UEET 601 Modern Manufacturing Introduction to manufacturing processes Metal Casting Casting Process Involves flow of molten metal into mold cavity - cavity has a shape of the finished part machined into it. Melt is allowed to cool and solidify. Final product removed from mold.
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Introduction to manufacturing processes
Direct or Forward - round billet forced through die opening
Hydrostatic Extrusion - billet is smaller, chamber filled with a fluid -HYDROSTATIC FLUID
Impact Extrusion - Blank or slug is extruded backward by impact force to form a thin walled tube
1-Powder production 2-Blending 3-Compaction
4-Sintering 5-Finishing operations
Process involves: -
- sheet or plate
- rods and tubes
- discrete products (e.g. bottles)
- glass fibers (for composite reinforcement)
a) Flat sheet plate
b) Tubes and Rods -
d) Discrete parts: - Several methods.
1. Casting – molten polymer allowed to solidify inside a mold cavity to acquire the desired shape. For thermosets, additional curing may be necessary. Examples: thermoplastic sheets & plates thermoset lenses, gears
2. Blow Molding- used to make thermoplastic bottles and hollow sections. Starting material is a a round heated solid-bottom hollow tube – preform. Preform inserted into two die halves and air is blown inside to complete the process
5. Cold Molding – charge is pressed into shape while cold then cured in an oven. Economical but usually poor surface finish
6. Injection Molding – Most widely used process. Suitable for high production of thermoplastics. Charge fed from a hopper is heated in a barrel and forced under high pressure into a mold cavity. Several types. Variety of parts can be made.
10. Foam Molding – Foaming agent is combined with the charge to release gas, or air is blown into mixture while forming. Used to make foams. Amount of gas determines the density
-Calendaring: molten plastic forced between two counter-rotating rolls to produce very thin sheets e.g. polyethylene sheets
-Spinning: modified form of extrusion in which very thin fibers or yarns are produced
-Machining: material removal process such as drilling, turning, thread cutting. E.g. nylon fasteners. In general thermoplastics have poor machinability.
Prototype is a new examinable product, usually still under development; required for tests and evaluation Rapid Prototyping is a new technology which speeds up the process of product development Usually, new physical model can be built from a CAD file in a matter of hours There are three basic types: Subtractive Additive Virtual
Turning Milling Drilling
Other Joining Processes
Brazing is done when two metals, which are not melted, are joined with a third metal that melts at temperatures above 840 deg F.
Soldering occurs when two metals, which are not melted, are joined by a third metal having a melting point below 840 deg. F