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1
Materials Selections
Casting
Casting processes
processes
Manufacturing Deformation
Deformation processes
processes
Materials
processes Shapping
Shapping
processes
processes Powder
Powder metal
metal processes
processes
Material
Material removal
removal
Processing
Property
Property
Metals Plastics Composites Ceramics Processing enhancing
enhancing
operations
operations Heat
Heat treatment
treatment
& processes
processes
Alloys Surface
Surface treatment
treatment
Surface
Surface
processing
processing
• Good • Plasticity • Strong • Strong Manufacturing operations
operations Coating
Coating and
and deposition
deposition
Manufacturing
conductor of processes
processes
• Light weight • Light • High- Welding
heat and Welding
weight temperature
electricity • Wide choice of
strength Joing
Joing Brazing
Brazing and
and soldering
soldering
• Low cost colors processes
processes
• Strong • Low thermal and
• Low electrical Adhesive
Adhesive bonding
bonding
• Easy to electrical Assembly
Assembly
conductivity
form conductivity operations
operations
• Waterproof Threaded
Threaded fasteners
fasteners
• Resistance to Mechanical
Mechanical
• Inexpensive wear fastening
fastening
Permanent
Permanent fastening
fastening
Shell mold
Casting parts
pattern
2
Powder Metal Processing
How do we manufacturing this?
• Starting materials are powders of metals or
ceramics
Material: Magnesium
• Usually involves pressing and sintering, in
which powders are first squeezed in a die
Sand casting cavity and then heated to bond the individual
Shell mold casting particles
Investment casting
Lost foam casting
Die casting
3
Material Removal Processes
How do we manufacturing this?
• Excess material removed from the starting workpiece so
what remains is the desired geometry
Material: Middle carbon steel • Processes
- Machining, such as turning, drilling, and milling;
Sand casting - Advanced machining, such as EDM
- Finishing machining, such as grinding, honing
Rolling
Open die forging
Close die forging
4
Produce Round Shape Different Type of Turnning Processes
- Turning (Svarvning)
Single point cutting tool removes material from a
rotating workpiece to form a cylindrical shape
• Drill Boring Reaming • The characteristic feature of the milling process is that each milling
Drill
cutter tooth removes its share in form of small individual chips.
• Boring • In milling operation, workpiece is usually stationary while miller is rotate.
• Reaming
• Broach
majority of holemaking
operation due to its simple,
quick and economic
5
Advanced machining
Grinding in Manufacturing Process
• Mechanical Energy Processes
Super-Finishing
(honing)
– Ultrasonic machining, Water jet cutting, Abrasive jet
Bar from Annealing
casting Forming
Hardened
Assembly
machining and Abrasive water jet cutting
Turning Grinding
• Thermal Energy process
Product – Electric Discharge Machining (EDM), Wire EDM, Electron
Production procedures of roller bearing, gear and shaft
Beam, Laser Beam, Arc Cutting
• Chemical Machining
– Chemical Milling, Blanking, Engraving and Photochemical
Machining
Ultrasonic Machining
Electrical discharge machining (EDM)
• High frequency vibration (20kHz) + abrasives
• Workpiece: hard, brittle materials • Sparks (lightening: 500 - 5,000 sparks per
such as ceramics, glass and carbides second) across a small gap between tool
and work to remove material, thus slow
• Tooling for many mechanical processes:
molds for plastic injection molding, extrusion
dies, wire drawing dies, forging and heading
dies, and sheet metal stamping dies
Water Jet Cutting (WJC)
• High pressure 400 MPa and high Laser Beam Machining
speed 900m/s water
6
Joining Processes
Solid state welding
Stereolithography (SL)
• Fusion welding
– Layer-by-layer curing of a liquid - Joining is accomplished
photopolymer by a laser by melting the two parts to be
– Control of laser by a scan-mirror system joined, in some cases adding
filler metal to the join.
Solid Ground Curing (SGC)
• Solid state welding
– Layer-by-layer curing of a liquid photopolymer - Joining is accomplished
through a mask by an UV-lamp through the application of
– Exposure of each layer in one step pressure at a temperature
below the melting temperature
Selective Laser Sintering of the base material; no filler
metal is used.
– Local melting/sintering of a powder by a laser
– Direct: the powder particles melt together • Brazing and soldering
Summary
• Casting processes
Sand casting, shell molding casting, die casting ...
• Deformation processes
Rolling, forging, extrusion
• Powder metal processes
• Material removal processes
Turning, milling, grinding, advanced machining ...
• Joining processes
• Surface treatment processes