This document provides an overview of various manufacturing processes including shaping operations, property-enhancing operations, surface processing, and assembly operations. It discusses primary shaping operations such as casting, forging, machining, and molding. Specific molding processes covered include compression molding, transfer molding, and injection molding. The document also summarizes heat treatment processes and surface treatments like electroplating, anodizing, sandblasting and shot peening.
This document discusses blow moulding, which uses compressed air to form hollow plastic products like bottles from thermoplastics. It describes the advantages of blow moulding over injection moulding, including its ability to produce irregular shapes with variable wall thickness at lower pressures. Extrusion blow moulding and injection blow moulding are the main types discussed, along with stretch blow moulding. The extrusion process and machinery are explained in detail. Common plastic materials used are also listed for small and large products.
This document discusses different types of blow molding processes used to make hollow plastic parts. It describes injection blow molding, stretch blow molding, and extrusion blow molding. Injection blow molding uses preforms made via injection molding and is used for small, high-volume products. Stretch blow molding also uses preforms but stretches them using a core rod and is used for bottles and jars. Extrusion blow molding extrudes a hollow plastic tube called a parison then air is pumped in to shape it in a mold, used for containers. The document outlines design considerations, advantages, disadvantages, applications, and examples of blow molding processes and products.
Extrusion is a process that uses pressure to force a billet through a die opening to create an object with a constant cross-section. Most metals are hot extruded due to the large forces required. Extrusion can produce complex shapes, especially for more readily extrudable metals like aluminum. Common extruded products include automotive and construction parts. Factors like temperature, pressure, and lubrication affect the extrusion process and properties of the final product. Defects can occur due to non-uniform deformation or temperatures that cause cracking.
Compression molding involves placing plastic material into a heated mold cavity, closing the mold, and applying pressure and heat to compress the material into shape. It is commonly used to make electrical components. Transfer molding similarly uses pressure to mold thermoset plastics, but involves transferring the material from a heated pot into the mold cavity. This document discusses these processes, providing details on their working principles, pros and cons, and an example of using compression molding to fabricate a microlens array from polycarbonate and glass for optical applications.
Transfer molding is a manufacturing process where a casting material is forced into an enclosed mold under pressure to form a casting. There are different types of transfer molding including resin transfer molding (RTM) and vacuum assisted resin transfer molding (VARTM). Thermoset polymers and fibers are common materials used. The transfer molding process involves placing the preheated molding compound in a transfer pot, closing the mold, and forcing the compound into the mold cavity under pressure where it cures. Applications include parts for the natural gas, electrical, and automotive industries. Advantages are uniform products and simpler production compared to other molding processes, while disadvantages include more material waste.
Injection molding is a manufacturing process that uses molds to produce plastic or rubber parts. Molds are hollow blocks that give the part its shape and allow it to cool. Thermoplastics can be molded repeatedly while thermosetting plastics set permanently after one molding. Injection molding machines consist of a hopper, barrel with a reciprocating screw, nozzle, and molds. The process involves melting plastic in the heated barrel and injecting it into the mold under pressure before allowing it to cool into the final shape.
1. The document describes different types of moulds used in plastic injection molding including two plate, three plate, split cavity, side core, and hot runner moulds.
2. A split cavity mould is suitable for moulding components with all-round external undercuts and uses sliding splits, angular lifts, or pins for actuation.
3. A side core or side cavity mould is used for components with local external undercuts and can be actuated via finger cams, dog leg cams, cam tracks, springs, or hydraulics.
This document discusses blow moulding, which uses compressed air to form hollow plastic products like bottles from thermoplastics. It describes the advantages of blow moulding over injection moulding, including its ability to produce irregular shapes with variable wall thickness at lower pressures. Extrusion blow moulding and injection blow moulding are the main types discussed, along with stretch blow moulding. The extrusion process and machinery are explained in detail. Common plastic materials used are also listed for small and large products.
This document discusses different types of blow molding processes used to make hollow plastic parts. It describes injection blow molding, stretch blow molding, and extrusion blow molding. Injection blow molding uses preforms made via injection molding and is used for small, high-volume products. Stretch blow molding also uses preforms but stretches them using a core rod and is used for bottles and jars. Extrusion blow molding extrudes a hollow plastic tube called a parison then air is pumped in to shape it in a mold, used for containers. The document outlines design considerations, advantages, disadvantages, applications, and examples of blow molding processes and products.
Extrusion is a process that uses pressure to force a billet through a die opening to create an object with a constant cross-section. Most metals are hot extruded due to the large forces required. Extrusion can produce complex shapes, especially for more readily extrudable metals like aluminum. Common extruded products include automotive and construction parts. Factors like temperature, pressure, and lubrication affect the extrusion process and properties of the final product. Defects can occur due to non-uniform deformation or temperatures that cause cracking.
Compression molding involves placing plastic material into a heated mold cavity, closing the mold, and applying pressure and heat to compress the material into shape. It is commonly used to make electrical components. Transfer molding similarly uses pressure to mold thermoset plastics, but involves transferring the material from a heated pot into the mold cavity. This document discusses these processes, providing details on their working principles, pros and cons, and an example of using compression molding to fabricate a microlens array from polycarbonate and glass for optical applications.
Transfer molding is a manufacturing process where a casting material is forced into an enclosed mold under pressure to form a casting. There are different types of transfer molding including resin transfer molding (RTM) and vacuum assisted resin transfer molding (VARTM). Thermoset polymers and fibers are common materials used. The transfer molding process involves placing the preheated molding compound in a transfer pot, closing the mold, and forcing the compound into the mold cavity under pressure where it cures. Applications include parts for the natural gas, electrical, and automotive industries. Advantages are uniform products and simpler production compared to other molding processes, while disadvantages include more material waste.
Injection molding is a manufacturing process that uses molds to produce plastic or rubber parts. Molds are hollow blocks that give the part its shape and allow it to cool. Thermoplastics can be molded repeatedly while thermosetting plastics set permanently after one molding. Injection molding machines consist of a hopper, barrel with a reciprocating screw, nozzle, and molds. The process involves melting plastic in the heated barrel and injecting it into the mold under pressure before allowing it to cool into the final shape.
1. The document describes different types of moulds used in plastic injection molding including two plate, three plate, split cavity, side core, and hot runner moulds.
2. A split cavity mould is suitable for moulding components with all-round external undercuts and uses sliding splits, angular lifts, or pins for actuation.
3. A side core or side cavity mould is used for components with local external undercuts and can be actuated via finger cams, dog leg cams, cam tracks, springs, or hydraulics.
Blow molding is a manufacturing process that uses air pressure to form hollow plastic parts like bottles. There are three main blow molding processes: extrusion blow molding where a tube of molten plastic (parison) is captured in a mold and inflated, injection blow molding where a preform is first injection molded and then blown, and stretch blow molding where preforms are first made via injection molding and then reheated and blown into shape. Blow molding can make parts from various plastics like PET, HDPE, and PP. It is used widely to make containers and bottles for foods, drinks, chemicals and more.
