MANUFACTURING.pptVIP

MANUFACTURING Manufacturing Processes Processes add value to materials A process involves a number of steps or operations Four basic processes applied on production materials are forming, material removal, assembly (or joining) and conditioning Forming operations change the geometry of the starting material without cutting it Material removal or separating processes remove a part of the starting material using a tool to get the desired geometry Combining processes join two materials or deposit material onto the exterior surface of the starting material Conditioning processes add value to the starting material by improving its internal and physical properties Forming Processes Casting A material in a liquid or semisolid form is poured or forced to flow into a mold cavity and allowed to solidify, thus taking the solid shape of the cavity The process can be applied on metals, ceramics and plastics The term casting is commonly used for metals The term molding is used for plastics Examples of molds – cake-pan, an ice-cube-tray or the footprints on a beach Types of castings – sand casting and die casting Sand casting – pouring molten metal into a sand mold, breaking up the mold to remove the casting Sand casting requires a pattern – a full sized model of the part Die casting is a permanent-mold-casting – molten metal is injected into the mold cavity under high pressure Molds for die casting are named as dies Forming Processes Pressing Pressing is commonly used for majority of sheet metal parts of an automobile A measured amount of material is poured into a mold. A plunger with its own shape is lowered to force the material to spread out and fill the mold The material is forced into the shape of the mold at the bottom and the shape of the plunger at the top Mechanical or hydraulic presses are used The plunger and the base of a forming die transform the sheet metal into the required shape – drawing – fuel tank of a motorbike Forming Processes Pressing Rolling is a type