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Dfm 7 Forming
- 1. Design for ManufactureDesign for Manufacture Forming ProcessesForming Processes Jonathan MarshJonathan Marsh
- 2. Lecture 6Lecture 6 -- RecapRecap MachiningMachining Design ConsiderationsDesign Considerations ToleranceTolerance Material PropertyMaterial Property Tool TypesTool Types Surface FinishSurface Finish 1010--NovNov--0808 Surface FinishSurface Finish MachiningMachining TurningTurning BoringBoring MillingMilling BroachingBroaching MachinesMachines CNCCNC Machine CentreMachine Centre
- 3. IntroductionIntroduction FormingForming IntroductionIntroduction Fundamentals of FormingFundamentals of Forming TheoryTheory Design Considerations in FormingDesign Considerations in Forming 1010--NovNov--0808 Design Considerations in FormingDesign Considerations in Forming MaterialsMaterials Draft anglesDraft angles Types of formingTypes of forming ForgingForging Vacuum formingVacuum forming FiringFiring
- 4. IntroductionIntroduction What does forming involve?What does forming involve? Deforming a work piece to a desired shapeDeforming a work piece to a desired shape Can be performed as a Hot / Cold ProcessCan be performed as a Hot / Cold Process Uses materials ability to flow plasticallyUses materials ability to flow plastically 1010--NovNov--0808
- 5. Design ConsiderationsDesign Considerations Design ConsiderationsDesign Considerations The main consideration in forming processes areThe main consideration in forming processes are centred on the work piece material.centred on the work piece material. Forming a WP will effect the material properties in theForming a WP will effect the material properties in the formed region.formed region. 1010--NovNov--0808 formed region.formed region. This can add significant strength to the final unit thatThis can add significant strength to the final unit that other processes can notother processes can not Cast Piece Crystals form randomly Cracks can propagate between crystal regions Machined Piece Crystals remain in original alignment. Shear cracks can develop along regions Formed Piece Crystals form with the piece keeping strength of original billet
- 6. Design ConsiderationsDesign Considerations Design ConsiderationsDesign Considerations Does process/material require Hot / Cold working.Does process/material require Hot / Cold working. Cold working is not actually cold, but colderCold working is not actually cold, but colder Used to create a fine grain structure and finish onUsed to create a fine grain structure and finish on formed WP previously hot formedformed WP previously hot formed 1010--NovNov--0808 formed WP previously hot formedformed WP previously hot formed NB: Can add around 20% to the costNB: Can add around 20% to the cost
- 7. Design ConsiderationsDesign Considerations Design ConsiderationsDesign Considerations Chose a material that allows a significant amountChose a material that allows a significant amount of plastic deformationof plastic deformation e.g. Aluminium, Copper, Thermoplasticse.g. Aluminium, Copper, Thermoplastics Available billet sizes and shapesAvailable billet sizes and shapes 1010--NovNov--0808 Available billet sizes and shapesAvailable billet sizes and shapes i.e. Vacuum Formingi.e. Vacuum Forming Tool Size, Shape and complexityTool Size, Shape and complexity Are draft angles required?Are draft angles required? Surface FinishSurface Finish ToleranceTolerance
- 8. Forming ProcessesForming Processes Plastic State Forming Forging Rolling Drawn Extrusion Hammer Hot DirectDeep 1010--NovNov--0808 Hammer Drop Press Swaging Hot Cold Direct Impact Deep Wire
- 9. Forming ProcessesForming Processes RollingRolling Continuous manufactureContinuous manufacture Can be performed hot/coldCan be performed hot/cold Used to produce Plate, Rail, TubeUsed to produce Plate, Rail, Tube 1010--NovNov--0808 Tool must be rotationally symmetricalTool must be rotationally symmetrical Medium Tolerances 0.05Medium Tolerances 0.05 –– 1 mm1 mm Good Surface finish 0.5Good Surface finish 0.5 –– 66mmm Rm Raa Very economical for continuous manufacture ofVery economical for continuous manufacture of certain shapescertain shapes
