Definition of Manufacturing Processes Manufacturing processes are the steps through which raw materials are transformed into a final product. The manufacturing

Definition of Manufacturing Processes

Manufacturing processes are the steps through which raw materials are transformed into a final product. The manufacturing process begins with the creation of the materials from which the design is made. These materials are then modified through manufacturing processes to become the required part. Manufacturing processes can include treating (such as heat treating or coating), machining, or reshaping the material. The manufacturing process also includes tests and checks for quality assurance during or after the manufacturing, and planning the production process prior to manufacturing.

Manufacturing Processes OET010/CTMET004

Manufacturing Processes OET010/CTMET004

RESOURCES FOR MANUFACTURING PROCESSES•TAG Information •CTAG Information •Rubric Manufacturing Processes •Sample Syllabus (from Rick Shiverdecker, Sinclair Community College) •Sample Syllabus-Miami University (from Rob Speckert)

http://regents.ohio.gov/transfer/tags/course_descriptions/oes_oet/OET010.htm

http://regents.ohio.gov/careertechtransfer/ctags/outcomes/CTAGMechanicalEnginTech.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/Rubric-Manufacturing-Processes.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/Syllabus-OPT2205-RAS-2014-b.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/ENT-152-Syllabus.pdf

1. Demonstrate an understanding of the interrelationships between material properties and manufacturing processes. * Primary Elements of Manufacturing-includes material selection and various processes

Manufacturing Processes Selection

2. Distinguish between different manufacturing processes such as forgings, extrusions, castings, forming, and finishing.*

Basic Manufacturing Processes

3. Distinguish between different fabrication processes such as welding, fasteners, and adhesives.*

4. Apply empirical data to determine speeds and feeds to optimize production efficiencies.*

E152 Intro to Machining

5. Demonstrate appropriate safety procedures and methods in a manufacturing setting.*

Examples – Safety Home work

OSHA Outreach General Industry 10 hour

6. Demonstrate proficiency in the use of measurement instruments.*

E152 Measurement WS

Example of Measurement Lab

E152 Class of Fit and Measurements

E152 SPC Lab

7. Tour local manufacturing facilities.

MANUFACTURING PROCESSES TEACHING MATERIALS BY OUTCOME

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/Primary-Elements-of-Manufacturing-includes-material-selection-and-various-processes.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/Primary-Elements-of-Manufacturing-includes-material-selection-and-various-processes.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/Manufacturing-Processes-Selection.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/Basic-Manufacturing-Processes.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/E152-Intro-to-Machining.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/Examples-%E2%80%93-Safety-Home-work.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/OSHA-Outreach-General-Industry-10-hour.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/E152-Measurement-WS.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/Example-of-Measurment-Lab.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/E152-Class-of-Fit-and-Measurements.pdf

http://www.techprepswohio.org/blog/wp-content/uploads/2014/09/E152-SPC-Lab.pdf

OET-010 Manufacturing Processes TAG Rubric MET

Working document. Last Revised: May 24, 2013

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The purpose of this guide is to provide a range of knowledge at which students can demonstrate proficiency for each objective. Subsequent college course success depends strongly on courses taught primarily at the “some applied skills present” and “applied skills strongly demonstrated” levels.

Objective Applied skills strongly demonstrated

Some applied skills present

Little applied skills present

No applied skills Present

1. Demonstrate an understanding of the interrelationships between material properties and manufacturing processes.

Develop a manufacturing plan based on the interrelationships between material properties and manufacturing processes needed to produce the part.

Decide the best manufacturing processes for various parts based on the material properties.

Explain why material selection is integral to design and manufacturing.

Discuss the impact of poor or improper material selection on product reliability and product failure liability.

Heat treat 5 specimens to determine material and carbon content and match to hardness achieved.

Analyze and classify the interrelationships between material properties and manufacturing processes.

Differentiate the manufacturing process that is used on common material properties.

Discuss material selection and manufacturing process criteria.

Discuss impact of material selection on design, manufacturing, assembly.

Understand the effect of steel additives such as sulfur to machining properties.

Explain and discuss the interrelationships between material properties and manufacturing processes.

Explain hardness related to tensile strength

Identify basic dynamic properties (impact, fatigue, creep)

Define machinability, formability, and weld ability.

Understand chip formation and affect of material microstructures.

Define the interrelationships between material properties and manufacturing processes.

Define characteristics of metallic and non- metallic materials

Identify basic physical properties of materials (density, thermal, optical, electrical)

Identify basic mechanical properties of materials (stress, strain, tensile, elongation, yield strength, shear strength—material removal), ductility, brittleness, toughness, hardness, hardness scales (e.g. Brinell, Rockwell)


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2. Distinguish between different manufacturing processes such as forgings, extrusions, castings, forming and finishing.

Construct and propose a plan to use the different manufacturing processes such as forgings, extrusions, castings, forming and finishing, completing parts in the most efficient manner.

Given a product, identify how that product is likely made, and validate or correct the answer using research.

Make patterns for sand casting and pour an aluminum part.

Understand gating and venting needs in a casting.