The document discusses various polymer processing techniques. It begins by explaining that the main goal of polymer processing is to produce usable objects and lists the necessary parameters for processing including flow, heat transfer, mass transfer, and chemical reactions. It then focuses on extrusion, describing it as shaping material by forcing it through a die. Various extrusion techniques are discussed including single screw extrusion, twin screw extrusion, blown film extrusion, co-extrusion, and injection molding. Other processing methods summarized include thermoforming, vacuum forming, rotational molding, calendering, and spinning.
Plastic manufacturing "forming and shaping plastics"Ayush Mathur
The document discusses various aspects of plastics manufacturing processes. It describes how plastics are formed and shaped through molding, cutting, forming, machining and joining. Some key plastics manufacturing processes discussed include injection molding, blow molding, compression molding, transfer molding, reaction injection molding, extrusion, and thermoforming. The properties of plastic parts are influenced by the manufacturing method and processing parameters used. Large, complex shapes can often be formed as a single unit through these plastic fabrication processes.
This document discusses various manufacturing processes for plastic components. It begins by explaining what plastics are, how they are made from polymers, and the different types of plastics including thermoplastics and thermosets. It then covers several common plastic manufacturing processes like compression molding, transfer molding, injection molding, blow molding, and extrusion. For each process, it provides details on how the process works, suitable materials, advantages and disadvantages, and common applications. It also discusses defects that can occur in injection molding and additives that are often included with plastics.
Cold isostatic pressing (CIP) is a technique where high pressure is applied uniformly to metal powder sealed in a flexible container. This compacts the powder to a density of 75-85% without die wall friction, resulting in a part with uniform density and no residual stresses. There are two methods - the wet bag process suited for batch production of complex parts, and the dry bag process using a fixed mold for mass production. CIP is used to make intricate or long shapes out of materials like titanium, tool steels, tungsten, and molybdenum powders.
Extrusion is a process that uses pressure to force a billet through a die opening to create an object with a constant cross-section. Most metals are hot extruded due to the large forces required. Extrusion can produce complex shapes, especially for more readily extrudable metals like aluminum. Common extrusion products include automotive and construction parts. Factors like temperature, pressure, and lubrication affect the extrusion process and properties of the final product. Defects can occur due to non-uniform deformation or temperatures that cause cracking.
Powder metallurgy is a process that involves compacting and forming metal powders into a solid object through sintering. It consists of 3 main steps - producing metal powders through various methods, compacting the powders into a green compact through pressing, and sintering the compact by heating it to fuse the particles together into a solid object. It allows for net-shape production of complex parts and close dimensional tolerances, and is used for applications where other fabrication methods are not suitable.
RTM is a low-pressure molding process, where a mixed resin and catalyst are injected into a closed mold containing a fiber pack or preform . when the resin has cured the mold can be opened and finished component removed.
Seminar on all electrical injection moulding machine mainanymona1991
This document provides information about the study and operation of all electric injection molding machines. It discusses the history of injection molding machines, describes the key components and operation of all electric machines, and compares them to hydraulic injection molding machines. All electric injection molding machines use servomotors to control each function, providing greater precision and accuracy than hydraulic machines while using 40-80% less energy. Maintenance of all electric machines focuses on preventative maintenance of components like sensors and motors.
This document provides an overview of injection molding. It describes the different types of injection molding machines and their key components. The complete injection molding process and cycle is explained, including plasticization, injection, packing, cooling, and ejection. Process parameters that affect quality are identified. Common defects are defined and potential causes are listed. Applications and advantages/disadvantages of injection molding are also summarized.
it is PDF are typed of myself. study triks & short & sweet (Technical manual) Of Diploma in Plastics technology(DPT-DPMT). All machine knowlage in plastics processing.
Er. Naresh Dhaker
(8890881858)
(CIPET JAIPUR)
Ideal process parameters in injection mouldingNaik Devang
This document discusses ideal process parameters for injection molding. It defines key terms like injection pressure, screw speed, back pressure, and nozzle. It explains the importance of melt temperature, flow rate, pressure, time, screw surface speed, and material drying. Process settings like mold temperature, cavity pressure, sprue bush diameter, and gate mechanism are also covered. The document emphasizes that melt temperature must be controlled to reproduce parts consistently across machines and that education is key to successful implementation of injection molding.
Blow molding is a plastic processing technique where a heated plastic material is extruded into a hollow shape called a parison, which is then placed inside a mold and inflated with air until it takes the shape of the mold cavity. There are different types of blow molding depending on how the parison is formed, such as extrusion blow molding where plastic is continuously extruded and cut into parisons. Common materials used for blow molding include HDPE, LDPE, PP, PVC, and PET. Key factors that affect blow molding include the parison characteristics, inflation pressure, mold design, and blow ratio.
Blow Molding is defined appropriately and also the process compatible materials are listed. Blow Molding is broadly classified as - extrusion type, injection type, Multilayer type. All three processes are explained appropriately with diagrams and their application is also listed. Since every thing has advantages and disadvantages, so is the case with blow molding. References are also cited correctly. I hope you all find it useful
(1) Compression molding is a manufacturing process used to mold thermosetting materials under heat and pressure in a mold cavity.
(2) The process involves preheating the molding material, placing it into the mold, applying pressure using a hydraulic press, and allowing the material to cure.
(3) Compression molding is commonly used to make electrical parts, dinnerware, gears, buttons, and automotive and medical components. It allows for high volume, low-cost production with minimal material waste.
This document discusses the manufacturing of plastic components through various plastic manufacturing processes. It begins by introducing plastics and classifying them as either natural or synthetic organic materials. The two main types of plastics are then described as thermosetting plastics and thermoplastics. Thermosetting plastics harden through a chemical reaction when heated and cannot be remelted or remolded, while thermoplastics soften when heated and harden again when cooled, allowing them to be remolded. Several common types of both thermosetting and thermoplastic materials are then outlined along with their typical uses. Injection molding is introduced as a high-speed manufacturing process for thermoplastics where molten plastic is injected into a
- Shell moulding is an efficient and economical casting method that uses a resin-sand mixture to form a thin "shell" around a heated pattern. This shell is then used as the mold cavity.
- Investment casting, also called lost-wax casting, is an ancient casting process used to produce complex shapes. It involves creating a wax pattern, coating it with refractory materials to form a ceramic "shell" mold, heating to remove the wax, and pouring molten metal into the shell. This allows for net-shape casting of intricate parts.
- Pressure die casting is a high-pressure casting process where molten metal is injected into steel dies to form castings. It is well-su
Thermoforming is a process where a plastic sheet is heated and formed into a desired shape using pressure, vacuum, or mechanical methods. There are three main thermoforming methods: vacuum forming uses vacuum pressure to draw the heated sheet onto a mold; pressure forming uses compressed air to force the sheet onto the mold more quickly; and mechanical forming uses matching molds to shape the sheet without vacuum or pressure. Common materials thermoformed include plastics like ABS, polyethylene, and PVC. Applications include food packaging, automotive and aircraft parts.
