group1_manufacturing process-class presentation
TRANSCRIPT
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Manufacturing process
Metal forming process
Metal removal process
Manufacturing systems and
Service Operations
By,
Sagar Bhore
Shenbagamoorthy M
Shubham Garg
Srajan Srivastava
Ratika Kapoor
Rahul Sarda1
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Manufacturing Process
Manufacture-derived from Latin Manu factuswhich means made by hand.
It is an industrial activity that changes the form of
raw material to create products.
Modern manufacturing includes all intermediate
processes required for the production and
integration of a product's components.
The production engineer should select themanufacturing process keeping in mind the needs
of the customer and at the same time with least
cost.
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Product Development
Parameters considered
while
designing
ManufacturabilityPerformance
Testability
Service
Quality
Cost
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Classification
ProcessedMaterial
Metallics
Polymers Ceramics
Glasses
Composites
Biomaterials
System ofOrganization
Discrete
Manufacturing Continuous
Manufacturing
Techniquesused
Solidification
Joining Plasticity
Cutting
Microstructurechange
CombinedProcess
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Casting
Casting, one of the oldest manufacturingprocesses, dates back to 4000 B.C. when copper
arrowheads were made.
Casting processes basically involve the
introduction of a molten metal into a mold cavity,
where upon solidification, the metal takes on the
shape of the mold cavity.
Sand CastingHigh Temperature Alloy,
Complex Geometry,
Rough Surface Finish
Investment CastingHigh Temperature Alloy,
Complex Geometry,Moderately Smooth Surface
Finish
Die CastingHigh Temperature Alloy,
Moderate Geometry,Smooth Surface
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Welding
Welding is a fabrication process that joinsmaterials, usually metals or thermoplastics, by
causing coalescence
Soldering and brazing involves melting a lower-
melting-point material between the workpieces to
form a bond between them, without melting the
workpieces.
Many different energy sources can be used for
welding, including a gas flame, an electric arc,
a laser, an electron beam, friction, and ultrasound.
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Metal Removal ProcessA part is created to its desired geometric
dimensions by the removal of excess materialfrom a work piece
A shearing force exerted through a certain cuttingtool
Qualities of a desirable manufacturing material
for this purpose would be:1) Lower Shear Strength (to make cutting easier)2) Shock Resistant (to withstand impact loading)3) Material must not have a tendency to stick tothe cutting tool
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Metal Removal Process
Machining can produce extreme dimensionalaccuracy, (tolerances of less than .001)
Machining accuracy allows it to produce surface
finish and smoothness that can't be achieved any
other way.
By combining different machining operations,
very complex parts can be made.
The removal process wastes material. Althougheconomical if the number of parts to be made is
small; labor, energy equipment, and scrap cost
are relatively high for large runs.
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Metal Removal Process
The cutting tool is used to remove the materials from the work piece through t
The removed metal or the waste generated are called ChipsProper Tool Geometry should be selected for efficient operation and surface a
Oblique Cutting Orthogonal Cutting 2D Representation
Tool life is moreHeat generated will be more
Chip flows sideways
Tool life is lessHeat generated will be less
Chip coils in light flat spiral
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Metal Removal Process
Speed (V)
-Relates velocity of the cutting tool to the work
piece
Feed (f)-Linear translation of tool per revolution with
respect to the work piece.
Depth of Cut (d)
-Distance the tool has plunged into the surface.
Material Removal Rate (MRR)
-Mass of material removed per unit machining time
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Material Removal Process
Conventionalmachining
Turning and related
operations
Drilling and related
operations
Milling
Other machining
operations (shaping,planing, broaching &
sawing)
Abrasiveprocesses
Nontraditional
machining
Grinding operations
Other abrasive
processes (honing,lapping & superfinishing)
Mechanical energy
process
Electrochemical
machining
Thermal energy
machining
Chemical machining11
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Turning
Facing:
Facing is the process of removing metal from the
end of a workpiece to produce a flat surface
Straight turning:
Work turned in a lathe so that the diameter is constant
over the length of the workpiece.
Taper turning :
An operation performed on a lathe that feeds a
tool at an angle to the length of the work piece in order
to create a conical shape
External grooving turning:
A method for removing the surface from a circular piece by bringing the cutting
edge of a tool against it while the piece is rotated.