Analyze and classify the between the different manufacturing processes such as forgings, extrusions, castings, forming and finishing.

Construct a process for making many different parts using the various manufacturing processes.

Plan a manufacturing process to make certain products.

Know when a forging is best and the benefits of forging properties.

Understand when grinding and polishing are necessary and the material removal.

Explain and discuss the differences between different manufacturing processes such as forgings, extrusions, castings, forming and finishing.

Identify, describe, show examples of products made using electro-chemical and electric discharge processes

Explain how threads are made. Identify types of threads and applications for each.

Define the different manufacturing processes such as forging, extrusion, casting, forming and finishing.

Identify, describe, and give examples of products made using material removal processes such as turning, milling, drilling, threading, and sawing.

Identify, describe, and give examples of products made using forming, extruding, and casting

Identify, describe, and give examples of products made using finishing processes such as grinding, sanding, coatings, and annealing.


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3. Distinguish between different fabrication processes such as welding, fasteners,

and adhesives.

• Construct and propose a plan to use different fabrication processes such as welding, fasteners, and adhesives to produce parts in the most efficient manner.

Evaluate the strengths and weakness of each of the fabrication processes such as welding, fasteners, and adhesives when it comes to the production of parts.

Given a product, identify how that product is likely fabricated, and validate or correct the answer using research.

• Analyze and classify the different fabrication processes such as welding, fasteners, and adhesives.

Distinguish the different types of Fusion welding, Resistance welding, and brazing.

Construct a process for making many different parts using the various fabrication processes.

Plan a manufacturing fabrication process to make certain products.

Know what the UNC UNF bolt thread classes are and Metric.

Tap and Die to create threads.

• Explain and discuss the differences between different fabrication processes such as welding, fasteners, and adhesives.

• Define the different fabrication processes such as welding, fasteners, and adhesives.

Identify, describe, show examples of types of fasteners.

Identify, describe, show examples of type of adhesives

Identify, describe, show examples of types of welding processes


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4. Apply empirical data to determine speeds and feeds to optimize production efficiencies.

• Construct and propose a plan to use the different empirical data to determine speeds and feeds to optimize production efficiencies.

• Produce the Speed and Feed data from the charts based on the material and machining process and calculate the proper feed and speed based on that different machining process.

• Evaluate the findings and determine if a different machining process would be required to optimize production efficiencies.

• Create a CNC program using manual G code technique to cut a part.

• Analyze and classify the empirical data to determine speeds and feeds to optimize production efficiencies

• Produce the Speed and Feed data from the charts based on the material and machining process and calculate the proper feed and speed based on that different machining process.

• Calculate N (RPM) using N=(12*V)/(π*D); Use and validate that V=(N* π*D)/12, and apply to real manufacturing examples

• Calculate forces (Fc- cutting force, Ff-feed force, and Fr-radial force) on a single point tool

• Show how these forces can be used to design fixtures, tool holders, and drive systems.

• Calculate material removal rate (MRR)Calculate HPspindle given HPs and MRR.

• Know the effect of speeds and feeds on surface finish and material removal ranges

• Explain and discuss the empirical data to determine speeds and feeds to optimize productionefficiencies.

• Discuss efficiency and energy losses.

• Determine HP motor using efficiency and HP spindle

• Explain that material removal is causing material to fail in shear.

• Recognize three feeds; feed in inches per minute, in inches per revolution, and in inches per tooth.

• Using a given feed determine the other two feed rates where appropriate. Use feed rate todetermine cut time

• Understand relationship of each feed to the process.

• Look up and demonstrate understanding of specific (or unit) HPs given material

• Describe speeds and feed to optimize production efficiencies

• Understand that allmanufacturing operations have limits (machine size, HP, tool size, finish, etc.)

• Use machinability reference books to look up suggested speeds and feeds.

• Identify values generally looked up in a reference book or required by the manufacturing operation (depth of cut, V, diameter of part or tool, and feed rate)


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5. Demonstrate appropriate safety procedures and methods in a manufacturing setting.

Construct and propose safety procedures and methods in a manufacturing setting to insure the safety of the employees.

Develop appropriate safety procedures and methods in a manufacturing setting.

Analyze and classify appropriate safety procedures and methods in a manufacturing setting.

Determine what is safe and unsafe in the many different manufacturing settings.

.

Explain and discuss the appropriate safety procedures and methods in a manufacturing setting.

Discuss OSHA and other safety enforcement agencies

Discuss importance of safety to industry productivity

Describe the appropriate safety procedures and methods in a manufacturing setting.

Demonstrate understanding of and need for Personal Protection Equipment.

Demonstrate understanding of and need for Lock Out Tag Out

Demonstrate understanding of and need for fall protection


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6. Demonstrate proficiency in the use of measurement instruments.

Select the proper measurement instruments based on the instruments accuracy and precision.

Perform the proper steps to determine the correct measurement on various features

Know the Vernier scale. Read micrometer to

fabricate and know precision.

Compare the differences of use of the measurement instruments.

Produce the correct measurement on various features.

Calculate allowance/interference and tolerance values for various classes of fit.

Solve and apply class of fit problems.

