Manufacturing Processes 1

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forging Forging is a product of hammering heated bars or

billets of material between dies

In forging hammers are used to exert thetremendous pressure that forces the metal into thedies.

Types of forging Drop forging- it is when the pressure during the

forming process was exerted by heavy impact. Press forging- it is when the pressure is from a slow

squeezing action.


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Advantages of forging over sand casting

Forging is better over sand casting because whenyou sand cast it is not smooth as if you were forging,

because when you forge it leave it smooth and lessbrittle.


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Die Casting

Die Casting is forcing a molten alloy or zinc into acavities between metal dies

It is the fast casting process It is used to make automobile, carburetors, toys, and

door handles.


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Dry sand cores: used when green

sand is not strong enough to from

some shapes; a mixture of sand and

biding substance

Core box: a box in which dry sand

cores are made.

The core is removed and baked in a

core oven to make it solid. A core is

used to extend through a castingand make a core hole.


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Core prints: made by acore to form openings inthe sand to support theends of the core.

Metal is poured intomold, flows aroundcore, leaves hole incasting. After cooling, itis removed from sand.

Dry sand core is brokenout. Casting is thencleaned. Any projectedfins are ground off on agrinder.


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The casting is sent to the

machine shop.

There, cored hole will be

enlarged by boring and

reaming.

The top and bottom

surfaces will be machined.

Small holes will be drilledand counter bored.


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Fastened by clamp and fed into rotating milling cutter.A wide variety of cuts are available by using different

shapes.

Accuracy is better when the machine is set up properly

and maintained. Laser-based milling is the most

accurate and has pinpoint abilities.

It can be used to design edges or cut inserts or slots in

boards to slide in properly with an object.

The Milling Machine


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Removes small amount of metal

to bring work to a very fine &

accurate finish.

Operator can tell machine

exactly how much to take off.

In cylindrical grinding the work

revolves on centers and moves

past the grinding wheel.

The machineautomatically

compensates for

abrasiveness on

the grinding

wheel.

Grinding Machine


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Used to shape cylinders, cones, and other rounded shapes.

Stock held at centers between face plate and chuck.

Individual Uses:

1. Turning

2. Facing

3. Drilling

4. Boring

5. Reaming

6. Knurling

Lathe


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Turning

Cutting external parts of cylindrical surfaces.

Facing

Cutting flat surfaces.

Drilling

Cutting a hole thru an object.

Boring

Cutting a hole partially thru an object.

Reaming

Knurling

Cutting groves in surface to allow better grip.


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Lathe


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Used to make holes in a non-moving object.

Usually followed by boring for improved roundness and

straightness.

1. Boring

2. Reaming

3. Counterboring

4. Spotfacing

5. Countersinking

Drill Press


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Boring

Enlarges the hole slightly rounder and straighter.

Reaming

Enlarges hole slightly and smoothes the surface.

Counterboring

The cutting of an enlarged cyulindrical protion at

the top of an existing hole.

Spotfacing

The cutting of a shallow Counterbore.

Countersinking

The cutting of an enlarged conical portion at one

end of a hole


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Drill Press


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The points oftangency must befound in the topview.

They must beprojected to theother views whererunouts arecarefully drawnfreehand.

Point of Tangency


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For Example , theupper top view in

Fig A would in eachcase be completelyblank, if lines werenot used to represent

rounded edges. The drawing then

would be misleading

No!

Correct

Fig. A


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Bronze Alloy of copper and tin

Brass Alloy of copper and zinc

Aluminum lightweight, corrosion resistant

and very malleable. Titanium Strong as steel but light as

aluminum


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Changed from paper to electronic based

Info from CAD programs are sent straight to

the machine CAD/CAM

CNC: vector-based drawing into toolmovement

Problems are created with a bad drawing


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Draft: A taper given to patterns to make it easier towithdraw from sand mold without damaging shape ofmold.

Injection molding- used to manufacture products suchas housings for electronic implements, automotivecomponents, food storage containers, and a variety ofother items

Fillet - Inside corners in particular should have fillets as

large as possible Round - A rounded outside corner


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Manufacturing Processes 1