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Turning
Roughing, or rough turning Finish turning13
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Drilling
Drillingis a cutting process that uses a drill bit to cut or enlarge a
hole of circular cross-section in solid materials.
The drill bit is a rotary cutting tool, often multipoint
The bit is pressed against the workpiece and rotated at rates from
hundreds to thousands of revolutions per minute
Drilling may affect the mechanical properties of the workpiece by
creating low residual stresses around the hole opening and a very
thin layer of highly stressed and disturbed material on the newly
formed surface
This causes the workpiece to become more susceptible to
corrosion at the stressed surface
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Drilling Operations
Reaming Tapping Counter Boring
Counter Sinking Centering Spot facing
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Boring In machining, boring is the process of enlarging a hole that has
already been drilled (or cast), by means of a single-point cutting
tool
Boring is used to achieve greater accuracy of the diameter of a
hole, and can be used to cut a tapered hole.
Boring can be viewed as the internal-diameter counterpart to
turning, which cuts external diameters
The boring bar may be supported on both ends (which only works if
the existing hole is a through hole), or it may be supported at one
end
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Milling
Milling is the most common form of machining, a material removal
process, which can create a variety of features on a part by
cutting away the unwanted material.
The cutting action of the many teeth around the milling cutter
provides a fast method of machining.
The machined surface may be flat, angular or curved. Thesurface may also be milled to any combination of shapes.
Milling machines are basically classified as Vertical or Horizontal.
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Types of Milling
Peripheral Milling Face
Milling This operation is also called plain millingoperation.
In this operation axis of rotating tool is
always kept parallel to the surface being
machined.
This operation is done by the cuttingedges on outside periphery of the milling
In the operation of face milling,axis of the milling cutter remains
perpendicular to the surface
being milled.
In this case cutting action is
done by end and outside of the
periphery18
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Peripheral Milling
Face Milling
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Other forms of milling
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Broaching
Broaching is a machining process for removal of a
layer of material of desired width and depth usually in
one stroke by a slender rod or bar type cutter having a
series of cutting edges with gradually increased
protrusion.
Broaching enables remove the whole material in one
stroke only by the gradually rising teeth of the cutter
called broach.
Commonly machined surfaces include circular and
non-circular holes, splines, keyways, and flat
surfaces.21
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Broaching
There are two main types of broaching: linear and rotary
In linear broaching, which is the more common process, the broach is
run linearly against a surface of the workpiece to effect the cut.
Linear broaches are used in a broaching machine, which is also
sometimes shortened to broach.
In rotary broaching, the broach is rotated and pressed into the
workpiece to cut an axis symmetric shape.
A rotary broach is used in a lathe or screw machine.22
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Broaching
Major advantages
Very high production rate (much higher than milling, planing, boring
etc.)
High dimensional and form accuracy and surface finish of the product
Roughing and finishing in single stroke of the same cutter
Needs only one motion (cutting), so design, construction, operationand control are simpler
Extremely suitable and economic for mass production
Limitations
Only through holes and surfaces can be machined
Usable only for light cuts, i.e. low chip load and unhard materials
Cutting speed cannot be high
Design, manufacture and restoration of the broaches are difficult and
expensive
Separate broach has to be procured and used whenever size, shapeand geometry of the job changes23
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SawingSawing is used to cut the correct sized work piece from a large
raw material stock and it is the first operation in manufacturing
There are several types of saws :
Hacksaws: straight blade, moving in a reciprocating motion;
Bandsaws: straight blade, ends welded together to make a loop,
moving continuously in one direction
Circular saws: blade in the shape of a circular disk, rotatingcontinuously.
Types of saws24
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Sawing Actions
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chip
slidetool-postpivot
chip
tool-post rotates as
slide returns;
workpiece shifted;
next stroke
(a) (b) (c)
chipchip
slidetool-postpivot
slidetool-postpivot
chip
tool-post rotates as
slide returns;
workpiece shifted;
next stroke
chip
tool-post rotates as
slide returns;
workpiece shifted;
next stroke
(a) (b) (c)
Shaping uses a single-point tool that is moved horizontally in a reciprocating
motion along a slide.
The ram holding the tool gets the reciprocating movement.
It is used to create a planar surface, usually to prepare rectangular blocks
that can later be used as workpieces for machining on a milling machine etc.
