4 - me20manufacture processes classification

8/9/2019 4 - ME20Manufacture Processes Classification

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Ken Youssefi Mechanical Engineering 1

Manufacturing Processes

Manufacturing is a process that converts raw materials into

products, it constitute:

• The selection of raw materials

• The sequence of processes needed to

manufacture the product

• The selection of manufacturing process


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Material Selection

Function

Material Shape

Process

Material selection and process cannot be separated from the shape

and the function of the product, two way interaction.

Function dictates the choice

of material and shape.

Process interacts

with shape.

Process is influenced

by material

Shape restricts thechoice of material

and process.


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Engineering Materials

Materials

Metals Plastics

Steel

Stainless steel

Die & tool steel

Cast iron

Ferrous Non-ferrous

Aluminum

Copper

Zinc

Brass

Titanium

Tungsten

Thermoplastics

Acryl ic

Nylon

ABS

Polyethylene

Polycarbonate

PVC

Thermosets

Phenolic

Polymide

Epoxies

Polyester

Elastomers

Rubber

Polyurethane

Silicone


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Engineering Materials

Materials

Metals PlasticsCeramics

Glass

Carbides

Nitrides

Graphite

Diamond

Glasses

Glass ceramics

Composites

Reinforced

plasticsMetal-Matrix

Ceramic-Matrix

Laminates


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Manufacturing

Processes

Assembly

Operations

Processing

Operations

Surface

Processing

Operations

Property

Enhancing

Processes

Shaping

Processes

Mechanical

Fastening

PermanentJoining

Processes


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Shaping Processes


ShapingProcesses

CastingSand, expendable pattern,

permanent mold

Machining

(material removal)

Turning, milling, drilling

grinding, boring, …..

Forming andShaping

Rolling, forging, extrusion,

drawing, sheet forming,

powder metallurgy, molding


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Property

Enhancing

Processes

Heat Treatment

Surface

Processing

Operations

Cleaning and

surface

treatments

Coating anddeposition

process

Coating and plating

Polishing, burnishing,

deburring, lapping, ..

Changing mechanical

properties of a material


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Assembly Operations


Assembly

Operations

Mechanical

Fastening

Permanent

Joining

Processes

Threaded

fasteners

Rivets

Welding

Brazing and

soldering

Adhesive

bonding


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Casting Process


• Selecting a suitable casting method.

• Preparing a mold cavity of the desired shape withproper allowance for shrinkage.

• Melting the metal with acceptable quality andtemperature.

• Pouring or forcing the metal into the cavity andproviding means for the escape of air or gases.

• Solidification process, must be properly designedand controlled to avoid defects.

• Mold removal.

• Finishing, cleaning and inspection operations.


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Sand Casting


Metals


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Casting process Classifications


Expendable Mold / Reusable Pattern

Sand Mold Casting

Plaster Mold Casting

Ceramic Mold Casting

Expendable Mold / Expendable Pattern

Investment Casting (Lost-wax process)

Evaporative Foam Casting

Permanent Mold / No Pattern

Permanent Mold Casting

Die Casting

Centrifugal Casting


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Casting Materials


Metals most commonly used in casting are;

• Iron (cast iron)

• Steel

•Stainless steel

• Aluminum alloys

• Magnesium alloys

• Brass, bronze and other copper alloys

• Nickel based supperalloys


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Large and small parts



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Manufacturing Processes – Forming


Extrusion (uniform

cross section)


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Ken Youssefi 16Mechanical Engineering

Rolling


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Forging


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Forged parts


Brass

and

steel

fittins

Machine parts


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Deep drawing


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Metal-Forming Process

for Food and Beverage

Containers

Ken Youssefi Mechanical Engineering Dept. 20

How aluminum

cans are made

https://www.youtube.com/watch?v=V7Y0zAzoggYhttps://www.youtube.com/watch?v=V7Y0zAzoggYhttps://www.youtube.com/watch?v=V7Y0zAzoggYhttps://www.youtube.com/watch?v=V7Y0zAzoggY


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Material Removal Processes - Turning


In turning operations the workpiece rotates and the cutting

tool is stationary. The process produces parts that are

round in shape. Parts as small as a screw with 1 mm indiameter to pistons with several inches in diameter can be

machined


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Turning Operations



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Material Removal - Turning


General view of a typical lathe, showing various components.

