable pattern casting: Crankshafts, brake components, machine bases. Vacuum casting, Die casting, Slush casting……

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

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.

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.

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

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.

Joining / Fabrication Welding : Brazing and Soldering Adhesive bonding 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

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

DFM considerations

DFM considerations Save material in Stamping from stock sheet metal

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

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

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

DFM considerations

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

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

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

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

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.