Shaping machine and shaping operation
Shaping
The planer like a shaper is a machine tool primarily intended to produce plane
and fiat surfaces by a single point cutting tool.
A planer is very large and massive compared to a shaper and capable of
machining heavy workpieces which cannot be accommodated on a shaper
Planing
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Grinding
The grinding operation involvesforcing a rotating abrasive Grinding
Wheel into a Workpiece.
This has proven to be the best
method for removing material in amanner which leaves a precision
surface.
The grinding operation is the final
machining process used to produce
precision Workpieces.Because of its high cost, the
grinding operation should be done as
efficiently as possible.Centreless Grinding
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Honing
Honing is a surface finishing operation based onabrasive action performed by a set of bonded
abrasive sticks.
It is generally used to finish bores of cylinders of
IC engine, hydraulic cylinders, gas barrels,bearings, etc.
It can reduce the level of surface roughness
below 32 m.
It produces a characteristics surface pattern
ascross hatched which is a fit case to retain
lubrication layer to facilitate motion to moving
parts28
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Metal Forming process
A group of manufacturing processes in which thematerial is shaped to a certain geometry by
applying external forces large enough to cause a
permanent deformation.
The deformed material experienced plasticdeformation, i.e. it will not return to its original
shape after the forces are released.
The external forces can be in the the form of
compression, tension, torsion, shearing,
bending,drawing or a combination of the various
forces.
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Hot Working and Cold Working
Hot working refers to theprocess where metals aredefromed above theirrecrystallizatontempereture and strainhardening does not
occur. Lower working forces to
produce a given shape,which means themachines involved don'thave to be as strong,which means they can bebuilt more cheaply
Hot working can removesome kinds of defectsthat occur in cast metals
Plastic deformationwhich is carried out ina temperature regionand over a timeinterval such that the
strain hardening is notrelieved is called coldworking.
A better surface finishmaybe achieved
Dimensional accuracycan be excellentbecause the work isnot hot so it doesn'tshrink on cooling
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Metal Forming process
Sheet
Sheet metal forming
Vacuum forming
Blow moulding
Drawing
Bulk
Powder
Forging
Rolling
Slip Casting
Pressing and
sintering
Isostatic pressing
Extrusion
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Metal RollingBasic Principle
The work material isplastically deformed bycompressive forces betweentwo constantly spinning rolls
Reduction in thicknesscalled draft
Shape changes but volumeremains constant
Point in the roll zone where
the surface velocity of therolls and that of the materialare exactly the same iscalled the no slip point
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ree g o ng our g o ng
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Direction of spin of the rolls can be
reversed
Enables the work to travel throughin one direction, then back through
in the other direction
Disadvantage - mechanical
requirements and power to
constantly overcome and reversethe angular momentum of the rolls
Three rolls that
always spin in thesame direction
An elevatormechanism lifts andlowers the work sothat it can be
passed back andforth through the
Roll force isreduced with asmaller radius ofthe rolls
Smaller radiusrolls deflecteasier and mustbe supported by
other rolls
Two High Rolling Millree g o ng
Millour g o ng
Mill
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Uses a small work roll backedup by many other rolls
Often used for cold rolling high
strength material to a very thin
width
Consists of several stands that the
work material constantly passesthrough
The total reduction between the
first and last stand is significant
Technical problems caused by the
speed of the work material
increasing as it passes through
Cluster Milling Tandem Rolling Mill
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Rotary Tube Piercing
Hot forming process
Compressive forcesapplied to a cylindercreate internal stresses
at the center The mandrel shaped
rolls rotate in the samedirection and are
oriented at an axis thatis at a slightly skewedangle to the axis of thepart causing the stockto be pulled through therolls forcing it against36
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Forging is a manufacturing process that involves
applying compressive forces to a work piece to
deform it, and create a desired geometric change
to the material.
Forging, similar to other forming processes,
effects the properties of the material of the forgedproduct.
Specifically, forging can strengthen the material by
eliminating cracks and empty spaces within the
metal. Forging a metal will also alter the metal's grain
structure with respect to the flow of the material
during its deformation.
Forging
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Open Die Forging
In an upsetting process the
work is placed between two
flat die and its height is
decreased by compressive
forces exerted between the
two die.
Since the volume of a metal
will remain constant
throughout its deformation, a
reduction in height will be
accompanied by an increase
Flat or slightly contoured die
are used to compress a work
piece, reducing its thickness
and increasing its length.