Source: Courtesy of Heidenreich & Harbeck.


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Material Removal Processes - Milling


Peripheral (slap) mil ling – the

axis of the tool is parallel to the

surface of the workpiece

Face (End) mill ing , the axis of the cutter is perpendicular to the workpiece

End Milling


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M f t i P M t i l R l


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Manufacturing Processes – Material Removal

Drilling

Broaching

Grinding



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Plastics

• Injection Molding

• Rotational Molding

• Blow Molding

• Foam Molding

• Extrusion

• Compression molding

• Thermoforming



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Manufacturing Processes - Plastics


InjectionMolding


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Injection Molding Machine


j i ldi


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Injection Molding Parts



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Rotational Molding (large parts)

Vertical wheel machine


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Blow Molding


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A salt shaker and a pepper mill set has metallic and nonmetallic

parts

• The bodies are made of Acrylic (thermoplastic) using injection

molding

• The top of the salt shaker is made of sheet steel (stamping) and

is plated for appearance.

• The knob on top of the pepper mill is made of steel by

machining (threaded on the inside)

• The square rod in the pepper mill is made of steel by extrusion

• The two grinder parts are made of stainless steel using powder metallurgy.

Too expensive to machine or cast.


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Ken Youssefi Mechanical Engineering Department 36

Numerical Control

• Numerical Control (NC) is a method ofautomatically operating a manufacturing machine

based on a code of letters, numbers, and special

characters.

• The numerical data required to produce a part is

provided to a machine in the form of a program,

called part program or CNC program.

• The program is translated into the appropriateelectrical signals for input to motors that run the

machine.

Three-axis Cincinnati Hydrotel milling machine 1952


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Three axis Cincinnati Hydrotel milling machine, 1952

d illi hi


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Modern CNC Milling Machines

Manufacturing Processes – Material removal


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Manufacturing Processes – Material removal

Computer Numerical Control (CNC)

Machining CentersKen Youssefi 39Mechanical Engineering

Computer Numerical Control machines are used to fabricate

complex shapes with better dimensional accuracy thanconventional machining.

CNC Machines


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CNC Machines Machining Centers, equipped with automatic tool changers,

are capable of changing 90 or more tools. Can perform

milling, drilling, tapping, boring… on many faces.

CNC M hi


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CNC Machines

Turning Centers are capable of executing many different types

of lathe cutting operations simultaneously on a rotating part.

( )


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Computer Numerical Control (CNC)

A CNC machine is an NC machine with the added feature of

an on-board computer.

2 The program path is generated

by computer

A solid model of the part is

created.1

Electrical Discharge Machine EDM


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Electrical Discharge Machine - EDMDie-sinking EDM systems, the electrode (cutting tool) and workpiece are

held by the machine tool. The power supply controls the electrical

discharges and movement of the electrode in relation to the workpiece.

During operation the workpiece is submerged in a bath of dielectric fluid

(electrically nonconducting). (Die-Sinking EDM is also called Sinker,

Ram-Type, Conventional, Plunge or Vertical EDM)


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CNC Machines


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CNC MachinesLaser Machining and Cutting (thermal cutting)

The machine utilizes an intense beam of focused laser light to cut the part.

Material under the beam experiences a rapid rise in temp. and is vaporized.

Laser cuts with a minimum of distortion, no mechanical cutting forces. .

Gas is blown into the cut to clear away molten metals,

or other materials in the cutting zone. In some cases,

the gas jet can be chosen to react chemically with the

workpiece to produce heat and accelerate the cutting

speed

W t J t M hi i


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Water Jet Machining


Uniform thickness parts

W t J t M hi i

http://img.directindustry.com/images_di/photo-g/5-axis-water-jet-cutting-machine-365748.jpg


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Water Jet Machining

4 - me20manufacture processes classification

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