Manufacturing Processes

 Mountain bike example

 Manufacturing process definition
 Deformation processes
 Casting processes
 Sheet metalworking
 Polymer processing
 http://www.stanford.edu/group/AIM/HETM/index.html
 http://www.sme.org/cgi-bin/getgmnpage.pl?/html/fmp.htm&&SME&

How would we manufacture a mountain bike ?

Top Handle Bar
Seat Tube
Saddle
P t
Post
Rear Brake Fork
Down Front Brake
Tube

Rear Pedal
Derailleur

(Courtesy of Trek Bicycle, 2002)

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 Manufacturing process decisions

 Specific manufacturing processes?

 How do the selected materials influence the choice of
manufacturing processes?
 Does product function or performance issues
influence our choice of mfg. processes?
 What criteria should we use to select processes?
 Which criteria are more important?
 Who will make the final decisions?

Changes?
Parts undergo sequence of processes

 Primary - alter the (“raw”) material’s basic shape or form.

Sand casting
Rolling
Forging
Sheet metalworking
 Secondary - add or remove geometric features from the basic forms
Machining of a brake drum casting (flat surfaces)
Drilling/punching of refrigerator housings (sheet metal)
Ti
Trimmingi off injection
i j ti moldedld d partt flash
fl h
 Tertiary - surface treatments
Polishing
Painting
Heat-treating
Joining

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 Types of manufacturing processes

Manufacturing
How is the input
Processes material changed?

Sheet Polymer
Deformation Casting Metal Processes Machining Finishing Assembly

Extrusion Centrifugal Bending Blow molding Boring Anodizing Automated

Forging Die casting Blanking Casting Drilling Honing Bonding
Rolling Investment Drawing Compression molding Facing Painting Brazing
Bar drawing Permanent mold Punching Extrusion Grinding Plating Manual
Wire drawing Sand casting Shearing Injection Molding Milling Polishing Riveting
Spinning Thermoforming Planing Soldering
Transfer molding Turning Welding
Sawing
ECM, EDM

Manufacturing Process Considerations

1. Production Volume
2 Part Size (overall)
2.
3. Shape Capability (features)
boss/depression 1D
boss/depression >1D
holes
undercuts (int./ext.)
uniform walls
cross sections - uniform/regular
rotational symmetry
captured cavities

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 Deformation processes

 Rolling
 Extrusion
 Drawing
 Forging

Rolling (of ductile materials)

Rollers in compression

thick
slab

thin
sheet

Plastic deformation

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 Rolling

bloom
structural

ingot
coil
slab
l b h
sheet

billet bar rod

Extrusion

Extrusion
die

Cross
sections
Ram

Billet

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 Drawing

D i die
Drawing di

Cross
sections

Pulling
Billet force

Forging (closed-die)

Ram pressure

Blocked Flash
preform

Gutter

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 Casting Processes

 Sand casting
 Die casting
 Investment casting

Sand casting (closed-mold)

Cope
Riser
Core
Flask Sprue

Parting Runner
line
Drag Gate

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Die casting

Stationary Moving
die die

Molten
metal

Plunger Ejector pins

Sprue

Parting line

Investment casting
Ceramic mold
4-part pattern tree (hardened slurry)

Wax pattern
Wa
is cast

Wax removed Molten metal Ceramic mold is

by melting solidifies in cast removed

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 Sheet Metalworking

 Bending
 Blanking
 Drawing
 Punching
 Shearing
 Spinning

Sheet metal drawing

Punch ram

Punch

Blank holder

Clamp
Die force

Blank
Drawn part

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 Example sheet metal parts

Types of manufacturing processes

Manufacturing
Processes

Sheet Polymer
Deformation Casting Metal Processes Machining Finishing Assembly

Extrusion Centrifugal Bending Blow molding Boring Anodizing Automated

Forging Die casting Blanking Casting Drilling Honing Bonding
R lli
Rolling I t t
Investment D i
Drawing C
Compression
i molding
ldi F i
Facing P i ti
Painting B i
Brazing
Bar drawing Permanent mold Punching Extrusion Grinding Plating Manual
Wire drawing Sand casting Shearing Injection Molding Milling Polishing Riveting
Spinning Thermoforming Planing Soldering
Transfer molding Turning Welding
Sawing
ECM, EDM

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Polymer Processes

 Compression molding
 Transfer Molding
 Blow molding
 Injection molding

Compression molding

Heated
mold Ram Pressure

Charge

Part

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 Transfer molding

Ram ppressure

Ram

Heated
mold
Sprue

Charge
Part

Blow molding

Air
Molten Mold blown
parison is halves into Part is
extruded close parison removed

Extruder
air injector

parison

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 Injection molding

Cavity half Core half

of mold of mold

Pellets

Feed hopper
Barrel

Ejector pins

Shear-heating Sprue

Mold closure direction

Parting
plane/surface Fixed Moving

Example of a box …with no undercuts

ejector parting
pins line

core

mold cavity
closure
direction
plastic
injection

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 Internal undercuts

ejector ppartingg
pins line

core

closure cavity
direction
plastic
injection

External undercuts

ejector parting
pins line

core

cavity

plastic
injection

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Solidification processes summary
molten material freezing solid Part
Casting Processes Polymer Processes
Sand Casting Injection Molding
Die Casting Blow Molding
Investment Casting ThermoForming
Centrifugal Compression Molding

Flow (voids, flash)

Cooling time (cycle time)
Temperature
Mold
ld complexity
l i
Warpage
Post processing
Costs (materials, tooling, processing)
Add to your
notes

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