bolt manufacturing process.pdf
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BOLT manufacturing processTRANSCRIPT
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Bolt Manufacture:
Process Selection
ver. 1
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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How would you make a bolt?
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Questions you might ask in response:Questions you might ask in response:
• Make it out of what (material)?( )• Make how many (volume)?• Make it how well (quality, tolerance)?(q y, )• Make how fast (rate or time)?• Make it how cheaply (cost)?Make it how cheaply (cost)?• Make it how large (size, dimensions)?• Make it for what (function)?Make it for what (function)?
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Possible Manufacturing Methods gfor Metal Bolts
C ti• Casting• Powder processing• Rolling / Heading• MachiningMachining• Welding head to threads
R id t t i• Rapid prototyping
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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CastingCasting• Sand • Die• Shell• Expendable mold
• Centrifugal• Squeeze
• Plaster• Ceramic
• Semi-solid• Single crystal
• Investment• Slush
g y• Directional
solidification• Pressure
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Sand CastingSand Casting
RisersSprue
Risers
GateCope
Parting Line
Gate
DragCasting
Parting Line
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Powder ProcessingPowder Processing
• Cold compaction and sinteringp g– Pressing– Rollingg– Extrusion– Injection moldingInjection molding– Isostatic pressing
• Hot Isostatic Pressing• Hot Isostatic Pressing
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Powder Pressing and Sinteringg g
PunchPunch
DieDie Part
Punch
Dual action press
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Cold Isostatic Pressing
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Hot Isostatic Pressing
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Rolling / HeadingRolling / Heading
• Roll the threads• Upset forge the headg
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Thread Rolling Machineg
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Thread Rolling Dieg
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Heading ProcessPunch
Blank
Kickout pin Die
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Forge for Headingg g
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MachiningCut threads on a lathe from hexagonal
stockstock
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Weld Head to ThreadsWeld Head to Threads• Threads :
ll d– rolled– machined
• Head:– cut from
barstock• Welding:
– arc– oxyacetylene
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y y
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Rapid Prototyping - PowderRapid Prototyping Powder Processing
Direct fabrication from a CAD file
• Selective Laser Sintering (SLS)3 D P i ti• 3-D Printing
• Light Engineered Net Shaping (LENS)
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Layered Manufacturingy g
LaserMirrorMirror
LayeredObject
Vat
Platform
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Selective Laser Sintering g(3D Systems)
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3D Printing Process (Soligen)
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3D Printing Head (Soligen)3D Printing Head (Soligen)
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Light Engineered Net Shaping (1)(S di N ti l L b)(Sandia National Lab)
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Light Engineered Net Shaping (2)Light Engineered Net Shaping (2)(Sandia National Lab)
Laser
Powderdeliverytube
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Light Engineered Net Shaping PartsLight Engineered Net Shaping Parts(Sandia National Lab)
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Organize ProcessesOrganize Processes
• CastingCasting• Powder
Compaction– Compaction– Rapid Prototyping
D f ti• Deformation• Machining
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Material Properties LimitsMaterial Properties LimitsProcess Effect on thread strength
Casting Brittle, due to grainstructure
P d C b b ittl d tPowder Can be brittle due tosintering process (voids,incomplete fusion)
Deformation Good strength due to coldDeformation Good strength, due to coldworking and graindeformation
Machining Reduced due to sharpac g educed due to s a pcorners, and cuttingthrough grains
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Problems due to grain structureProblems due to grain structure• Cast objects have grains that j g
grow together.• Cast objects are not cold workedCast objects are not cold worked.
Th f f tTherefore, fracture can occur along grain boundaries more
ileasily.
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Si t i P blSintering Problems
Voids Incomplete fusion
vs.
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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Grain Deformation vs CuttingGrain Deformation vs. Cutting(rolling vs. machining)
MachinedRolledRolled
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Mass ProductionMass ProductionProcess Mass Production
Casting Yes
Powder Yes for compaction;No for Rapid Prototyping
D f i YDeformation Yes
Machining Yesg
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CostCostProcess Cost
Casting Low
Powder Can be high; especiallyrapid prototyping
D f ti LDeformation Low
Machining Lowg
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FlexibilityFlexibilityProcess Flexibility
Casting Low
Powder High for RapidPrototyping
Deformation Low
Machining HighMachining High
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ToleranceToleranceProcess Tolerance
Casting Low
Powder Good
D f i G dDeformation Good
Machining Highg g
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Which process to pick?
• Normal sized bolts, mass d d d t thproduced, good strength:Rolling and heading
• Small bolts, mass produced:Machining on screw machineMachining on screw machine
• Large bolts, small numbers:M hi iMachining
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009
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SummarySummary
• Choice depends on what you are trying• Choice depends on what you are trying to accomplish.Ch i i t i l t k• Choosing is not a simple task.
• Lots of thought and calculations are needed.
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