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23 ME 14 - ManufacturingProcesses

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4 views

23 ME 14 - ManufacturingProcesses

Uploaded by

hani
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
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Process Name Category Sub-category Working Principle

Sand Casting is the method in


which we pour molten metal in a
Sand Casting Casting Sand Molding
mold and it is removed after
soldification.

Rotating drill bit removes


High-Pressure
Die Casting Casting material to create holes in
Casting
workpieces.

Rotating multi-tooth cutter


Injection Molding Molding Plastic Forming removes material as it moves
across a surface.

Application of high force


Cold Forging Forming Deformation without heating to change
material properties

Apllicaton of high pressure with


Hot Forging Forming Deformation heated surface to deform
sharpely

converting metal into powder to


Powder Metallurgy Forming Sintering
be casted

Material forced through a die to


Extrusion Forming Continuous Shape form long profiles of uniform
cross-section.

Medium-Temp Heating filler metal above its


Joining
Bonding melting point to join ends
Brazing
It uses non consumable
Tungsten electrode which
TIG Welding Joining Arc Welding creates arc, melts base metal
with inert gas shielding for clean
welds.
It uses consumable electrode
MIG Welding Joining Arc Welding
with inert gases

Rotating part is fed against


Turning Machining Metal Cutting
cutting to shape the metal

In Drilling rotating drill bit is


used to make hole in material.It
Drilling Machining Hole Making
remove material in the form of
chips
Suitable Materials to
Examples of Applications
be Processed

Valves, Engine Blocks, Pumps Iron, aluminum, brass

Aluminum, zinc,
Holes in parts, mold making
magnesium alloys

Thermoplatics ( Acrylic ,
Bottle caps, plastic containers
Tyflon )

Cutlerey, Automotive Low-carbon steel,


components , Fastners aluminum

machinary parts, aircraft


Steel, aluminum, copper
components, railway tracks

Magnetic parts, Cutting tools, Iron, copper, ceramic


Automoive componenets composites

Aluminium, plastics ,
Aluminum frames, pipes, rods
copper

Copper, aluminum, steel


Plumbing, Aerospace, Electronics
alloys

Aerospace frames, medical Stainless steel, titanium,


devices, Stainless steel fabrication aluminum
Construction, medicine, home
Mild steel, stainless steel
appliances

Metals (steel, aluminum),


Shafts, bolts, screws
plastics

Holes in parts, mold making Metals, plastics, wood


Important Formula Calculations

Volume of Metal required: V=


Volume of Mold Cavity - Shrinkage Volume

"Pressure Calculation:"
Pressure = Force/Area
"Injection Pressure:"
Pressure = Force/Area
where F is the force exerted, A is mold
cross-sectional area.

"Deformation Force:"
F = σ_y×A
where σ_y is yield strength, A is cross-
sectional area.

"Forging Force:"
F=k×A
where k is material constant, A is
cross-sectional area.

"Compaction Pressure:"
Pressure = Force/Area
where F is the force exerted,A is mold
cross-sectional area.

"Extrusion Speed:"
S = Volume/Time

none

"Heat Input:"
H = ((V×I×60))/(Travel Speed)
where V is voltage, I is current." "
"Heat Input:"
"H = " ((V×I×60))/(Travel Speed)
Material Removal Rate (MRR):
MRR=π×D×f×d
where D is diameter, f is feed rate, d is
depth of cut.

Cutting Speed:V=(π×D×N)/1000
where D is drill bit diameter, N is spindle
speed (RPM).
Important Specs of Machines/Tools

Pattern making tools, Jolt , furnance

Uses High Pressure to force metal into to make smooth surfaces


of metal

High precision , Fast process with smooth finish

Cold forging press, high-force, low-speed operation

Forging press, capable of 1-10 tons of force, heated die

Precise and minimal wastage complex components

Extruder machine, typically 150-500°C, variable die design

Strong as base metals and works for bonds of 0.05 to 0.15mm

precise welds with minimal spatter and suitable for all positions
Generally for sizes of 0.6 to 1.6 mm, suitable for flat,
horizonatal and vertical surfaces

Cutting speed usually varies from 300 to 100 m/min and feed
rate from 0.1 to 1 mm/rev

Hole Diameter ranges from small 0.5mm to large 100 mm


depending on size of drill bit.
Classification of Manufacturing
Processes
Self-understanding
Summary Note
Level

Cost effective for large and complex parts and results in


Good
Rough surface finish

Produces dense parts with high speed and tolerances. Good

injection of molten metal into mold to produce high volume


Low
products

Minimum material wastage to produce high tolerances Good

For high performance and complex parts Good

ideal for high volume production Good

Used for long, consistent shapes; works with metals and


Medium
polymers.

Heating filler metal above 450 degrees creating strong and


Good
durable bonds

Uses inert gases to offer high quality results Medium


Fast, efficient welding for structural components and heavy
Low
materials.

Used for cylindrical surfaces with high finish Medium

Common for precision holes in parts; applications in


Medium
metalworking and carpentry.
Self-interest
Pictures of Raw Materials Pictures of Semi-Finished Part
Level

High

High

Low

Medium

High

High

Medium

High

Medium
Low

Medium

Medium
Pictures of Finished Part Pictures of Tools Pictures of Machines
Pictures of Equipment

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