After each compression of
the material the open die
advance along the length of
the work piece and perform
another forging compression.
UPSETTING COGGING
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O Di F i
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Open die with convex
surfaces are used to deform
the work piece.
The result is to causematerial to flow out of one
area and to both sides.
In edging, open die with
concave surfaces plastically
deform the work material.
Edging acts to causematerial to flow into an area
from both sides.
Edging and fullering both are
used to redistribute bulk
quantities of the forging'smaterial.
Open Die ForgingFULLERING EDGING
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Impression die forging Impression die forging manufacture involves
compression of a work piece by the use of
impression die, (molds), that contain cavities that actto restrict the flow of metal within the die during thedeformation of the work
The material will fill the space within the die cavity asit is plastically compressed into the molds.
Closing of the molds completes the deformation,hence impression forging is also referred to asclosed die forging.
The forged metal part will now have the geometricdimensions of the mold, provided a complete filling ofthe die cavity occurred during the process.
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Heading
A process by which
stock is upset at its
end in order to
increase the cross
section of the materialin this area
Used for producing
fasteners that include
nails, screws, nuts
and bolts
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Roll Forging
Roll forging is a forming technique that
utilizes opposing rolls to shape a metalpart.
Even though roll forging uses rolls in
order to accomplish the deformation of
the material it is classified as a forging
process and not a rolling process. Moresimilarly to forging than rolling, it is a
discrete process and not a continuous
one.
Roll forging is usually performed hot.
Applications : Majorly used in
automotive industry
Products : Shaft of various geometrics,
knives, hand tools, leaf springs
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Sizing
Sizing is a forging process thatis used mainly to finish work thathas already been manufactured.
It is a cold forming process.
Sizing uses a lot of force over a
short distance producing veryaccurate dimensions in thefinishing of these parts. Thismanufacturing technique canalso be used to create work withexcellent surface quality.
Sizing is characteristic in thatduring the operation, the flow ofwork material is unrestricted inall directions except that overwhich the force is applied.
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Piercing
Piercing is a forming technique that isoften performed as an auxiliary
process in conjunction with other
forging processes, in the
manufacture of a part.
It can be used to create a cavity orhole in the work piece. Piercing does
not break through the material's
surface, like a drilling operation but
cavity is pressed into the work thats
why it is a forging operation.
Piercing will effect the properties ofthe work material, and change the
grain structure of the part.
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Swaging
Swaging is a forming method of reducing aregular or irregular cross section area of tube, bar
or wire using two or more dies which surround the
outside of the work-piece completely or partially,
to a round predetermined diameter. It is usually cold working process but sometimes
may done as a hot working process
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Hobbing Hobbing is a cold working, forging process in which a punch
with an exact geometry at its end is pressed into a workpiece.
The special punch, called a hob, will create a cavity with theprecise dimensions desired.
Due to the high tolerances of the hob, the high pressuresapplied during the manufacturing process, and the fact that
the operation is performed cold, very accurate dimensionsand surface quality are obtained within the cavity.
A common application of hobbing in modern industry is toproduce molds or die cavities for other manufacturingoperations
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Skew Rolling
A process typically used formaking ball bearings
A round wire or rod stock is
fed into the roll gap and
spherical blanks are formedby the continuous rotating
rolls
The balls are then ground
and polished
This process is hot metal
process
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Drawing
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Drawing is an operation in which the cross-section of solid rod, wire ortubing is reduced or changed in shape by pulling it through a die.
The principle of this procedure consist of reducing the thickness of apointed ,tapered wire by drawing it through a conical opening in a toolmade of a hard material.The wire will take shape of the hole.
Drawing
This process is widely used for the production of thicker walled
seamless tubes and cylinders therefore; shafts, spindles, and small
pistons and as the raw material for fasteners such as rivets, bolts,
screws.
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Extrusion
In extrusion, the workpiece is placed in a container andcompressed until pressure inside the metal reaches
flowstress levels.
The workpiece completely fills the container and additional
pressure causes it to travel through an orifice and form the
extruded product.
Extrusion can be forward (direct) or backward (reverse),
depending on the direction of motion between ram and
extruded product.
Extruded product can be solid or hollow.
Tube extrusion is typical of forward extrusion of hollow
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