This document discusses various types of polymers and polymer processing techniques. It begins by defining polymers as substances made of repeating molecular units called mers. Polymers are classified as thermoplastics or thermosets depending on whether they can be remelted or undergo further chemical reactions. Common polymer processing techniques include extrusion, injection molding, blow molding, thermoforming, and composites fabrication. The document provides details on the basic mechanisms and applications of these important industrial polymer processes.
This document describes the development of a small plastic injection moulding machine for producing small plastic articles in small-scale industries. It discusses the design, construction, and testing of the machine. The machine is capable of injecting molten resins into a closed, cooled mould to produce plastic products. The design concept, operation, and assembly of component parts are covered. The document also provides details on the working principle of plastic injection moulding, including the various constructional parts of the machine like the PID controller, band heaters, thermocouple, and solid state relay. It discusses the assembly procedure and includes calculations and results from the first trial using polypropylene plastic.
Blow molding is a manufacturing process that uses air pressure to form hollow plastic parts like bottles. There are three main blow molding processes: extrusion blow molding where a tube of molten plastic (parison) is captured in a mold and inflated, injection blow molding where a preform is first injection molded and then blown, and stretch blow molding where preforms are first made via injection molding and then reheated and blown into shape. Blow molding can make parts from various plastics like PET, HDPE, and PP. It is used widely to make containers and bottles for foods, drinks, chemicals and more.
The document discusses various polymer processing techniques. It begins by explaining that the main goal of polymer processing is to produce usable objects and lists the necessary parameters for processing including flow, heat transfer, mass transfer, and chemical reactions. It then focuses on extrusion, describing it as shaping material by forcing it through a die. Various extrusion techniques are discussed including single screw extrusion, twin screw extrusion, blown film extrusion, co-extrusion, and injection molding. Other processing methods summarized include thermoforming, vacuum forming, rotational molding, calendering, and spinning.
Plastic manufacturing "forming and shaping plastics"Ayush Mathur
The document discusses various aspects of plastics manufacturing processes. It describes how plastics are formed and shaped through molding, cutting, forming, machining and joining. Some key plastics manufacturing processes discussed include injection molding, blow molding, compression molding, transfer molding, reaction injection molding, extrusion, and thermoforming. The properties of plastic parts are influenced by the manufacturing method and processing parameters used. Large, complex shapes can often be formed as a single unit through these plastic fabrication processes.
This document discusses various manufacturing processes for plastic components. It begins by explaining what plastics are, how they are made from polymers, and the different types of plastics including thermoplastics and thermosets. It then covers several common plastic manufacturing processes like compression molding, transfer molding, injection molding, blow molding, and extrusion. For each process, it provides details on how the process works, suitable materials, advantages and disadvantages, and common applications. It also discusses defects that can occur in injection molding and additives that are often included with plastics.
Cold isostatic pressing (CIP) is a technique where high pressure is applied uniformly to metal powder sealed in a flexible container. This compacts the powder to a density of 75-85% without die wall friction, resulting in a part with uniform density and no residual stresses. There are two methods - the wet bag process suited for batch production of complex parts, and the dry bag process using a fixed mold for mass production. CIP is used to make intricate or long shapes out of materials like titanium, tool steels, tungsten, and molybdenum powders.
Extrusion is a process that uses pressure to force a billet through a die opening to create an object with a constant cross-section. Most metals are hot extruded due to the large forces required. Extrusion can produce complex shapes, especially for more readily extrudable metals like aluminum. Common extrusion products include automotive and construction parts. Factors like temperature, pressure, and lubrication affect the extrusion process and properties of the final product. Defects can occur due to non-uniform deformation or temperatures that cause cracking.
Powder metallurgy is a process that involves compacting and forming metal powders into a solid object through sintering. It consists of 3 main steps - producing metal powders through various methods, compacting the powders into a green compact through pressing, and sintering the compact by heating it to fuse the particles together into a solid object. It allows for net-shape production of complex parts and close dimensional tolerances, and is used for applications where other fabrication methods are not suitable.
RTM is a low-pressure molding process, where a mixed resin and catalyst are injected into a closed mold containing a fiber pack or preform . when the resin has cured the mold can be opened and finished component removed.
Seminar on all electrical injection moulding machine mainanymona1991
This document provides information about the study and operation of all electric injection molding machines. It discusses the history of injection molding machines, describes the key components and operation of all electric machines, and compares them to hydraulic injection molding machines. All electric injection molding machines use servomotors to control each function, providing greater precision and accuracy than hydraulic machines while using 40-80% less energy. Maintenance of all electric machines focuses on preventative maintenance of components like sensors and motors.
This document provides an overview of injection molding. It describes the different types of injection molding machines and their key components. The complete injection molding process and cycle is explained, including plasticization, injection, packing, cooling, and ejection. Process parameters that affect quality are identified. Common defects are defined and potential causes are listed. Applications and advantages/disadvantages of injection molding are also summarized.
it is PDF are typed of myself. study triks & short & sweet (Technical manual) Of Diploma in Plastics technology(DPT-DPMT). All machine knowlage in plastics processing.
Er. Naresh Dhaker
(8890881858)
(CIPET JAIPUR)
Ideal process parameters in injection mouldingNaik Devang
This document discusses ideal process parameters for injection molding. It defines key terms like injection pressure, screw speed, back pressure, and nozzle. It explains the importance of melt temperature, flow rate, pressure, time, screw surface speed, and material drying. Process settings like mold temperature, cavity pressure, sprue bush diameter, and gate mechanism are also covered. The document emphasizes that melt temperature must be controlled to reproduce parts consistently across machines and that education is key to successful implementation of injection molding.
Blow molding is a plastic processing technique where a heated plastic material is extruded into a hollow shape called a parison, which is then placed inside a mold and inflated with air until it takes the shape of the mold cavity. There are different types of blow molding depending on how the parison is formed, such as extrusion blow molding where plastic is continuously extruded and cut into parisons. Common materials used for blow molding include HDPE, LDPE, PP, PVC, and PET. Key factors that affect blow molding include the parison characteristics, inflation pressure, mold design, and blow ratio.
Blow Molding is defined appropriately and also the process compatible materials are listed. Blow Molding is broadly classified as - extrusion type, injection type, Multilayer type. All three processes are explained appropriately with diagrams and their application is also listed. Since every thing has advantages and disadvantages, so is the case with blow molding. References are also cited correctly. I hope you all find it useful
(1) Compression molding is a manufacturing process used to mold thermosetting materials under heat and pressure in a mold cavity.
(2) The process involves preheating the molding material, placing it into the mold, applying pressure using a hydraulic press, and allowing the material to cure.
(3) Compression molding is commonly used to make electrical parts, dinnerware, gears, buttons, and automotive and medical components. It allows for high volume, low-cost production with minimal material waste.