Read a Vernier caliper to produce quality parts.

Know dimensional metrology and how to measure parts to within .001 accuracy.

Explain the use of measurement instruments.

Demonstrate the proper use of each type of measurement instruments.

Discuss class of fit in design of mating parts, Identify the difference between tolerance and allowance/interference.

Demonstrate understanding of how to measure parts given dimensions and specifications.

Describe the use of different measurement instruments.

Identify and describe the need for tolerances.

Demonstrate understanding of tolerance.

Demonstrate proficiency in reading Vernier, dial, and digital calipers and micrometers.

Demonstarte proficiency in reading linear scales and gages.

Describe relationship and importance of measured values to specifications.


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7. Tour local manufacturing facilities (optional)

Propose some different manufacturing process at the local manufacturing facilities.

Tour local manufacturers – at least 2 per semester as needed.

Compare the difference manufacturing process at the local manufacturing facilities.

Explain the use of the different manufacturing process at the local manufacturing facilities.

Use various media and tours to explain manufacturing processes and how products are made.

Describe the tour of manufacturing facilities.

Participate in tours of manufacturing facilities

Use guest lecturers to discuss current topics affecting local manufacturing industry

Use videos and other media to demonstrate manufacturing processes and systems



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Objective

1. Demonstrate an understanding of the interrelationships between material properties and manufacturing processes.

COURSE OUTLINE

SURVEY OF MANUFACTURING PROCESSES INSTRUCTOR: STEVE SYKES Mon/Wed 2:30PM – 5:15PM OFFICE: 778-7946 (Room 434) TEXT: MODERN MANUFACTURING PROCESSESSME - DAVID L. GOETSCH Email:[email protected]

WEEK DATE LAB/ACTIVITY LECTURE/DEMONSTRATION ASSIGNMENTS

WEEKLY SCHEDULE OF TOPICS, ACTIVITIES, AND ASSIGNMENTS

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2/16

2/23

3/02

3/09

3/16

3/23

3/30

4/06

4/13

4/20

4/27

5/04

Lecture

Lecture

Lecture

Exam 1,

Lecture

Lecture

Lab

Exam 2

Spring Break

Lecture

Lecture/Lab

Lecture

Exam 3, Lab

Lecture

Lecture/Lab

Lecture/Lab

Exam 4

Brief overview of courseIntroduction of Manufacturing ProcessesManufacturing Safety

Engineering Materials, Metals, Physical Metallurgy

Heat Treatment

Welding/Related Processes

Welding Related Processes

Welding Symbols

Welding Lab

-------------------------------------------------

Pattern Making, Casting Processes

Sand Castings

Sand Castings (lab)

Field Trip

Metrology, Metal Cutting Theory

Turning Processes/

Milling Processes

Final’s WeekManufacturing Research Presentation

Chap. 1,17HO

Chap. 2

Chap. 7

Chap. 14

Chap. 14

Hand-out

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Chap. 5

Handout

Handout

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Chap. 9

Chap. 9

Chap. 10

mailto:[email protected]

Engineering Materials

Engineering Materials

Metals Plastics Ceramics

OxidesNitrides

CarbidesGlasses

Glass CeramicsGraphiteDiamond

Composites

Ceramic matrixReinforced plastics

Laminates

Ferrous

SteelsStainless Steels

Tool and Die SteelsCast Irons

Non-ferrous

AluminumCopperTitaniumTungsten

Thermoplastics

AcrylicsABS

NylonsPolyethylene's

PVC

Thermosets

EpoxiesPhenolicsPolyimides

Elastomers

RubbersSilicones

Polyurethane's

Three Groups of Plain Carbon Steel

Low-Carbon Steelless than 0.30% carbon contentalso called mild steel

products: screws, nails, nuts, washers, wire, and misc.. machine parts (do not require high strength)

Medium-Carbon Steel0.30 % to 0.60% carbon contentless ductile, harder, and has greater strength vs low-carbon steel

products: shafts, rods, gears, spindles, and other parts requiring medium strength and wear resisting surfaces

High Carbon Steel0.60 to 1.7% (but seldom exceeds 1.5% carbon content)Highest strength and hardnessResponds readily to heat-treatment

products: cutting tools, cable, music wire and cutlery

Grades of Steel

Grade usually denotes the chemical composition of a particular steel

Grades may vary in chemical composition from almost pure iron to a material of complex constitution.

A particular grade of carbon steel usually has specified limits for various elements

Grade DesignationAISI and SAE is used to designate standard carbon specified to chemical composition ranges

AISI - American Iron and Steel InstituteSAE - Society of Automotive Engineers

Important to note theses designations do not indicate specifications.Prefix M is used designate a series of merchant-quality steelsSuffix H designates standard hardenability steels

Plain Carbon & Low Alloy Steels

- most common systems in the United States used to classify steels (SAE) Society of Automotive Engineers (AISI) American Iron & Steel Institute

51120 51120 51120 1018 1018 1018

5 1 1.20 1 0 .18

Grades of Steel

type of steel approximate percentage percentage principle alloy of of principle alloy carbon (in hundredths)

Grades of Steels

First digit is the principle allowing element present

1 Carbon

2 Nickel

3 Nickel-chromium

4 Molybdenum

5 Chromium

6 Chromium-vanadium

7 Tungsten

8 Nickel-chromium-molybdenum

9 Silicon-manganese

Plain Carbon Steels Identification cont.

