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The document discusses the manufacturing process, emphasizing the importance of selecting the right material and process combination for producing parts with desired properties. It highlights casting as a key manufacturing method, detailing its various types and applications, particularly in industries like automotive and aerospace. Additionally, it outlines the responsibilities of manufacturing engineers in ensuring product manufacturability and cost-effectiveness.

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Miguel Rodrigues
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2 views

Ajuda

The document discusses the manufacturing process, emphasizing the importance of selecting the right material and process combination for producing parts with desired properties. It highlights casting as a key manufacturing method, detailing its various types and applications, particularly in industries like automotive and aerospace. Additionally, it outlines the responsibilities of manufacturing engineers in ensuring product manufacturability and cost-effectiveness.

Uploaded by

Miguel Rodrigues
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Introdução

The manufacturing process is the science and technology by which a


material is converted into its final shape with the necessary structure
and properties for its intended use. Formation of the desired shape is
a major portion of processing. The product processing could be a
simple, one-step operation or a combination of various processes,
depending on the processability of the material used and the
specifications for the finished part, which includes surface finish,
dimensional tolerances, and so forth. The method of selecting the
appropriate process is closely tied to the selection of material.

What leads to a successful manufacturing process? The performance


of any manufacturing process depends on

All these factors result from decisions made in selecting the process–
material–part combination. As designers and engineers developing a
new product, at this juncture, we already have the basic part drawing
and a selection of various material–process combinations feasible for
the part. The next stage is arriving at the material-manufacturing
process combination that is technically and economically
feasible. Figure 6.1 shows the taxonomy of manufacturing processes.
The processes are arranged by similarity of function.

Manufacturing processes can be broadly classified into three


categories. Based on the desired outcome, they are primary,
secondary, or tertiary processes. To discuss all the process and their
parameters in detail is beyond the scope of this book. We shall look
into the key processes, their classification, and their specific design
guidelines.

Casting: Casting is the fastest way to attain simple or complex


shapes for the part from its raw material. The casting process
basically is accomplished by pouring a liquid material into a mold
cavity of the shape of the desired part and allowing it to cool. The
different types of casting methods (for both metals and nonmetals)
are shown in Figure 6.2.

Design engineers, manufacturing engineers, and industrial engineers,


in analyzing
alternative methods for producing a part or a product or for
performing an individual

operation or an entire process, are faced with cost variables that


relate to materials,
direct labor, indirect labor, special tooling, perishable tools and
supplies, utilities, and
invested capital. The interrelationship of these variables can be
considerable, and
therefore, a comparison of alternatives must be detailed and
complete to assess properly
their full impact on total unit costs.

Manufacturing engineers have a dual responsibility. Primarily, they


provide the tooling,
equipment, operation sequence, and other technical wherewithal to
enable a product
to be manufactured. Secondarily, they have a responsibility to ensure
that the
design provided to the manufacturing organization is satisfactory
from a manufacturability
standpoint.

O setor de processamento de materiais tem como principal intuito a


obtenção de uma
determinada peça através de diversos métodos que, alterando a
fisiologia, assim como
possivelmente a composição e as propriedades do material, permitem
que o mesmo adquira as
características desejadas para uma determinada função.
A fundição, um dos processos de manufatura mais relevantes e
recorrentes no
processamento de materiais, consiste no vazamento de material
previamente fundido em
moldes pré-definidos que, após o arrefecimento, adquire a forma
desejada. A moldagem
divide-se, tradicionalmente, em areia, moldagem em gesso, coquilha,
cera perdida, assim
como injetada. Cada um destes define-se pelas suas particularidades
e metodologias, o que
permite a abrangência de uma vasta área de complexidades e
elevada flexibilidade.
Atualmente, este processo predomina principalmente em aplicações
industriais,
nomeadamente nos setores de maquinaria de alto calibre,
componentes elétricos de elevada
complexidade, como motores e geradores, assim como na indústria
automóvel e transporte,
que contribuiu desde os anos recentes em valores superiores a 60%
para o mercado de
fundição a nível mundial, revelam análises recentes do mercado
global. Estudos decorrentes
demonstram igualmente um aumento da procura de aplicações de
fundição ao longo dos anos,
com um incremento de 2% desde 2015, assim como a sua presença
na produção, onde cerca
de 90% dos bens produzidos industrialmente requerem aplicações de
fundição.
Estes fenómenos justificam-se não só pelo constante aprimoramento
do processo de
fundição, como também a expansão das possibilidades de aplicações
deste processo com o
desenvolvimento tecnológico em softwares de modelação e
simuladores, que garantem uma
previsão quase exata e ideal do produto final.

Die Casting

Die casting is a widely utilized manufacturing process in which molten


metal is injected into a mold

cavity under high pressure to produce complex , precise, and high


quality metal components

This technique plays a pivotal role in various industries, including


automotive, aerospace, electronics,

and consumer goods, due to its efficiency in mass production


and ability to achieve dimensional accuracy.

James – pagina 778

Metal casting is one of the most ancient techniques used for


manufacturing metal

parts, Metal casting is the process of forming metallic objects by


melting metal, pouring
it into the shaped cavity of a mold and allowing it to solidify. The
process of casting

involves the basic operations of pattern making, sand preparation,


molding, melting of

metal, pouring in molds, cooling, shake-out, fettling, heat-treatment


finishing and

inspection. The flow process chart (Fig 1.1) illustrates these stages in
sequence.

In comparison to other manufacturing processes like rolling, forging,


welding, powder

metallurgy, machining, pressing etc., the casting process has the


following advantages:

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