This document discusses the manufacturing of plastic components through various plastic manufacturing processes. It begins by introducing plastics and classifying them as either natural or synthetic organic materials. The two main types of plastics are then described as thermosetting plastics and thermoplastics. Thermosetting plastics harden through a chemical reaction when heated and cannot be remelted or remolded, while thermoplastics soften when heated and harden again when cooled, allowing them to be remolded. Several common types of both thermosetting and thermoplastic materials are then outlined along with their typical uses. Injection molding is introduced as a high-speed manufacturing process for thermoplastics where molten plastic is injected into a
- Shell moulding is an efficient and economical casting method that uses a resin-sand mixture to form a thin "shell" around a heated pattern. This shell is then used as the mold cavity.
- Investment casting, also called lost-wax casting, is an ancient casting process used to produce complex shapes. It involves creating a wax pattern, coating it with refractory materials to form a ceramic "shell" mold, heating to remove the wax, and pouring molten metal into the shell. This allows for net-shape casting of intricate parts.
- Pressure die casting is a high-pressure casting process where molten metal is injected into steel dies to form castings. It is well-su
Thermoforming is a process where a plastic sheet is heated and formed into a desired shape using pressure, vacuum, or mechanical methods. There are three main thermoforming methods: vacuum forming uses vacuum pressure to draw the heated sheet onto a mold; pressure forming uses compressed air to force the sheet onto the mold more quickly; and mechanical forming uses matching molds to shape the sheet without vacuum or pressure. Common materials thermoformed include plastics like ABS, polyethylene, and PVC. Applications include food packaging, automotive and aircraft parts.
This document discusses various types of polymers and polymer processing techniques. It begins by defining polymers as substances made of repeating molecular units called mers. Polymers are classified as thermoplastics or thermosets depending on whether they can be remelted or undergo further chemical reactions. Common polymer processing techniques include extrusion, injection molding, blow molding, thermoforming, and composites fabrication. The document provides details on the basic mechanisms and applications of these important industrial polymer processes.
This document describes the development of a small plastic injection moulding machine for producing small plastic articles in small-scale industries. It discusses the design, construction, and testing of the machine. The machine is capable of injecting molten resins into a closed, cooled mould to produce plastic products. The design concept, operation, and assembly of component parts are covered. The document also provides details on the working principle of plastic injection moulding, including the various constructional parts of the machine like the PID controller, band heaters, thermocouple, and solid state relay. It discusses the assembly procedure and includes calculations and results from the first trial using polypropylene plastic.
This document describes the development of a small plastic injection moulding machine for producing small plastic articles in small-scale industries. It discusses the design, construction, and testing of the machine. The machine is capable of injecting molten resins into a closed, cooled mould to produce plastic products. The design concept, operation, and assembly of component parts are covered. The document also provides details on the working principle of plastic injection moulding machines in general and discusses the various constructional parts of the developed machine such as the PID controller, band heaters, thermocouple, and solid state relay.
Polymer processing involves converting plastic raw materials into finished products. There are primary, secondary, and tertiary processing methods. The selection of a processing method depends on factors like the product design, material properties, production quantity, and cost. Common primary methods include injection molding, extrusion, blow molding, and compression molding. The polymer properties like water absorption, physical form, thermal stability, and melt flow properties affect the suitable processing technique. Proper consideration of these factors ensures efficient processing and quality product manufacture.
Fabrication of Plastics in polymer technology for B.Tech students in India specially for JNTU K,H&A in Andhra Pradesh Telangana and also for other Indian Universities.
By
Gurram.Achyuth Kumar
A
1. The document describes the design optimization and manufacturing plan for a plastic container using injection molding. It discusses selecting high density polyethylene as the material and designing the mold.
2. The key steps of injection molding are described, including feeding plastic pellets into a heated barrel, injecting the molten plastic into the mold, cooling and hardening in the mold shape, and then ejecting the part.
3. The document outlines designing the container dimensions at 40mm x 40mm x 2mm thick and selecting injection molding process parameters to minimize sink marks on the final part.
The document provides information about plastic injection moulding. It defines plastic as a polymeric substance that can be easily shaped and moulded. Plastics are used for their ability to be formed into complex shapes, their light weight, strength and availability in different colors. The main types of plastics are thermoset and thermoplastic. Injection moulding is described as the process of injecting melted plastic into a mould to form a part. Key aspects of the injection moulding process like the machine, mould, raw materials and defects are discussed. Injection moulding is concluded to be a very versatile process for producing a wide variety of plastic products.
The document discusses various polymer processing techniques. It begins by defining polymer processing as converting solid or liquid polymers into finished products using steps like pre-shaping, shaping, and post-shaping operations. Common shaping methods include extrusion, injection molding, blow molding, thermoforming, and calendaring. The document then provides details on specific processes like extrusion, injection molding, blow molding, compression molding, and fiber spinning techniques. It emphasizes that the choice of processing method depends on factors like the polymer type and the desired product shape and properties.
This document discusses various plastic processing techniques. It describes techniques for both thermosets and thermoplastics, including casting, thermoforming, and extrusion molding. Casting involves melting plastic and pouring it into a mold, while thermoforming uses heat and pressure to form plastic sheets. Extrusion molding is a high volume process where plastic is continuously extruded through a die to form parts. The document provides details on the materials, processes, advantages, disadvantages and applications of these different plastic processing techniques.
PLASTIC MOULDING and Methods involving in itGaurav Tyagi
plastic moulding a topic with some less knowledges
but surely help out the masters as well as unger graduates in their assignments
no need to modify just go through it and take some innovative ideas and some will be making some more better ones
but for those who are in a hurry and want to minimise their time or wants to save their time its a copmlete package just go through it
Lo #3b (common)manufacturing technology (jan 2016) part 2Abdulaziz AlSuwaidi
This document provides information on various casting and molding manufacturing processes, including shell molding, investment casting, lost foam casting, and die casting. It describes the key steps for each process, as well as their advantages and disadvantages. Shell molding involves creating a hardened sand shell around a pattern, which is then used to make castings. Investment casting, also known as lost-wax casting, uses wax patterns invested in refractory materials to create molds. Lost foam casting uses polystyrene foam patterns that vaporize when molten metal is poured. Die casting involves injecting molten metal into steel dies under high pressure to form parts.
Thermoplastics are polymers that become moldable above a certain temperature and harden upon cooling. Injection molding is a common molding process where thermoplastic is heated, injected into a mold under high pressure, and solidifies. It is used for mass production of parts with complex shapes and high accuracy like toys, containers, and automobile parts. Blow molding uses air pressure to inflate hot plastic into a mold, while thermoforming shapes heated plastic sheets over molds using vacuum or pressure forming. Both processes are used to make packaging and large plastic items.
Blow Mould Tool Design and Manufacturing Process for 1litre Pet BottleIOSR Journals
the concepts of Blow molding is a process used to produce hollow objects from thermoplastic. The
basic blow molding process has two fundamental phases. First, a parson (or a perform) of hot plastic resin in a
somewhat tubular shape is created. Second, compressed air is used to expand the hot perform and press it
against mould cavities. The pressure is held until the plastic cools. Blow molding process is used for which has
thin wall sections.In this thesis, blow mould design is to be done for a bottle having 0.5mm thickness. This
thickness cannot be filled in pressure injection molding. So blow molding is considered for pet bottle design.