SAE 4140

First digit 4 chromium-molybdenum Second digit 1 1.0 percent of major alloyThird/Fourth digit’s 40 .40 percent carbon

Plain Carbon Steel Identification cont.

Steel Properties

Alloy Content


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Objective

2. Distinguish between different manufacturing processes such as forgings, extrusions, castings, forming and finishing.

COURSE OUTLINE




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4/27

5/04

Lecture

Lecture

Lecture

Exam 1,

Lecture

Lecture

Lab

Exam 2

Spring Break

Lecture

Lecture/Lab

Lecture

Exam 3, Lab

Lecture

Lecture/Lab

Lecture/Lab

Exam 4



Heat Treatment



Welding Symbols

Welding Lab

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Sand Castings

Sand Castings (lab)

Field Trip


Turning Processes/

Milling Processes


Chap. 1,17HO

Chap. 2

Chap. 7

Chap. 14

Chap. 14

Hand-out

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Chap. 5

Handout

Handout

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Chap. 9

Chap. 9

Chap. 10


Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Sand Cores

Figure 11.6 Examples of sand cores showing core prints and chaplets to support cores.


Vertical Flaskless Molding

Figure 11.7 Vertical flaskless molding. (a) Sand is squeezed between two halves of the pattern. (b) Assembled molds pass along an assembly line for pouring. (c) A photograph of a vertical flaskless molding line. Source: Courtesy of American Foundry Society.

(c)


Sequence of Operations for Sand-Casting

Figure 11.8 Schematic illustration of the sequence of operations for sand casting. (a) A mechanical drawing of the part is used to generate a design for the pattern. Considerations such as part shrinkage and draft must be built into the drawing. (b-c) Patterns have been mounted on plates equipped with pins for alignment. Note the presence of core prints designed to hold the core in place. (d-e) Core boxes produce core halves, which are pasted together. The cores will be used to produce the hollow area of the part shown in (a). (f) The cope half of the mold is assembled by securing the cope pattern plate to the flask with aligning pins and attaching inserts to form the sprue and risers. Continued on next slide.


Shell-Molding Process

Figure 11.9 The shell-molding process, also called dump-box technique.


Sequence of Operations in Making a Ceramic Mold

Figure 11.10 Sequence of operations in making a ceramic mold. Source: Metals Handbook, Vol. 5, 8th ed.


Expandable-Pattern Casting Process

Figure 11.11 Schematic illustration of the expandable-pattern casting process, also known as lost-foam or evaporative casting.


Figure 11.12 (a) Metal is poured into mold for lost-foam casting of a 60-hp. 3-cylinder marine engine; (b) finished engine block. Source: Courtesy of Mercury Marine.

(b)(a)

Evaporative Pattern Casting of an Engine Block


Investment Casting Process

Figure 11.13 Schematic illustration of investment casting (lost-wax) process. Castings by this method can be made with very fine detail and from a variety of metals. Source: Courtesy of Steel Founder’s Society of America.


Comparison of Investment-Cast and Conventionally Cast Rotors

Figure 11.15 Cross-section and microstructure of two rotors: (top) investment-cast; (bottom) conventionally cast. Source: Advanced Materials and Processes, October 1990, P. 25. ASM International.


Vacuum-Casting

Figure 11.16 Schematic illustration of the vacuum-castin process. Note that the mold has a bottom gate. (a) Before and (b) after immersion of the mold into the molten metal. Source: After R. Blackburn.


Hot-Chamber Die-Casting

Figure 11.17 Schematic illustration of the hot-chamber die-casting process.


Cold-Chamber Die-Casting

Figure 11.18 Schematic illustration of the cold-chamber die-casting process. These machines are large compared to the size of the casting, because high forces are required to keep the two halves of the dies closed under pressure.


Types of Cavities in Die-Casting Die

Figure 11.19 Various types of cavities in a die-casting die. Source: Courtesy of American Die Casting Institute.


Centrifugal-Casting Process

Figure 11.20 (a) Schematic illustration of the centrifugal-casting process. Pipes, cylinder liners, and similarly shaped parts can be cast with this process. (b) Side view of the machine.


Semicentrifugal Casting and Casting by Centrifuging

Figure 11.21 (a) Schematic illustration of the semicentrifugal casting process. Wheels with spokes can be cast by this process. (b) Schematic illustration of casting by centrifuging. The molds are placed at the periphery of the machine, and the molten metal is forced into the molds by centrifugal force.


Types of Melting Furnaces

Figure 11.26 Two types of melting furnaces used in foundries: (a) crucible, and (b) cupola.


Characteristics of Casting


P a g e | 40


Objective

3. Distinguish between different fabrication processes such as welding, fasteners,

and adhesives.

