matl manufacturing

8/17/2019 Matl Manufacturing

1/19

Materials


2/19

Properties of Materials

Mechanical Properties: strength, toughness, ductility,hardness, elasticity, fatigue, creep.

Behavior Under Loading: tension, compression, bending,torsion, shear.

Physical Properties: density, specific heat, thermal expansion,thermal conductivity, melting point, electrical and magnetic

properties.

Chemical Properties: oxidation, corrosion, degradation,toxicity, flammability.


3/19

Types of Materials

Ferrous Metals: iron and steel.

Nonferrous Metals and Alloys: aluminum,magnesium, copper, nickel, titanium, superalloys,

beryllium, zirconium, lowmelting alloys, precious metals.

Plastics: thermoplastics, thermosets, elastomers.

Ceramics: glass, graphite, diamond.

Composite materials: reinforced plastics, metalmatrix and ceramicmatrix composites, honeycomb

structures.


4/19

!errous Metals: "pplications

# $tructural: building structures, concrete reinforcement

# "utomotive: chassis, engine parts, drive train, body

parts# Marine: ship hulls, structure, engines

# %efense: tanks, weapons

# &onsumer Products: appliances, recreational vehicles,

toys, utensils and tools


5/19

'onferrous Metals: "pplications

# "rchitectural: aluminum windows and doors

# "utomotive: aluminum engine blocks, copper

wiring, mag wheels

# Marine: brass(bronze fittings, bearings, propellers

# %efense: brass shell casings

# &onsumer Products: electrical wiring, utensils,

)ewelry, electronics


6/19

Plastics *Polymers+

# &ompared to metals, plastics have lower density,

strength, elastic modulus, and thermal and

electrical conductivity, and a higher coefficient of

thermal expansion

# The design of plastic parts should include

considerations of their low strength and stiffness,and high thermal expansion and low resistance to

temperature.


7/19

Plastics: "pplications

# "rchitectural: electrical and thermal insulation, weather

seals, carpets, wall coverings, paint

# "erospace: electrical and thermal insulation, instrument

panels,upholstery, seals

# "utomotive: body panels, instrument panels, upholstery,

electrical and thermal insulation, seals, hoses, tires

# &onsumer Products: toys, sporting goods, appliances, tools,

utensils, clothing, shoes, packaging


8/19

Manufacturing

The Process of &onverting -aw

Materials nto Products/


9/19

Manufacturing a Product:

0eneral &onsiderations# Material $election

# Processing Methods

# !inal $hape and "ppearance

# %imensional and $urface !inish

# 1conomics of Tooling# %esign -e2uirements

# $afety and 1nvironmental &oncerns


10/19

&hoosing Methods of Production

3se a $election &hart


11/19

Manufacturing Processes for Metals

# Casting: expendable mold and permanent mold.

# Forming and Shaping: rolling, forging, extrusion, drawing, sheetforming, powder metallurgy, molding

# Machining: turning, boring, drilling, milling, planing, shaping,

broaching, grinding, ultrasonic machining, chemical machining, electricaldischarge machining *1%M+, electrochemical machining, highenergy

beam machining

# oining: welding, brazing, soldering, diffusion bonding, adhesive

bonding, mechanical )oining

# Finishing: honing, lapping, polishing, burnishing, deburring, surfacetreating, coating, plating


12/19

&asting Processes

Introduction of molten metal into a mold cavity; upon solidification, metal conforms to the shape of the cavity.

%ie &asting $and &asting


13/19

!orming and $haping Processes

Bulk deformation processes that induce shape changesby plastic deformation under forces applied by tools

and dies.

!orging

1xtrusion


14/19

Machining Processes

Material removal from a work piece: cutting, grinding,

nontraditional machining processes.

Milling 4athe Machine


15/19

'& Machine Tool and &ontroller


16/19

'& Punch Press Machine


17/19

Manufacturing Processes

for Plastics

# Plastics are shipped to manufacturing plants as

pellets or powders and are melted )ust before the

shaping process. Polymers melt at relatively lowtemperatures and are easy to handle.

# Plastics can be molded and formed, as well asmachined and )oined, into many shapes with

relative ease.


18/19

n)ection Molding of Plastics


19/19

Selective Laser Sintering System

Courtesy of the University of !e"as

matl manufacturing

Documents