The mould is prepared by first modeling the part, extracting core & cavity and generating CNC program. Blow
mould tool design is done in Pro/Engineer according to HASCO standards. A prototype of the pet bottle using
blow mould design is also included.
This is also called as moulding of plastics into articles. To give shapes to plastics, several methods of fabrication are used. They are
1. Compression moulding
2. Injection moulding
3. Transfer moulding
4. Extrusion moulding
This document provides an overview of plastic mould design and the injection moulding process. It discusses the importance of plastic parts in modern industries and advantages of plastics over metals. Key topics covered include design considerations for plastic parts, common plastic materials, types of moulds, injection mould components like the cavity and core, and the six main steps of the injection moulding process: mould closing and clamping, injection, dwelling, cooling, plasticizing resin, and mould opening and ejection. The document also provides a brief overview of injection moulding machines.
The document discusses injection molding techniques. It begins by defining injection molding as a process where molten plastic is injected into a mold to produce parts. It describes the basic components of older and modern injection molding machines. The process involves plastic pellets being melted and injected under pressure into molds through a nozzle to produce parts, which then cool and are ejected. Key advantages are high production rates and the ability to produce complex parts in various plastics.
The document summarizes a student project on improving the quality of plastic injection mould design using mould flow analysis. It describes the objectives of designing and developing an automatic injection moulded product for a glass. Design concepts were developed in CATIA software and analyzed in Plastic Advisor/Pro-E software. The results revealed improvements in the quality of the mould design using concurrent engineering and computer-aided design approaches. The project aimed to improve the design of an existing product and its mould through mould flow analysis.
Injection moulding is a manufacturing process that involves injecting material into a mould to produce parts. Main components of an injection moulding machine include a clamping unit, injection unit, drive unit, mould, hydraulic system, and control system. Common materials used are plastics like PVC, ABS, and polypropylene. The injection moulding process involves feeding material into a heated barrel, injecting it into a mould cavity, and allowing it to cool and harden into the desired shape.
Injection moulding is a manufacturing process that involves injecting material into a mould to produce parts. Main components of an injection moulding machine include a clamping unit, injection unit, drive unit, mould, hydraulic system, and control system. Common materials used are plastics like PVC, ABS, and polypropylene. The injection moulding process involves feeding material into a heated barrel, injecting it into a mould cavity, and allowing it to cool and harden into the desired shape.
Similar to Lo #2 manufacturing process primary secondary part 1 (20)
The document contains multiple paragraphs describing various financial scenarios involving compound interest calculations, present and future worth analyses, and decisions around capital investments and alternatives. Specific situations mentioned include accumulating money over time at different interest rates, calculating returns on past investments, determining deposit amounts and times to reach savings goals with compound interest, and analyzing costs and returns for manufacturing, research, charity and capital purchase decisions over multiple years.
This document discusses advanced manufacturing technology, specifically automation fundamentals and CAD/CAM/CNC. It defines automation and its three basic components: power, a program of instructions, and a control system. It describes closed-loop and open-loop control systems. It also discusses different types of automation including fixed, programmable, and flexible automation. Additionally, it outlines hardware for automation including sensors, actuators, interface devices, and process controllers. The document also provides an overview of CAD/CAM/CNC, describing CAD, CAM software, NC and CNC systems, DNC, machine tools, and NC programming addresses and codes.
This document provides an overview of chapter 8 from the textbook "Basics of Engineering Economy" which covers breakeven analysis, sensitivity analysis, and payback analysis. The key topics covered include determining the breakeven point for a single project, breakeven between two alternatives, sensitivity of parameters to estimate variations, and sensitivity analysis of multiple parameters and alternatives. Methods like setting net present value or annual worth equations equal to zero are demonstrated for finding breakeven points. Sensitivity analysis procedures involve selecting parameters to vary, defining a range and increment of variation, and computing a measure of worth like net present value across the variations.
This document discusses benefit-cost analysis for public sector projects. It covers analyzing single projects and multiple alternatives. For single projects, the benefit-cost ratio is calculated by dividing the present worth of benefits by the present worth of costs. A ratio of 1 or greater means the project is justified. For multiple alternatives, alternatives are ordered by increasing cost and incremental benefit-cost ratios are calculated to determine which alternative is selected at each step. Direct benefits are compared to a do-nothing option first before being compared to each other. The document provides examples of applying these techniques.
Breakeven analysis determines the level of activity or production needed for a project's revenue to equal its costs. It can be used to analyze a single project or compare two alternatives. Payback period estimates the time required for cash inflows to recover the initial investment. Both tools provide useful initial screening but should not replace discounted cash flow analysis for final project evaluation and selection.
This document discusses benefit-cost analysis for public sector projects. It defines key terms like costs, benefits, and dis-benefits. It explains that the conventional B/C ratio compares benefits minus dis-benefits to costs. A modified B/C ratio includes maintenance and operation costs in the numerator. It provides examples of calculating B/C ratios for single projects and using the incremental B/C method to select between alternatives. Engineers must consider ethical issues when involved in public policy making and planning projects.
This document discusses measurement and inspection techniques used in manufacturing. It covers topics such as interchangeability, dimensional tolerances, measurement instruments including calipers, micrometers and dial indicators, and surface texture. Interchangeable parts allow for easy assembly and repair of devices while minimizing time and skill required. Dimensional tolerances and proper measurement are important for ensuring interchangeability and quality control. A variety of tools are used to accurately measure dimensions and inspect parts.
The document discusses annual worth (AW) analysis and rate of return (ROR) calculations. It defines AW as converting cash flows to an equivalent uniform annual amount over one life cycle. Calculating ROR involves finding the interest rate that sets the present worth of cash flows equal to zero. ROR can be used to evaluate projects by comparing to the minimum acceptable rate of return.
1. The document discusses various methods for analyzing engineering project alternatives using present worth analysis, including analyzing alternatives with equal lives, different lives, and infinite lives.
2. Key methods include using the least common multiple of lives or a specified study period to convert alternatives to equal service for comparison, and calculating the capitalized cost for alternatives with infinite lives.
3. The examples demonstrate how to use these present worth analysis methods to evaluate alternatives, convert cash flows to present worth, and select the alternative with the highest present worth value or lowest capitalized cost.
The document discusses several ethical theories: egoism, which holds that rightness depends on self-interest; contractarianism, which says society follows an implicit social contract; consequentialism, which assesses rightness based on outcomes; virtue ethics, which focuses on good character; and empathy ethics, which bases actions on understanding others' perspectives. It provides examples of how each theory might approach scenarios like speeding without cameras or the trolley problem.
This document provides an overview of several ethical theories: deontologism, consequentialism, and virtue ethics. Deontologism judges actions based on adherence to moral rules or duties, prioritizing rules over consequences. Consequentialism judges actions based on their outcomes and consequences, with the goal of maximizing happiness. Virtue ethics focuses on developing moral character and virtues through habitual good behaviors and choices over time. The document compares the strengths and weaknesses of each approach and provides examples of applying them to ethical dilemmas.