- 11. Forming ProcessesForming Processes ForgingForging Forging is plastic forming of metal by localisedForging is plastic forming of metal by localised compressioncompression “Bashing with huge hammer”“Bashing with huge hammer” Types: Hammer, Open die, drop forging, pressTypes: Hammer, Open die, drop forging, press 1010--NovNov--0808 Types: Hammer, Open die, drop forging, pressTypes: Hammer, Open die, drop forging, press forging etc.forging etc. Very quickVery quick –– AutomatedAutomated Tolerances TypicallyTolerances Typically 1mm can be 0.1mm1mm can be 0.1mm Surface finish 5Surface finish 5 –– 2525 mmm Rm Raa Used on most metalsUsed on most metals Limit to the complexity of shapeLimit to the complexity of shape Hammer Open
- 13. Forming ProcessesForming Processes ExtrusionExtrusion Extrusion is plastic forming of material forcing itExtrusion is plastic forming of material forcing it through a diethrough a die “Like squeezing toothpaste”“Like squeezing toothpaste” Tolerances Typically 0.25mmTolerances Typically 0.25mm –– 2.5mm2.5mm 1010--NovNov--0808 Tolerances Typically 0.25mmTolerances Typically 0.25mm –– 2.5mm2.5mm Surface finish 1Surface finish 1 –– 33 mmm Rm Raa
- 14. Forming ProcessesForming Processes Pressing / Deep DrawingPressing / Deep Drawing Formation of 3D parts by plastically stretching material.Formation of 3D parts by plastically stretching material. Design must take account thinning of materialDesign must take account thinning of material Very quick 2000/minVery quick 2000/min Use adequate radii to prevent tearing/sheeringUse adequate radii to prevent tearing/sheering 1010--NovNov--0808 Use adequate radii to prevent tearing/sheeringUse adequate radii to prevent tearing/sheering Highly dependant on material propertiesHighly dependant on material properties Tolerances 0.2Tolerances 0.2 –– 5 mm5 mm Surface finish 0.5Surface finish 0.5 -- 2525 mmm Rm Raa
- 15. Forming ProcessesForming Processes SwagingSwaging Repeatedly hammering tube or bar to form a 3D profileRepeatedly hammering tube or bar to form a 3D profile Requires ductile material usually metalRequires ductile material usually metal Production around 400 parts/hrProduction around 400 parts/hr Tolerances 0.05Tolerances 0.05 –– 5 mm5 mm 1010--NovNov--0808 Tolerances 0.05Tolerances 0.05 –– 5 mm5 mm Surface finish 0.2Surface finish 0.2 –– 22 mmm Rm Raa Used for creating necks in tube splines etcUsed for creating necks in tube splines etc
- 16. Forming ProcessesForming Processes Blanking / Punching / SheeringBlanking / Punching / Sheering Creating form buy cutting punching shapes.Creating form buy cutting punching shapes. From Scissors to large presses…From Scissors to large presses… Very quick 1Very quick 1--5 sec/part5 sec/part Used for sheet material 0Used for sheet material 0--100mm thick100mm thick 1010--NovNov--0808 Used for sheet material 0Used for sheet material 0--100mm thick100mm thick Tolerance depends on thicknessTolerance depends on thickness 0.050.05 –– 10mm10mm Edge roughness 0.8Edge roughness 0.8 –– 2525 mmm Rm Raa
- 17. Forming ProcessesForming Processes SpinningSpinning Creating a shape from sheet material formed over aCreating a shape from sheet material formed over a spinning mandrelspinning mandrel Can be done on a lathe.Can be done on a lathe. Production rates 200 parts /hrProduction rates 200 parts /hr 1010--NovNov--0808 Production rates 200 parts /hrProduction rates 200 parts /hr Tolerances 0.1Tolerances 0.1 –– 2mm2mm Surface finish 0.2Surface finish 0.2 -- 66 mmm Rm Raa Used for axisymmetric shapes,Used for axisymmetric shapes, e.g. reflectors, light shades, trumpet bellse.g. reflectors, light shades, trumpet bells
- 18. Forming ProcessesForming Processes Vacuum formingVacuum forming Used to produce shapes by sucking material over a patternUsed to produce shapes by sucking material over a pattern Widely used to from plastic sheetWidely used to from plastic sheet Thickness 1Thickness 1--10mm thick10mm thick Tolerances dependant on size 1Tolerances dependant on size 1-- 10mm10mm 1010--NovNov--0808 Tolerances dependant on size 1Tolerances dependant on size 1-- 10mm10mm Surface finish as originalSurface finish as original Used for plastic containers, packaging etcUsed for plastic containers, packaging etc
