Manufacturing Processes (continued)
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1 Manufacturing (continued) Machining Some other processes Material compatibilities Process (shape) capabilities Manufacturing costs Correct pg 142, question 34i should read Fig 6.18 question 34j should read Fig 6.18 Machining processes Manufacturing (subtractive, removal) Deformation Sheet Metal Polymer Machining Finishing Assembly Forging Rolling Bar drawing Wire drawing Centrifugal Die casting Investment Permanent mold Sand casting Bending Blanking Drawing Punching Shearing Spinning Blow molding Compression molding Injection Molding Thermoforming Transfer molding Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM Anodizing Honing Painting Plating Polishing Automated Bonding Brazing Manual Riveting Soldering Welding 1
2 Drilling Milling 2
3 Turning Grinding 3
4 Chip formation Machining removal of material Sawing using a toothed blade. Milling from a flat surface by a rotating cutter tool. Planing using a translating cutter as workpiece feeds. Shaping - from a translating workpiece using a stationary cutter. Boring - increasing diameter of existing hole by rotating the workpiece. Drilling- using a rotating bit forming a cylindrical hole. Reaming to refine the diameter of an existing hole. Turning - from a rotating workpiece. Facing - from turning workpiece using a radially fed tool. Grinding - from a surface using an abrasive spinning wheel. Electric discharge machining - by means of a spark. 4
5 Surface roughness Machining process considerations solid material machining material removed sawing, turning, boring, milling, drilling, grinding, ECM Add to your notes hardness, strength of material shear forces = strong jigs & fixtures tool/bit wear, replacement size of workpiece, fit machine? volume removed rate of removal, hp needed tolerances operator skill, CNC costs (materials, tooling, processing) 5
6 Finishing processes Manufacturing protection? Deformation Sheet Metal Polymer Machining Finishing Assembly Forging Rolling Bar drawing Wire drawing Centrifugal Die casting Investment Permanent mold Sand casting Bending Blanking Drawing Punching Shearing Spinning Blow molding Compression molding Injection Molding Thermoforming Transfer molding Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM Anodizing Honing Painting Plating Polishing Automated Bonding Brazing Manual Riveting Soldering Welding Assembly processes fastening / joining of 2 or more components Manufacturing Deformation Sheet Metal Polymer Machining Finishing Assembly Forging Rolling Bar drawing Wire drawing Centrifugal Die casting Investment Permanent mold Sand casting Bending Blanking Drawing Punching Shearing Spinning Blow molding Compression molding Injection Molding Thermoforming Transfer molding Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM Anodizing Honing Painting Plating Polishing Automated Bonding Brazing Manual Riveting Soldering Welding permanent? 6
7 Some other types of manufacturing processes Cold heading EDM Wire EDM Thermoforming Rotomolding (see slides) Cold heading 7
8 EDM Electrical-Discharge Machining (a) (b) (c) Figure (a) Schematic illustration of the electrical-discharge machining process. This is one of the most widely used machining processes, particularly for die-sinking operations. (b) Examples of cavities produced by the electrical-discharge machining process, using shaped electrodes. Two round parts (rear) are the set of dies for extruding the aluminum piece shown in front (see also Fig. 15.9b). Source: Courtesy of AGIE USA Ltd. (c) A spiral cavity produced by EDM using a slowly rotating electrode, similar to a screw thread. Source: American Machinist. Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page Wire EDM Wire EDM (a) Figure (a) Schematic illustration of the wire EDM process. As much as 50 hours of machining can be performed with one reel ocl,gieal,2gt2lgslr2eul,g p CgstniCeCRll6lmfrgulnl tl3ltosdfreitouriopecl r2gt1ldpnrel,gr2l,giel(harll,giel(halsnt2guerll Source: Courtesy of AGIE USA Ltd. (b) (c) Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page
9 Wire EDM parts Thermoforming (thin sheets of plastic) Refuse can cover 9
10 Rotomolding-rotational molding Steps in Rotational Molding Process: 1.A pre-measured amount of plastic resin is placed into a mold. 2.The mold is then moved into an oven where it is rotated on both axis. As the resin melts, it coats the inside surface of the mold cavity, allowing for excellent uniform wall thickness. 3.Once the resin is completely fused, the mold is removed from the oven and cooled by air or water. 4.Then the part is removed from the mold gas tank Learning objectives Differentiate primary, secondary and tertiary p y, y y processes Characterize basic manufacturing processes 10
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