Machining processes such as turning are used to further refine parts by removing unwanted material. Turning involves securing a workpiece to a lathe and rotating it at high speeds while a single-point cutting tool removes material. Common turning operations include external operations like turning, grooving, and threading as well as internal operations like drilling, boring, and tapping. Turning can achieve high tolerances and is well-suited for producing cylindrical or rotational parts.
This document summarizes various metal working processes including hot and cold working. It discusses bulk deformation processes like rolling, forging, extrusion and drawing which involve significant deformation of the starting workpiece. Rolling is described as reducing thickness between two rotating cylinders. Extrusion forces metal to flow through a die to take its shape. Drawing pulls wire through progressively smaller dies. Forging compresses metal between dies to impart shapes. The document also covers sheet metal working processes like bending, drawing and shearing which are performed on metal with a high surface area to volume ratio using punch and die tools.
This document discusses primary and secondary manufacturing processes and distinguishes between them. It focuses on sand casting as a primary manufacturing process. Sand casting involves pouring molten metal into a sand mold cavity. The mold is formed by packing sand around a pattern and then removing the pattern, leaving a cavity in the shape of the desired part. The document describes the key elements of sand casting, including the pattern, cores, sand, gating and riser systems. It also discusses common casting defects and the steps in the sand casting process.
Lo #1 design factors in manufacturing processes (sept 2015)Abdulaziz AlSuwaidi
The document discusses design for manufacturing and assembly (DFMA). It provides 11 general principles for DFMA, including minimizing the number of components, using standard parts, designing for ease of manufacturing and assembly, establishing tolerances within production capabilities, using modular designs, and eliminating unnecessary adjustments. Following DFMA principles leads to benefits like shorter time to market, lower production costs, higher product quality, and greater customer satisfaction.
The document discusses key factors to consider for design for manufacturing and assembly (DFMA). It identifies 10 rules for reducing manufacturing costs and difficulty: 1) reduce the total number of parts, 2) develop a modular design, 3) use standard components, 4) design for multi-functionality, 5) design for multi-use, 6) design for ease of fabrication, 7) avoid separate fasteners, 8) minimize assembly directions, 9) maximize compliance during assembly, and 10) minimize part handling. The document emphasizes that 70% of manufacturing costs are determined during the design phase, so DFMA principles should be followed to optimize production efficiency and costs.
The document provides information on capital investment problems and cash flows, focusing on factors related to how time and interest affect money. It discusses single payment factors to find the future or present value of a single amount. It also covers uniform series factors to relate the present worth, future worth, or annual equivalent of a uniform series of cash flows. Finally, it examines gradient formulas, including arithmetic gradients where cash flows change by a constant amount each period, and geometric gradients where they change by a constant percentage each period. Formulas and examples are provided for each type of cash flow problem.
This document defines key terminology used in financial appraisal tools. It discusses fundamental concepts like alternatives, cash flows, time value of money, and evaluation criteria. It also defines interest rate, rate of return, simple interest, and compound interest. Various symbols used in financial analysis are introduced, like principal (P), future value (F), interest rate (i), and number of periods (n). Cash flow diagrams and the distinctions between rate of return, cost of capital, and minimum attractive rate of return are covered at a high level. Finally, common spreadsheet and financial calculator functions for present value, future value, payments, number of periods, interest rate, and internal rate of return are listed.
The document discusses annual worth (AW) analysis and rate of return (ROR) calculations. It defines AW as converting cash flows to an equivalent uniform annual amount over one life cycle. Calculating ROR involves finding the interest rate that sets the present worth of cash flows equal to zero. ROR can be used to evaluate projects by comparing to the minimum acceptable rate of return.
The document discusses various techniques for economic analysis of alternatives using present worth analysis:
1. Present worth analysis requires converting all cash flows to their present value using the minimum attractive rate of return. Costs are assigned a negative sign and revenues a positive sign.
2. For mutually exclusive alternatives, the alternative with the highest positive present worth is selected. For independent projects, all alternatives with a positive present worth are selected.
3. When alternatives have unequal lives, they must be compared over an equal period of time using either the least common multiple of lives or a specified study period.
4. Capitalized cost analysis is used to evaluate alternatives that have an extremely long useful life and is calculated as the annual
Determination of Equivalent Circuit parameters and performance characteristic...pvpriya2
Includes the testing of induction motor to draw the circle diagram of induction motor with step wise procedure and calculation for the same. Also explains the working and application of Induction generator
Generative AI Use cases applications solutions and implementation.pdfmahaffeycheryld
Generative AI solutions encompass a range of capabilities from content creation to complex problem-solving across industries. Implementing generative AI involves identifying specific business needs, developing tailored AI models using techniques like GANs and VAEs, and integrating these models into existing workflows. Data quality and continuous model refinement are crucial for effective implementation. Businesses must also consider ethical implications and ensure transparency in AI decision-making. Generative AI's implementation aims to enhance efficiency, creativity, and innovation by leveraging autonomous generation and sophisticated learning algorithms to meet diverse business challenges.
https://www.leewayhertz.com/generative-ai-use-cases-and-applications/
Tools & Techniques for Commissioning and Maintaining PV Systems W-Animations ...Transcat
Join us for this solutions-based webinar on the tools and techniques for commissioning and maintaining PV Systems. In this session, we'll review the process of building and maintaining a solar array, starting with installation and commissioning, then reviewing operations and maintenance of the system. This course will review insulation resistance testing, I-V curve testing, earth-bond continuity, ground resistance testing, performance tests, visual inspections, ground and arc fault testing procedures, and power quality analysis.
Fluke Solar Application Specialist Will White is presenting on this engaging topic:
Will has worked in the renewable energy industry since 2005, first as an installer for a small east coast solar integrator before adding sales, design, and project management to his skillset. In 2022, Will joined Fluke as a solar application specialist, where he supports their renewable energy testing equipment like IV-curve tracers, electrical meters, and thermal imaging cameras. Experienced in wind power, solar thermal, energy storage, and all scales of PV, Will has primarily focused on residential and small commercial systems. He is passionate about implementing high-quality, code-compliant installation techniques.
Applications of artificial Intelligence in Mechanical Engineering.pdfAtif Razi
Historically, mechanical engineering has relied heavily on human expertise and empirical methods to solve complex problems. With the introduction of computer-aided design (CAD) and finite element analysis (FEA), the field took its first steps towards digitization. These tools allowed engineers to simulate and analyze mechanical systems with greater accuracy and efficiency. However, the sheer volume of data generated by modern engineering systems and the increasing complexity of these systems have necessitated more advanced analytical tools, paving the way for AI.
AI offers the capability to process vast amounts of data, identify patterns, and make predictions with a level of speed and accuracy unattainable by traditional methods. This has profound implications for mechanical engineering, enabling more efficient design processes, predictive maintenance strategies, and optimized manufacturing operations. AI-driven tools can learn from historical data, adapt to new information, and continuously improve their performance, making them invaluable in tackling the multifaceted challenges of modern mechanical engineering.
