Manufacturing final summary
(Theory)
Concepts:
What is the dilemma between manufacturing & design?
To achieve design quality, material should be strong but for ease of manufacturing material shouldn’t
be strong
Definitions:
Metal forming = plastic strain
Ductility = ability to form metals
Drawing = forming metal into convex/ concave shapes
Impact extrusion = high speed cold extrusion
Blanking = cut out segment is used as part
Punch = cut out segment is scrap
Draft = is the measure of work squeezing
Machining = cutting through shear to shape material
Generating =machining through tool feed motion
Forming = machining through tool shape
Turning = cutting through workpiece rotation by fixed tool
(RW) = resistance welding= group welding processes that use heat & pressure to merge metals
(AW) = arc welding = fusion welding process merging metals by electric arc between electrode &
workpiece
(SMAW) = shielded metal arc welding = stick welding =Uses a consumable electrode consisting of a
filler metal rod coated with chemicals that provide flux and shielding
(RSEW)= resistance seam welding= uses rotating wheel electrodes to make a series of overlapping
spot welds
(RPW)=resistance projection welding= RW process that merges metals at one or more small contact
points on part
Brazing=soldering = a joining process where filler metal is melted and distributed by capillary action
across faying surface between metal parts being joined
(base metal doesn’t melt only filler metal does)
Adherends = parts being joined by adhesive
, Tables:
Casting molds
expendable Permanent
Production rate limited by time to make ✓ Higher production rate
molds
✓ More complex shapes Limited geometry
Die casting
Advantages Disadvantages
Economical for mass production
Limited to metals with low melting points
Good accuracy & surface finish
Thin sections are possible
Rapid cooling provides: Geometry of work part must allow it’s removal
1. Small grain size from the die
2. Good strength for casting
extrusion
Direct Indirect
Also known as: Also known as:
forward extrusion backward / reverse extrusion
Small portion of billet remains (butt) Can’t support extrude exiting the die
Friction is a factor Hollow arm is less rigid
Ram and final product have same direction Ram and final product have opposite directions
(Theory)
Concepts:
What is the dilemma between manufacturing & design?
To achieve design quality, material should be strong but for ease of manufacturing material shouldn’t
be strong
Definitions:
Metal forming = plastic strain
Ductility = ability to form metals
Drawing = forming metal into convex/ concave shapes
Impact extrusion = high speed cold extrusion
Blanking = cut out segment is used as part
Punch = cut out segment is scrap
Draft = is the measure of work squeezing
Machining = cutting through shear to shape material
Generating =machining through tool feed motion
Forming = machining through tool shape
Turning = cutting through workpiece rotation by fixed tool
(RW) = resistance welding= group welding processes that use heat & pressure to merge metals
(AW) = arc welding = fusion welding process merging metals by electric arc between electrode &
workpiece
(SMAW) = shielded metal arc welding = stick welding =Uses a consumable electrode consisting of a
filler metal rod coated with chemicals that provide flux and shielding
(RSEW)= resistance seam welding= uses rotating wheel electrodes to make a series of overlapping
spot welds
(RPW)=resistance projection welding= RW process that merges metals at one or more small contact
points on part
Brazing=soldering = a joining process where filler metal is melted and distributed by capillary action
across faying surface between metal parts being joined
(base metal doesn’t melt only filler metal does)
Adherends = parts being joined by adhesive
, Tables:
Casting molds
expendable Permanent
Production rate limited by time to make ✓ Higher production rate
molds
✓ More complex shapes Limited geometry
Die casting
Advantages Disadvantages
Economical for mass production
Limited to metals with low melting points
Good accuracy & surface finish
Thin sections are possible
Rapid cooling provides: Geometry of work part must allow it’s removal
1. Small grain size from the die
2. Good strength for casting
extrusion
Direct Indirect
Also known as: Also known as:
forward extrusion backward / reverse extrusion
Small portion of billet remains (butt) Can’t support extrude exiting the die
Friction is a factor Hollow arm is less rigid
Ram and final product have same direction Ram and final product have opposite directions
