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ManufacturingManufacturing EngineeringEngineering 22BAGGT23NECBAGGT23NEC
2013/14 I.
Óbu
da U
nive
rsity
Bán
ki D
onát
Fac
ulty
of M
echa
nica
l and
Saf
ety
Eng
inee
ring
Inst
itute
of M
ater
ial S
cien
ce a
nd M
anuf
actu
ring
Eng
inee
ring
2013/14 I.
Dr. Mikó Balázsmiko.balazs@bgk.uni-obuda.hu
Bán
ki D
onát
Fac
ulty
of M
echa
nica
l and
Saf
ety
Eng
inee
ring
Inst
itute
of M
ater
ial S
cien
ce a
nd M
anuf
actu
ring
Eng
inee
ring
Steps of the blank designSteps of the blank design
Blank type selection
Identify the manufacturing allowances
Choice
3Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
Choice
Design of the blank shape
Design documentation
BlankBlank typestypes• Rolled bars or plates• Drawing bars• Forged parts
• Free forging• Die forging
• Casted parts• Sand casting
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• Sand casting• Automated sand casting• Die casting• Lost-wax casting• Injection moulding
• Welded construction
Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
Rolled bars or platesRolled bars or plates
Mass productionCheapStandard sizeHot forming
Application:• piece production• small cutting
5Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
RolledRolled bar bar � ø 7 – 180
� ����6 – ����60
� 5x10 – 50x140
� � 10 – 48
� Plates 0.2 - 100
Blank materialManufacturingallowances
Addings
Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu 6
Addings
Hidegen húzott rudakHidegen húzott rudakApplication:• the largest diameter no need to cutting• accurate fixturing
Accuracy: h10, h9, h8Surface roughness: Ra=12.5 Blank material
Manufacturingallowances
7
Size:The larges diameter of the part.
Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
allowances
Addings
� ø 1 – 80
� ����3 – ����50
� � 4 – 46
FFreeree fforgingorging• Complicated• Inaccurate• No size and mass limit• Simple blank geometry• Piece production
Blank materialManufacturingallowances
8Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
Blank materialallowances
Addings
Hammer
Anvil
Blank
Die forgingDie forging
• Die – close cavity• More complicate blanks• More accurate• Expensive tooling• Mass production
11Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
Blank
Die
Die
Flash
CastingCasting• Sand casting• Automated sand casting• Casting to metal mould• Lost-wax casting• Injection moulding
12Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
Sand castingSand casting
•Wood or plastic pattern.• Inaccurate.• Piece production• No mass and size limits
13Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
Mould
Blank
Manufacturingallowances
Addings
Automated sand castingAutomated sand casting• Metal pattern• Sand forming by automated system• More accurate parts• Mass production
16Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
Casting to metal mouldCasting to metal mould• Mould made of steel• Expensive mould• Accurate parts• Light metal parts• Mass produltion
17Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
Moulding processMoulding process
1. Cleaning 2. Filter
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1. Cleaning 2. Filter
3. Filter 4. A ClosingManufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
Moulding processMoulding process
5. Moulding 6. Cooling and solidification
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5. Moulding 6. Cooling and solidification
7. Opening 8. VerifyingManufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
LostLost--wax castingwax casting
•Wax pattern – Ceramic cover – Heat treatment -Casting• Small, complicate workpieces•Very accurate
21Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
LostLost--waxwax castingcasting processprocess
Wax mould Wax patterms
Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu 22
Wax mould Wax patterms
Covering Heat treatment – burning and smelting
Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu 23
Casting Cooling and solidification
InjectionInjection mouldingmoulding
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• Expensive tooling•Very accurate• Low melting point materials
Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
WeldingWelding• Good material use• Lot of different welding technology• Weldingability• Deformation, fixturs
Weld
Components
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Manufacturing engineering II -miko.balazs@bgk.uni-obuda.hu
Cutting allowances
Weld
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