DEEP LEARNING FOR SMART GRID INTRUSION DETECTION: A HYBRID CNN-LSTM-BASED MODELijaia
As digital technology becomes more deeply embedded in power systems, protecting the communication
networks of Smart Grids (SG) has emerged as a critical concern. Distributed Network Protocol 3 (DNP3)
represents a multi-tiered application layer protocol extensively utilized in Supervisory Control and Data
Acquisition (SCADA)-based smart grids to facilitate real-time data gathering and control functionalities.
Robust Intrusion Detection Systems (IDS) are necessary for early threat detection and mitigation because
of the interconnection of these networks, which makes them vulnerable to a variety of cyberattacks. To
solve this issue, this paper develops a hybrid Deep Learning (DL) model specifically designed for intrusion
detection in smart grids. The proposed approach is a combination of the Convolutional Neural Network
(CNN) and the Long-Short-Term Memory algorithms (LSTM). We employed a recent intrusion detection
dataset (DNP3), which focuses on unauthorized commands and Denial of Service (DoS) cyberattacks, to
train and test our model. The results of our experiments show that our CNN-LSTM method is much better
at finding smart grid intrusions than other deep learning algorithms used for classification. In addition,
our proposed approach improves accuracy, precision, recall, and F1 score, achieving a high detection
accuracy rate of 99.50%.
Impartiality as per ISO /IEC 17025:2017 StandardMuhammadJazib15
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3. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
3Manufacturing Technology
Shaping operations alter the geometry of the starting work
material by various methods. Common shaping processes
include casting, forging, and machining.
Shaping Operation
4. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
4Manufacturing Technology
Most shape processing operations apply heat, mechanical force or a
combination of these to effect a change in geometry of the work
material.
There are various ways to classify the shaping processes.
1. Solidification processes
2. Particulate processing
3. Deformation process
4. Material removal process
Shaping Operation
5. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
5Manufacturing Technology
In solidification processes the starting material is heated to liquid
or semifluid that cools and solidifies to form the part geometry.
Nearly all materials can be processed this way if it has relatively low
melting point, such as polymers, metals, and glass ceramics.
The molted material is forced or poured into a mold to form the
required shape.
Casting is the name used for metals, and molding is the common
term used for plastic.
Shaping Operation – 1. Solidification
6. Plastic Molding processes
Shaping of plastic material is achieved by the
application of heat and pressure. There are many
ways in which this can be done, depending on the
nature of the polymer, the type and size of the
product and the quantity and dimensional accuracy
required.
The methods described here are
Compression molding
Transfer molding and
Injection molding.
6
7. Plastic molding processes
Forms of supply :
Plastic materials used in molding are normally in the
form of powder or small chips known as granules or
as
Preforms.
Additives :
Before molding granules are mixed with other
ingredients –Known as additives in order to modify or
eliminate undesirable properties and to develop their
useful characteristics.
7
8. Additives
Plasticizers- added particularly to PVC,to give greater flexibility and make it easy to
form.
Stabilizers- added to avoid decomposition of PVC
Lubricants- added to reduce the adhesion between polymer and hot metal surfaces used
for molding.
Fillers- Used to improve physical properties (fillers could be wood flour, cork dust,
asbestos, carbon black, chalk and chopped fiber glass.
Ultra-violet absorbers- added to reduce adverse effect of sunlight.
Colorants- added to give the final product greater appeal, as a means of identifying (in
cable insulation) to simulate a natural or traditional product (like leather bags),
8
9. Molding process consideration
Metals have definite melting point and in general tend to be free- flowing in a molten
state but plastic have no definite melting point, they are just soft by the application of
heat as thick viscous fluid hence, result high pressure is required for molding.
The viscosity is reduced by the application of heat, but there is an upper temperature
limit at which the polymer begins to break down in some way. This is known as
degradation.( all polymers are bad conductor of heat and are susceptible to overheating)
There is also lower limit of temperature below which the polymer will not be soft
enough to flow in to the mold. Therefore the temperature of the mold must be between
upper and lower limits and will directly affects the viscosity of the polymer.
All the molding process require three stages:
1) Application of heat to soften the molding material;
2) Forming to the required shape in the mold
3) Removal of heat
9
10. Types of molding Processes
1.Compression Molding:
Used for thermosetting plastics
The process is carried out in a hydraulic press with
heated platens.
Compression molding is used to produce a wide
variety of products, including electrical and domestic
fittings, toilet seats and covers, bottle tops and various
closures and tableware.
10
11. 2.Transfer molding
Used for thermosetting plastics
This process is similar to compression molding except that the plasticizing and molding
functions are carried out separately
This process is suited to the production of parts incorporating small metal inserts, and
those products having variation of section thickness can be produced.
Curing time is less and greater accuracy is achieved than with compression molding.
The main limitation of this process is the loss of material in sprue, runners and gates-as
thermosetting material cure during molding, this cannot be reused.
Molding tools are usually more complex and therefore more costly than compression
molding tools.
Typical products produces by this process are motor- car distributors cap and domestic
electric plugs.
11
13. 1313Manufacturing Technology
Injection molding is a process in which a
polymer is heated to a highly plastic state and
forced to flow under high pressure into a
mold cavity, where it solidifies.
The molded part, called a molding, is then
removed from the cavity. The production cycle
time is typically in the range of 10 to 30 sec,
although cycles of 1 min or longer are not
uncommon for large parts.
For small parts, the mold can be built to
contain multiple cavities, also making the mold
expensive. Thus, injection molding is
economical only for large production
quantities.
Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
Shaping Operation – 1. Solidification – Injection MoldingInjection Molding
14. 14
Process & EquipmentProcess & Equipment
14Manufacturing Technology
Equipment for injection molding evolved from metal die casting. A large
injection molding machine is shown in Figure below. As illustrated in the
schematic in Figure below, an injection molding machine consists of two
principal components: (1) the plastic injection unit and (2) the mold
clamping unit.
Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
Shaping Operation – 1. Solidification – Ex) Injection MoldingInjection Molding
15. 1515Manufacturing Technology
The injection unit is much like an extruder. It consists of a barrel
that is fed from one end by a hopper containing a supply of plastic
pellets.
Inside the barrel is a screw whose operation surpasses that of an
extruder screw in the following respect: in addition to turning for mixing
and heating the polymer, it also acts as a ram that rapidly moves
forward to inject molten plastic into the mold.
A non-return valve mounted near the tip of the screw prevents the
melt from flowing backward along the screw threads.
Injection Unit
Process & EquipmentProcess & Equipment
Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
Shaping Operation – 1. Solidification – Ex) Injection MoldingInjection Molding
16. 1616Manufacturing Technology
The clamping unit is concerned with the operation of the mold.
Its functions are to (1) hold the two halves of the mold in proper
alignment with each other; (2) keep the mold closed during
injection by applying a clamping force sufficient to resist the
injection force; and (3) open and close the mold at the
appropriate times in the molding cycle.