COURSE OUTLINE




1

2

3

4

5

6

7

8

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9

10

11

12

13

14

15

16

1/12

1/19-21

1/26

2/02

2/09

2/16

2/23

3/02

3/09

3/16

3/23

3/30

4/06

4/13

4/20

4/27

5/04

Lecture

Lecture

Lecture

Exam 1,

Lecture

Lecture

Lab

Exam 2

Spring Break

Lecture

Lecture/Lab

Lecture

Exam 3, Lab

Lecture

Lecture/Lab

Lecture/Lab

Exam 4



Heat Treatment



Welding Symbols

Welding Lab

-------------------------------------------------


Sand Castings

Sand Castings (lab)

Field Trip


Turning Processes/

Milling Processes


Chap. 1,17HO

Chap. 2

Chap. 7

Chap. 14

Chap. 14

Hand-out

----

Chap. 5

Handout

Handout

----

Chap. 9

Chap. 9

Chap. 10


Fillet Weld

Base Metal metal to be welded

Bond Line the junction of the weld metal and the base metal

Depth of Fusion the distance that fusion extends into the base metal

Face of Weldthe exposed surface of a weld on the side from which the weld was made

Leg of Fillet Weldthe distance from the root of the joint to the toe of the fillet weld

Root of Weldthe shortest distance from the root of the fillet weld to its face

Throat of Fillet Weldthe point or points at which the bottom of the weld intersects the base metal surface or surfaces

Toe of a Weldthe junction between the face of a weld and the base metal

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Groove Weld

Bevel Anglethe angle formed between the prepared edge of a member and a plane perpendicular to the surface of a member

Groove Anglethe total included angle of the groove between parts to be joined by a groove weld

Groove Facethe surface of a member included in the groove

Root Facethat portion of the groove face adjacent to the root of the joint

Root Openingthe separation between the members to be joined at the root of the joint

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Forces in Welding

Shielded Metal Arc Welding (SMAW)an arc welding process which produces coalescence of metals by heating them with an arc between a coveredelectrode and the work. Shielding is obtained from decomposition of the electrode covering. Pressure is notused and filler metal is obtained from the electrode. (Stick )

44

Standard Location of Element of a Welding Symbol

45

Weld Fillet Gage

Checking Fillet Throat Size Checking Fillet Leg Size

Fasteners in Aviation

Fastener Overview:Types of Fastener:

Permanent FasteningWelding Adhesive BondingRiveting

Temporary Fastening

ThreadedNon-Threaded

Permanent Fastening

Welding Adhesive BondingRiveting

48

Adhesive Bonding

49

• Adhesive bonded composite test strips

Riveting

50

• Rivet joints on a Cessna 152

Adhesives and Glues

Definition

An adhesive is a compound that adheres or bonds two items together.

The use of the terms adhesive and glue is confused.

Historically natural compounds used as an adhesive were called glues

Historically, glue only referred to protein colloids prepared from animal tissues.

Synthetic compounds were called adhesives.

Today the meaning of the term “adhesive” has been extended to any type of glue-like substances that is used to attach one material to another.

History of Adhesives

The first adhesives were gums and other plant resins.

Vegetable gums:

Guar gum

Gum Arabic

Archaeologists have found 6000-year-old ceramic vessels that had broken and been repaired using plant resin.

Most early adhesives were animal glues made by rendering animal products.

Native Americans use of buffalo hooves

Hide glue

Bone glue

Fish glue

Rabbit skin glue

History--cont.

Native Americans in what is now the eastern United States used a mixture of spruce gum and fat as adhesives and as caulk to waterproof seams in their birch bark canoes.

During the times of Babylonia, tar-like glue was used for gluing statues.

Egypt was one of the most prominent users of adhesives. The Egyptians used animal glues to adhere tombs, furniture, ivory, and papyrus.

Mongols used adhesives to make their short bows.

In Europe in the Middle Ages, egg whites were used to decorate parchments with gold leaves.

In the 1700s, the first glue factory was founded in Holland, which manufactured hide glue.

In the 1750s, the British introduced fish glue.

As the modernization continued, new patents were issued by using rubber, bones, starch, fish, and casein.

Adhesive/Glue Terms

Pot timeThe amount of time that can elapse between when the adhesive is exposed/mixed until the reaction develops to the point that the adhesive will not produce a good joint.Movement of the joint during this time should not reduce the strength of the joint.Varies with the type of adhesive and the environment.

Set timeStarts with the assembly of the joint.Any stress applied to the joint during this time will reduce the strength of the joint.For some adhesives it is the amount of time pressure should be held on the joint.

Cure timeThe amount of time before the adhesive reaches maximum strength. Varies with the type of adhesive an the environment

Advantages and Disadvantages of Adhesive Bonding

Advantages

No stress concentrations due to piercing of the adherend

Improved fatigue resistance

Lighter weight structures

Ability to join and seal simultaneously

Ability to join shock-sensitive substrates

Can be less expensive than mechanical fasteners

Process can be easily automated

Disadvantages

Strength is dependent upon the condition of the adherend surface

Limited non destructive quality control methods

Can be more expensive

Bond quality is dependent upon many variables

No single universal adhesive for all applications

Limited disassembly and repair

Categories of Adhesives

StructuralNaturalSynthetic adhesivesThermoplastic adhesivesThermosetting

Pressure sensitive

Structural adhesives harden by one of four (4) methods:

1. Evaporation of a solvent or water (white glue),

2. Reaction with radiation (dental adhesives),

3. Chemical reaction (two part epoxy)

4. Cooling (hot melt)

• Pressure sensitive adhesives (PSA’s) form a bond simply by the application of light pressure to marry the adhesive with the adherend.