- 19. Forming ProcessesForming Processes Vacuum formingVacuum forming 1010--NovNov--0808
- 20. Forming ProcessesForming Processes Other Forming ProcessesOther Forming Processes BendingBending Bending of sheet or bar into desired shape can be doneBending of sheet or bar into desired shape can be done hot / cold depending on material properties.hot / cold depending on material properties. Types: Angle, Roll, Draw, SeamingTypes: Angle, Roll, Draw, Seaming 1010--NovNov--0808 Types: Angle, Roll, Draw, SeamingTypes: Angle, Roll, Draw, Seaming EmbossingEmbossing Pressing of shapes into sheet or surfaces to formPressing of shapes into sheet or surfaces to form desired shape e.g. Credit carddesired shape e.g. Credit card HydroformingHydroforming Fluid Pressure used to expand material into dieFluid Pressure used to expand material into die Wire DrawingWire Drawing Like extrusion but pulling the material through the dieLike extrusion but pulling the material through the die
- 21. Forming ProcessesForming Processes CeramicsCeramics Have some very good properties includingHave some very good properties including resistance to temperature and wear resistanceresistance to temperature and wear resistance Long used in the electrical industry for resistanceLong used in the electrical industry for resistance properties now more commonly in engineering.properties now more commonly in engineering. 1010--NovNov--0808 properties now more commonly in engineering.properties now more commonly in engineering. In general ceramics are a hard, brittle materialIn general ceramics are a hard, brittle material with high compressive strength.with high compressive strength. Compounds of metallic and non metallic materialsCompounds of metallic and non metallic materials normally in crystalline form.normally in crystalline form. Ceramics are formed from paste/powder (Pottery)Ceramics are formed from paste/powder (Pottery) or Viscous hot material (Glass)or Viscous hot material (Glass)
- 22. Forming ProcessesForming Processes CeramicsCeramics –– GlassGlass Glass is usually formed from a moltenGlass is usually formed from a molten viscous liquid molded into a 3D Solidviscous liquid molded into a 3D Solid Used from bottles, windows, vases etcUsed from bottles, windows, vases etc Glass ManufacturingGlass Manufacturing 1010--NovNov--0808 Glass ManufacturingGlass Manufacturing Plate rolled or floated on molten tin.Plate rolled or floated on molten tin. Molded into many forms, casting, blowMolded into many forms, casting, blow molding, Pressing etcmolding, Pressing etc Largely AutomatedLargely Automated Can be hand craftedCan be hand crafted
- 23. Forming ProcessesForming Processes CeramicsCeramics –– Crystalline CeramicsCrystalline Ceramics Ceramics are from formed aggregates shaped asCeramics are from formed aggregates shaped as moist paste/powder and solidified.moist paste/powder and solidified. Used from pottery to semi conductorsUsed from pottery to semi conductors Usually brittle material not good for postUsually brittle material not good for post 1010--NovNov--0808 Usually brittle material not good for postUsually brittle material not good for post processing some can be machinedprocessing some can be machined Ceramic ManufacturingCeramic Manufacturing Plastic formingPlastic forming –– blend of ceramic and additives to makeblend of ceramic and additives to make a formable mixture by Pressure heat, injection molding.a formable mixture by Pressure heat, injection molding. Additive is then removed.Additive is then removed. Slip CastingSlip Casting -- Slurry is cast into a porous mold and theSlurry is cast into a porous mold and the liquid reduces by capillary action.liquid reduces by capillary action.
- 24. Forming ProcessesForming Processes CeramicsCeramics –– CastingCasting 1010--NovNov--0808