The clamping unit consists of two platens, a fixed platen and a
movable platen, and a mechanism for translating the latter.
Clamping Unit
Process & EquipmentProcess & Equipment
Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
Shaping Operation – 1. Solidification – Ex) Injection MoldingInjection Molding
19. Factors affecting selection of molding
method;
Type of material to be molded
The dimensional accuracy
The required output
Example:
small quantity, thermosetting plastic material and not
high degree of accuracy would favor –compression
molding
Larger quantities of higher accuracy from thermosetting
plastic would favor Transfer molding; while high volume
production from thermo plastic material would be carried
out using the injection molding process.
19
20. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
20Manufacturing Technology
In Particulate processing, the starting material are powders of metals or
ceramics.
The process includes pressing of the powder into designed die, and
then sintering.
Sintering is heating the material powder below its melting point make
the particles adhere to each other to form one piece.
So the powder is first squeezed into a die cavity under high pressure
and then heated to bond the individual particles together.
Shaping Operation – 2. Particulate Processing
22. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
22Manufacturing Technology
Deformation processes, in which the starting material is a ductile
solid (commonly metal) that is deformed to shape the part.
In the deformation processes, the starting work part is shaped by
the application of forces that exceed the yield strength of the
material. For the material to be formed in this way, it must be
sufficiently ductile to avoid fracture during deformation. To
increase ductility (and for other reasons), the work material is
often heated before forming to a temperature below the melting
point. Deformation processes are associated most closely with
metalworking and include operations such as forging and
extrusion, shown in Figure 1.8. Figure 15.19 shows a forging
operation performed by a drop hammer.
Shaping Operation – 3. Deformation Process
25. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
25Manufacturing Technology
Also included within the deformation processes category is sheet
metalworking, which involves bending, forming, and shearing
operations performed on starting blanks and strips of sheet metal.
Several sheet metal parts, called stampings because they are
made on a stamping press, are illustrated in Figure 16.35.
Shaping Operation – 3. Deformation Process
26. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
26Manufacturing Technology
Material removal processes are operations that remove excess
material from the starting workpiece so that the resulting shape is
the desired geometry. The most important processes in this
category are machining operations such as turning, drilling, and
milling, shown in Figure 1.9. These cutting operations are most
commonly applied to solid metals, performed using cutting tools
that are harder and stronger than the work metal.
Grinding is another common material removal process.
Shaping Operation – 4. Material Removal Process
27. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
27Manufacturing Technology
Shaping Operation – 4. Material Removal Process : Finishing Processes
Grinding is a material removal process accomplished by abrasive particles
that are contained in a bonded grinding wheel rotating at very high surface
speeds. The grinding wheel is usually disk shaped, and is precisely balanced
for high rotational speeds.
28. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
28Manufacturing Technology
Shaping Operation – 4. Material Removal Process
29. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
29Manufacturing Technology
Shaping Operation – 4. Material Removal Process : Finishing Processes
Lapping is an abrasive process used to produce surface finishes of extreme
accuracy and smoothness. It is used in the production of optical lenses,
metallic bearing surfaces, gages, and other parts requiring very good finishes.
30. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
30Manufacturing Technology
Shaping Operation – 4. Material Removal Process : Finishing Processes
Honing is an abrasive process performed by a set of bonded abrasive sticks.
A common application is to finish the bores of internal combustion engines.
Other applications include bearings, hydraulic cylinders, and gun barrels.
31. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
31Manufacturing Technology
Shaping Operation – 4. Material Removal Process : Finishing Processes
Superfinishing is an abrasive process similar to honing. Both processes use a
bonded abrasive stick moved with a reciprocating motion and pressed against the
sur- face to be finished. Superfinishing differs from honing in the following
respects [4]: (1) the strokes are shorter, 5 mm (3/16 in); (2) higher frequencies are
used, up to 1500 strokes per minute; (3) lower pressures are applied between the
tool and the surface, below 0.28 MPa (40 lb/in2); (4) workpiece speeds are lower,
15 m/min (50 ft/min) or less; and (5) grit sizes are generally smaller.
32. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
32Manufacturing Technology
Shaping Operation – 4. Material Removal Process : Finishing Processes
Polishing is used to remove scratches and burrs and to smooth rough
surfaces by means of abrasive grains attached to a polishing wheel rotating
at high speed— around 2300 m/min (7500 ft/min). Buffing is similar to
polishing in appearance, but its function is different. Buffing is used to
provide attractive surfaces with high luster.
Polishing
Buffing
33. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
33Manufacturing Technology
The second major type of part processing is performed to
improve mechanical or physical properties of the work material.
These processes do not alter the shape of the part, except
unintentionally in some cases.
The most important property-enhancing processes involve heat
treatments, which include various annealing and strengthening
processes for metals and glasses.
Sintering of powdered metals is also a heat treatment that
strengthens a pressed powder metal work part. Its counterpart in
ceramics is called firing.
Property-enhancing Operation
34. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
34Manufacturing Technology
Surface Processing Surface processing operations include (1)
cleaning, (2) surface treatments, and (3) coating and thin film
deposition processes.
Cleaning includes both chemical and mechanical processes to remove
dirt, oil, and other contaminants from the surface.
Surface treatments include mechanical working such as shot peening
and sand blasting, and physical processes such as diffusion and ion
implantation.
Coating and thin film deposition processes apply a coating of material
to the exterior surface of the work part. Common coating processes
include electroplating, anodizing of aluminum, organic coating (call it
painting), and porcelain enameling. Thin film deposition processes
include physical vapor deposition and chemical vapor deposition to
form extremely thin coatings of various substances.
Surface Processing
36. Manufacturing Processes –Manufacturing Processes – Processing OperationProcessing Operation
36Manufacturing Technology
Surface Processing
Electroplating is a process that uses electric
current to reduce dissolved metal cations so that
they form a coherent metal coating on an electrode.
The term is also used for electrical oxidation of
anions onto a solid substrate, as in the formation
silver chloride on silver wire to make silver/silver-
chloride electrodes
Anodized Aluminum
Anodizing is an electrolytic passivation process used to
increase the thickness of the natural oxide layer on the
surface of metal parts.
The process is called anodizing because the part to be
treated forms the anode electrode of an electrical circuit.
Anodizing increases resistance to corrosion and wear,
and provides better adhesion for paint primers and glues
when compared to anodizing done on bare metal.
Electroplating
37. Manufacturing Processes –Manufacturing Processes – Assembly OperationsAssembly Operations
37Manufacturing Technology
Permanent joining processes ; include welding, brazing, soldering, and
adhesive bonding. They form a joint between components that cannot be
easily disconnected.
Mechanical fastening ; Certain mechanical assembly methods are available
to fasten two (or more) parts together in a joint that can be conveniently
disassembled. The use of screws, bolts, and other threaded fasteners are
important traditional methods in this category. Other mechanical assembly
techniques form a more permanent connection; these include rivets, press
fitting, and expansion fits.
Permanent Joining Processes & Mechanical Fastening
(Note : Details of welding shall be studied at Fabrication and Welding course later.