• Pressure sensitive adhesives are designed with a balance between flow and resistance to flow.

• PSA’s are designed for either permanent or removable applications

Natural Adhesives

Type Notes

Fish Improved temperature resistance, resistance to water compared to above

Animal Made from collagen, (Skin/bone) with sugar and glycerol added for flexibility.Supplied as powder/bead which is dissolved in water

Casein Made from milk precipitated with acid. Supplied a powder for mixing with water. Improved properties compared to all above glues

Vegetable Based on starch, dextrine.Supplied as a powder for mixing with water. Low strength. Low resistance to water/high temps

Generally set by solvent evaporation.

They are generally of low strength and are susceptible to moisture and mold.

Their use is restricted to the joining of low strength materials.

http://www.roymech.co.uk/Useful_Tables/Adhesives/Nat_Adhesives.html

Synthetic Adhesives Elastomers

Based on natural and synthetic rubbers set by solvent evaporation or heat curing.

They have relatively low shear strength and suffer from creep and are therefore used for unstressed joints.

They are useful for flexible bonds with plastics and rubbers.

Natural Rubber Rubber solution with bonding be evaporation of solvent. Not suitable for loaded structures or adverse environments.Good for water but low resistance to oils and solvents

Polychloroprene (Neoprene)

Polyurethene Two component adhesives which can be formulated for applications.Resistant to acids, oils some solvents and alkalis. Susceptible to moisture.Load bearing duties viable.Flexible bonds suitable for shock and vibratory loading. High strength joints

Silicone Rubber Set at room temperatures.Has a high temperature service temperature of up to 300o C.Low shear strength. Very good sealing /space filling adhesive - widely used for glazing

http://www.roymech.co.uk/Useful_Tables/Adhesives/Adhesives.html#Types

Thermoplastic Adhesives

FusibleSolublePoor heat and creep resistant.They are normally used for low/medium loads.They have good resistance to oils but poor resistance to water.

Polyvinyl Acetate (PVA)

Supplied as an emulsion in water, for porous materials, especially woodShear strength is goodResistant to oilPoor resistance to waterLow heat tolerance ( White glue)

Cyanoacrylates Harden quickly in seconds based on catalytic action of surface moisture. Good for rubber. Care needed when used with metals in moist warm conditions. "Superglue"

Thermo Setting Adhesives

Type Info

Resorcinol resins

Good water resistance.Used for exterior plywood.

Polyesters (unsaturated)

Usually made to harden by chemical action rather than by the evaporation of solvents and thus cure with little shrinkage.

Polyamides High performance adhesives requiring higher curing temperatures and bonding pressures (up to 0.7 MPa ). High cost adhesive.

Epoxy resins Epoxy (mostly 2-part) adhesives have good strength and chemical resistance, do not produce volatiles during curing, and have low shrinkage. Form extremely strong and durable bonds with most materials in well-designed joints. Single part adhesives require heat for setting or long setting times.

Set as a result of the build up of molecular chains to produce a rigid cross linked structure.

Using Adhesives

Apply adhesiveUniform layerSome suggest using a notched applicator.Insure joint has sufficient adhesive to form a squeeze line when the joint is clamped.

No squeeze line = insufficient adhesive (starved joint)Excessive adhesive squeezing out = wasted adhesive

• Select the best adhesive for the materials being used and the environment.– Follow manufacturers

instructions.

• Prepare joint– Clean– Close fitting– Dampen

Using Adhesives--cont.

Force surfaces togetherUse correct amount of pressure

Insufficient pressure will result in a poor jointExcessive pressure may reduce joint strength

ClampsNails or other fasteners

Adhesive Failure

Adhesives can fail at several different points.Common failures are:

CohesiveAdhesive (Interfacial)Mixed fractureAlternating crack path


P a g e | 65


Objective

4. Apply empirical data to determine speeds and feeds to optimize production efficiencies.

COURSE OUTLINE




1

2

3

4

5

6

7

8

*

9

10

11

12

13

14

15

16

1/12

1/19-21

1/26

2/02

2/09

2/16

2/23

3/02

3/09

3/16

3/23

3/30

4/06

4/13

4/20

4/27

5/04

Lecture

Lecture

Lecture

Exam 1,

Lecture

Lecture

Lab

Exam 2

Spring Break

Lecture

Lecture/Lab

Lecture

Exam 3, Lab

Lecture

Lecture/Lab

Lecture/Lab

Exam 4



Heat Treatment



Welding Symbols

Welding Lab

-------------------------------------------------


Sand Castings

Sand Castings (lab)

