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Casting
Forming
Plastics processing
Cutting
Joining
Surface treatment
Casting
Permanent good finish, low porosity, high Costly mold, simpler gears, gear housings
mold production rate shapes only
Die Excellent dimensional accuracy, costly dies, small parts, gears, camera bodies,
high production rate non-ferrous metals car wheels
Centrifugal Large cylindrical parts, good Expensive, few shapes pipes, boilers,
quality flywheels
Sand Casting
Sand Casting
pattern: positive
funnel sprue
runners gate
cavity
{risers, vents}
Sand Casting Considerations
(b) Why is the pattern not exactly identical to the part shape?
- how to determine?
Sand Casting Considerations..
(d) taper
- do we need it ?
- Styrofoam pattern
- dipped in refractory slurry dried
- sand (support)
- pour liquid metal
- foam evaporates, metal fills the shell
- cool, solidify
- break shell part
molten
metal
support polystyrene
sand pattern burns;
polystyrene gas escapes
pattern
Plaster-mold, Ceramic-mold casting
- permanent mold
- rotated about its axis at 300 ~ 3000 rpm
- molten metal is poured
0
max
2a
2b
0
Casting Design: guidelines
Casting
Forming
Plastics processing
Cutting
Joining
Surface treatment
Forming
Example products:
Al/Steel frame of doors and windows, coins, springs,
Elevator doors, cables and wires, sheet-metal, sheet-metal parts…
Rolling
Hot-rolling
Cold-rolling
Rolling
Important Applications:
Steel Plants,
Raw stock production (sheets, tubes, Rods, etc.)
Screw manufacture
Rolling Basics
tf Vf Vf
to to tf
Vo
Vo
stationary die
Screw manufacture:
rolling die
thread rolling machine
[Heated] metal is beaten with a heavy hammer to give it the required shape
Hot forging,
open-die
Stages in Open-Die Forging
[source:www.scotforge.com]
Stages in Closed-Die Forging
(a)
(b)
Flash
(c)
[source:www.scotforge.com]
Extrusion
[source:www.magnode.com]
Typical use: ductile metals (Cu, Steel, Al, Mg), Plastics, Rubbers
Common products:
chamber die
extruded shape
hydraulic
stock
piston
chamber
F (pulling force)
Casting
Forming
Plastics processing
Cutting
Joining
Surface treatment
Sheet Metal Processes
Processes:
Shearing
Punching
Bending
Deep drawing
Shearing
Main use: to cut large sheet into smaller sizes for making parts.
Punching
t sheet
die die
clearance
Punching
Main uses: cutting holes in sheets; cutting sheet to required shape
nesting of parts
(a)
(b)
Sheet metal bending
This section is
under extension
T = Sheet thickness
Neutral axis
L = Bend length
This section is R = Bend radius
in compression
Ideal case: k = 0.5 Real cases: k = 0.33 ( R < 2T) ~~ k = 0.5 (R > 2T)
Bending: cracking, anisotropic effects, Poisson effect
Final R
i i
Rf
Initial f
How to handle springback:
3
R RY RY
(a) Compensation: the metal is bent by a larger angle i 4 i 3 i 1
Rf ET ET
part
die die die die die