OET-010 Manufacturing Processes TAG Rubric COURSE OUTLINE
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1 OET-010 Manufacturing Processes TAG Rubric COURSE OUTLINE MET Objective SURVEY OF MANUFACTURING PROCESSES INSTRUCTOR: STEVE SYKES Mon/Wed 2:30PM 5:15PM OFFICE: (Room 434) TEXT: MODERN MANUFACTURING PROCESSES SME - DAVID L. GOETSCH ssykes@edisonohio.edu 2. Distinguish between different manufacturing processes such as forgings, extrusions, castings, forming and finishing. WEEKLY SCHEDULE OF TOPICS, ACTIVITIES, AND ASSIGNMENTS WEEK DATE LAB/ACTIVITY LECTURE/DEMONSTRATION ASSIGNMENTS 1 2 1/12 1/19-21 Lecture Lecture Brief overview of course Introduction of Manufacturing Processes Manufacturing Safety Chap. 1,17 HO Engineering Materials, Metals, Physical Metallurgy Chap /26 Lecture Heat Treatment Chap /02 Exam 1, 5 2/09 Lecture Welding/Related Processes Chap /16 Lecture Welding Related Processes Chap /23 Lab Welding Symbols Hand-out 8 3/02 Exam 2 Welding Lab ---- * 3/09 Spring Break /16 Lecture Pattern Making, Casting Processes Chap /23 Lecture/Lab Sand Castings Handout 11 3/30 Lecture Sand Castings (lab) Handout 12 4/06 Exam 3, Lab Field Trip /13 Lecture Metrology, Metal Cutting Theory Chap /20 Lecture/Lab Turning Processes/ Chap /27 Lecture/Lab Milling Processes Chap /04 Exam 4 Final s Week Manufacturing Research Presentation
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4 Sand Cores Figure 11.6 Examples of sand cores showing core prints and chaplets to support cores.
5 Vertical Flaskless Molding (c) Figure 11.7 Vertical flaskless molding. (a) Sand is squeezed between two halves of the pattern. (b) Assembled molds pass along an assembly line for pouring. (c) A photograph of a vertical flaskless molding line. Source: Courtesy of American Foundry Society.
6 Sequence of Operations for Sand-Casting Figure 11.8 Schematic illustration of the sequence of operations for sand casting. (a) A mechanical drawing of the part is used to generate a design for the pattern. Considerations such as part shrinkage and draft must be built into the drawing. (b-c) Patterns have been mounted on plates equipped with pins for alignment. Note the presence of core prints designed to hold the core in place. (d-e) Core boxes produce core halves, which are pasted together. The cores will be used to produce the hollow area of the part shown in (a). (f) The cope half of the mold is assembled by securing the cope pattern plate to the flask with aligning pins and attaching inserts to form the sprue and risers. Continued on next slide.
7 Shell-Molding Process Figure 11.9 The shell-molding process, also called dump-box technique.
8 Sequence of Operations in Making a Ceramic Mold Figure Sequence of operations in making a ceramic mold. Source: Metals Handbook, Vol. 5, 8 th ed.
9 Expandable-Pattern Casting Process Figure Schematic illustration of the expandable-pattern casting process, also known as lost-foam or evaporative casting.
10 Evaporative Pattern Casting of an Engine Block (a) (b) Figure (a) Metal is poured into mold for lost-foam casting of a 60-hp. 3-cylinder marine engine; (b) finished engine block. Source: Courtesy of Mercury Marine.
11 Investment Casting Process Figure Schematic illustration of investment casting (lost-wax) process. Castings by this method can be made with very fine detail and from a variety of metals. Source: Courtesy of Steel Founder s Society of America.
12 Comparison of Investment-Cast and Conventionally Cast Rotors Figure Cross-section and microstructure of two rotors: (top) investmentcast; (bottom) conventionally cast. Source: Advanced Materials and Processes, October 1990, P. 25. ASM International.
13 Vacuum-Casting Figure Schematic illustration of the vacuum-castin process. Note that the mold has a bottom gate. (a) Before and (b) after immersion of the mold into the molten metal. Source: After R. Blackburn.
14 Hot-Chamber Die-Casting Figure Schematic illustration of the hot-chamber die-casting process.
15 Cold-Chamber Die-Casting Figure Schematic illustration of the cold-chamber die-casting process. These machines are large compared to the size of the casting, because high forces are required to keep the two halves of the dies closed under pressure.
16 Types of Cavities in Die-Casting Die Figure Various types of cavities in a die-casting die. Source: Courtesy of American Die Casting Institute.
17 Centrifugal-Casting Process Figure (a) Schematic illustration of the centrifugal-casting process. Pipes, cylinder liners, and similarly shaped parts can be cast with this process. (b) Side view of the machine.
18 Semicentrifugal Casting and Casting by Centrifuging Figure (a) Schematic illustration of the semicentrifugal casting process. Wheels with spokes can be cast by this process. (b) Schematic illustration of casting by centrifuging. The molds are placed at the periphery of the machine, and the molten metal is forced into the molds by centrifugal force.
19 Types of Melting Furnaces Figure Two types of melting furnaces used in foundries: (a) crucible, and (b) cupola.
20 Characteristics of Casting Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN Pearson Education, Inc., Upper
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