Field Trip


Turning Processes/

Milling Processes


Chap. 1,17HO

Chap. 2

Chap. 7

Chap. 14

Chap. 14

Hand-out

----

Chap. 5

Handout

Handout

----

Chap. 9

Chap. 9

Chap. 10


Speeds & Feeds

RPM = 4CS/D

RPM = REVOLUTIONSD= DIAMETER

CS = CUTTING SPEED

Time Calculation

t = L / fRPM

t = time

L = length

f = feed inches per minute

RPM = revolutions per minute

Machine Routing


P a g e | 71


Objective

5. Demonstrate appropriate safety procedures and methods in a manufacturing setting.

COURSE OUTLINE




1

2

3

4

5

6

7

8

*

9

10

11

12

13

14

15

16

1/12

1/19-21

1/26

2/02

2/09

2/16

2/23

3/02

3/09

3/16

3/23

3/30

4/06

4/13

4/20

4/27

5/04

Lecture

Lecture

Lecture

Exam 1,

Lecture

Lecture

Lab

Exam 2

Spring Break

Lecture

Lecture/Lab

Lecture

Exam 3, Lab

Lecture

Lecture/Lab

Lecture/Lab

Exam 4



Heat Treatment



Welding Symbols

Welding Lab

-------------------------------------------------


Sand Castings

Sand Castings (lab)

Field Trip


Turning Processes/

Milling Processes


Chap. 1,17HO

Chap. 2

Chap. 7

Chap. 14

Chap. 14

Hand-out

----

Chap. 5

Handout

Handout

----

Chap. 9

Chap. 9

Chap. 10


Manufacturing Safety

1.Remember that the shop is a place for work, not horseplay,a. Any tricks or pranks are dangerous to you and your friends.b. Do not be responsible for sending a fellow student to the hospital by playing a practical

joke. For one moment of laughter, you will pay with a lifetime of regret.

2.Whenever possible, use the buddy system when working at a difficult task.

3.Dress safely.a. Roll up your sleeves, tuck in or remove your tie, and wear a shop coat or an apron b. Remove all jewelry, including rings and watches.

A watchband, for example, can catch in moving machinery c. Keep your hair cut short or out of the way.

Long hair around moving parts is dangerous and must be covered with a net or cap.

d. Always wear special protective clothing when working in the welding, forging, and foundry areas.

Important Safeguards


4.Protect your eyes and ears.a. Wear goggles or a shield whenever there are sparks.

You only have two eyes. Protect them.b. Wear safety glasses when grinding or buffing or whenever there is danger of flying

chips c. Wear special goggles or a shield for gas and arc welding.d. Wear goggles and protective clothing when pouring hot metal in the foundry or when

working with acids.e. Wear ear protection whenever shop noise is loud enough to damage ears

5.Take proper care of hand tools.a. Most accidents are caused by incorrect use of hand tools or poor tool maintenance.

Leaving scraps of metal lying around is always a hazard.b. Dull tools are dangerous.

Always keep tools sharp.


6.Use tools correctly.a. Choose the right tool or equipment for the job.

The work can then be done faster and more safely.b. There is always a right and a wrong way to use a tool.

Learn to use a tool the right way c. Never carry sharp tools in your pockets.

7.Use portable electric hand tools correctly. a. These tools operate on 110 volts.

This voltage can kill or cause a serious shock or burn under certain conditions.b. Always check the electric hand tool before using it.

Make sure the cord is in good condition and that it does not have a broken plug or switch.c. Always keep the cord away from oil or hot surfaces.d. Never use electric tools around flammable vapors and gases.

This could cause an explosion.e. Always be sure that your hands are dry when using an electric hand tool.


8.Observe safety rules when running machines.a. Always follow the safety rules given in each unit on each machine.b. Stop the machine before oiling, lubricating, or adjusting.c. Never feel the surface of metal while it is being machined.d. Clean chips off with a brush never with a rag or your hand.‑e. Never allow anyone to stand near the machine you are using.f. Never use measuring tools on metal while it is being machined.g. Keep the guards in place.

They were put there for your protection. 9.Be a good housekeeper.

a. Do your part in keeping the shop clean and in order.b. Clean the tool or machine after using it.c. Put away all tools and accessoriesd. Wipe up any oil or grease on the floor.e. Get rid of waste materials.f. Put your work away at the end of the period.g. A clean shop is likely to be a safe shop.

Do not wait for someone else to clean up


10.Ask for first aid every time you need it.a. Do not laugh off a small injury or burn.

Get first aid no matter how slight the injury. Infection may start many days after you scratch your hand.

b. Report every accident to your instructor. If necessary, he or she will send you to the school nurse or to a doctor.

c. A small burn, a metal sliver in your finger, or a cut can easily cause blood poisoning. A piece of metal in the eye can cause blindness. Don't believe it never happens; each year there are over 153,000 eye injuries to

students.

Whenever you are involved in any shop activity, remind yourself of these basic rules of safety, and practice them: (1) dress properly (2) know your job (3) and do your job correctly.

Ouch!


P a g e | 80


Objective

6. Demonstrate proficiency in the use of measurement instruments.

COURSE OUTLINE




1

2

3

4

5

6

7

8

*

9

10

11

12

13

14

15

16

1/12

1/19-21

1/26

2/02

2/09

2/16

2/23

3/02

3/09

3/16

3/23

3/30

4/06

4/13

4/20

4/27

5/04

Lecture

Lecture

Lecture

Exam 1,

Lecture

Lecture

Lab

Exam 2

Spring Break

Lecture

Lecture/Lab

Lecture

Exam 3, Lab

Lecture

Lecture/Lab

Lecture/Lab

Exam 4



Heat Treatment



Welding Symbols

Welding Lab

-------------------------------------------------


Sand Castings

Sand Castings (lab)

Field Trip


Turning Processes/

Milling Processes


Chap. 1,17HO

Chap. 2

Chap. 7

Chap. 14

Chap. 14

Hand-out

----

Chap. 5

Handout

Handout

----

Chap. 9

Chap. 9

Chap. 10


KEY WORDS

CALIBRATION – Comparison

METROLOGY – Science of Measurement

TRACEABILITY – Unbroken Chain of Comparisons

UNCERTAINTITY – Error in Measurement

ACCREDITATION – Third Party Ascertain

CALIBRATION INTERVAL – Equipment Remains Reliable

MFG 110S

Center-lineDistance

BC

A

A. ____________

B. ____________

C. ____________

Inside Diameter

S1S2

S3

83

A

B

C

D

E

F

I.D.

I.D.

Block

84

A

B

D

C

Flange

85

Counter-BoreI.D.

Counter-BoreDepth

A

B

C

O.D.

D

86

A

B

C

DE

F

HG

A._______

B._______

C._______

D._______

E._______

F._______

G._______

H._______

Lab Practice

Lab Practice

Met 110S

?

1. _______

2. _______

3. _______

4. _______

5. _______ Angle ?


P a g e | 88


Objective

7. Tour local manufacturing facilities (optional)

COURSE OUTLINE




1

2

3

4

5

6

7

8

*

9

10

11

12

13

14

15

16

1/12

1/19-21

1/26

2/02

2/09

2/16

2/23

3/02

3/09

3/16

3/23

3/30

4/06

4/13

4/20

4/27

5/04

Lecture

Lecture

Lecture

Exam 1,

Lecture

Lecture

Lab

Exam 2

Spring Break

Lecture

Lecture/Lab

Lecture

Exam 3, Lab

Lecture

Lecture/Lab

Lecture/Lab

Exam 4



Heat Treatment



Welding Symbols

Welding Lab

-------------------------------------------------


Sand Castings

Sand Castings (lab)

Field Trip


Turning Processes/

Milling Processes


Chap. 1,17HO

Chap. 2

Chap. 7

Chap. 14

Chap. 14

Hand-out

----

Chap. 5

Handout

Handout

----

Chap. 9

Chap. 9

Chap. 10


Field Trip

MINISTER MACHINE


P a g e | 90



SYLLABUS PART I

EDISON COMMUNITY COLLEGEMFG 114S SURVEY OF MANUFACTURING PROCESSES

4 CREDIT HOURS

COURSE DESCRIPTION:

Detailed overview of manufacturing processes including metrology, materials, heat- treating, machine tool operations, metal forming, welding processes and castings. Lab provides practical experience in metrology, machining practices, and welding processes. Lab fee.

COURSE GOALS:

The student will:

1. Define and apply basic measurement terms.

2. Interpret drawing dimensions and accurately apply them to the measurement of parts.

3. Quantify tolerances and explain their significance in gage selection.

4. Identify and select the proper inspection instrument for a given application.

5. Identify common materials used in manufacture and the types of processes commonly performed on those materials.

6. Describe the importance of heat treatment in the processing of metals.

7. Identify the basic processes for forming materials.

8. Describe modern tool geometry’s and identify tool geometry’s and their uses given information from the tool manufacturer.

9. Calculate and specify tool speeds, feeds, and depth of cut from standard equations or from manufacturer's data.

10. Describe common lathe and drilling processes, including their application and cutting parameters.

11. Identify common milling processes, including their application and cutting parameters.

12. Generate a simple CNC program using the manual, G-code programming technique

13. Specify grinding wheel parameters for various metals, removal rates, and required surface finishes

14. Specify appropriate welding processes and filler metals.

15. Correctly apply symbols to drawings to specify welding processes and parameters.

16.Experience hands-on exercises with selected manufacturing processes.

TOPIC OUTLINE:

17. Measurement terminology and systems18. Measurement instruments19. Materials for manufacture20. Steels and steel designations21. Heat treatment22. Casting processes23. Forming and shaping processes24. Sheet metal processes25. General machining practices and parameters26. Tool materials27. Turning processes28. Milling processes29. CNC Machines and manual CNC programming30. Grinding processes31. Welding processes and symbology

MFG 114S Part 1/11-15-02/2-15-05

Deleted Text 7-18-05

Documents

Definition of Manufacturing Processes Manufacturing processes are the steps through which raw materials are transformed into a final product. The manufacturing