Structural foam molding
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Mechanical Testing of Materials
This presentation is for mechanical engineering/ civil engineering students to help them understand the different type of destructive mechanical testing of materials. The tensile testing, hardness, impact test procedures are explained in detail.
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Hardness testing
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1. Sheet metal forming operations include bending, stretching, deep drawing, and other processes where sheets are formed. Bending involves shaping a straight length into a curve and can be done using presses or rolls.
2. Deep drawing uses a die and punch to shape flat sheets into cup-shaped parts. Stretch forming clamps sheet edges and stretches the sheet over a die into the desired shape.
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This document discusses tensile testing and universal testing machines. It defines tensile testing as applying opposing tensile forces to a test specimen to measure the specimen's properties. A universal testing machine typically uses a hydraulic cylinder to apply the force. The document lists several material properties that can be determined from tensile tests, including strength, ductility, elasticity, and stiffness. It provides diagrams illustrating how properties like tensile strength, modulus of elasticity, and breaking stress are calculated from the stress-strain graph generated during tensile testing. Finally, it gives some examples of industries that use tensile testing, like aerospace and textiles, and notes benefits like determining batch quality and aiding design.
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- Common impact tests include the Charpy and Izod tests, which involve striking a notched sample with a falling pendulum. The Charpy test uses a simply supported beam setup while the Izod uses a cantilever.
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This document discusses impact testing procedures according to ASTM A370 and E-23 standards. It describes the apparatus, testing procedures, significance, and interpretation of results for Charpy impact testing. Charpy impact testing involves breaking a notched specimen with a single blow from a pendulum to determine the material's resistance to brittle fracture. The document provides details on specimen preparation, conditioning, breaking procedures, and measuring absorbed energy and fracture appearance to characterize ductile versus brittle behavior.
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The document discusses two common impact tests: the Charpy and Izod impact tests. The Charpy test involves dropping a pendulum onto a notched sample to measure the energy absorbed during fracture. It is used to evaluate toughness and notch sensitivity, especially of metals. The Izod test also measures energy absorbed during fracture but holds the sample in a cantilevered beam configuration rather than three-point bending. Both tests are useful for determining the strength and ductility of materials, especially their ability to withstand shocks and impacts in applications like forging, rubber products, and plastics.
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Basic knowledge about refractory materials include in these slides . Hopefully these slides satisfies you what are you searching for.
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Manufacturing Technology 1 - Welding Operating principle, basic equipment, merits and applications of: Fusion welding processes : Gas welding - Types – Flame characteristics; Manual metal arc welding – Gas Tungsten arc welding - Gas metal arc welding – Submerged arc welding – Electro slag welding; Operating principle and applications of : Resistance welding - Plasma arc welding – Thermit welding – Electron beam welding – Friction welding and Friction Stir Welding; Brazing and soldering; Weld defects: types, causes and cure.
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This document discusses bending tests which are used to determine a material's strength and elastic properties by applying forces to its surface. The bending test uses a universal testing machine to apply forces to a test specimen in three or four-point bending configurations to induce internal stresses. The test results are used to evaluate a material's strength, ductility and failure modes under bending forces.
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The document describes the Vickers hardness test. It uses a diamond pyramid indenter to make an indentation on the material being tested under a specified load ranging from 5 to 120 kg. The indentation left has a square shape regardless of load. The diagonal lengths of the indentation are measured under a microscope and used to calculate the Vickers hardness number, providing a continuous scale of hardness values. Factors like load, indentation shape, and temperature can affect the results. Advantages include consistency of indentation shape and suitability for testing a range of materials and surfaces. A disadvantage is it takes more time than other hardness tests.
Unit 4 ultrasonic testing method
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Introduction, Principle of operation, Piezoelectricity. Ultrasonic probes, CRO techniques,advantages,
Limitation & typical applications. Applications in inspection of castings, forgings,Extruded steel parts,
bars, pipes, rails and dimensions measurements. Case Study –Ultrasonography of human body.
Me8392 manufacturing technology-i part-a questions & answers-
The document provides definitions and explanations of various manufacturing processes and terms. It discusses different types of patterns used in casting, advantages and disadvantages of die casting, requirements of good patterns, functions of cores, and lost wax casting process. It also describes arc welding equipment, features of friction welding, resistance welding process, purpose of flux, and how to avoid slag inclusions in welding. Various plastic processing methods like film blowing, compression moulding, parts made by rotational moulding, and definition of parison and degree of polymerization are also summarized.
Hot isostatic pressing
One of the welding processes that used in Engineering field is hot isostatic pressing.
Thanks for the colleagues who give this slides to publish.
Plasma spraying (type of thernal spraying)
The document discusses plasma spraying, which involves injecting powder particles into a plasma jet created by heating an inert gas. The particles are accelerated, heated, and impact the substrate, forming a coating. Key factors that affect the plasma spraying process include substrate roughness, gas pressure, particle size, arc power, plasma gas flow rate, and torch-to-base distance. The document provides examples of plasma sprayed coatings for applications such as wear resistance and thermal barrier coatings. It also describes two case studies on plasma sprayed titanium-graphite and diamond-reinforced molybdenum coatings.
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Polymers are long molecular chains made of repeating monomers. They can be thermosets that permanently harden, or thermoplastics that soften when heated. Composites contain fibers embedded in a polymer matrix to achieve properties neither material has alone. Fiber reinforced plastics are composites with fibers like glass, carbon, or aramid in a plastic matrix. The fibers increase strength and stiffness while the matrix binds them and transfers stress. Composites find applications where high strength and low weight are required.
Plastics
Plastics are polymers made from both natural and synthetic materials. There are two main categories of plastics based on their behavior with heat: thermoplastics, which soften when heated and harden when cooled, and thermosets, which permanently set during the heating process. Common plastics include acrylics, used for windows and skylights, and PVC, known for its corrosion resistance. Fiberglass reinforced plastics and glassfiber reinforced concrete are composite materials used in construction for their strength, durability, and lightweight properties.
Glass_Reinforced_Plastic_pptx.pptx
This document discusses glass reinforced plastic (GRP), including its composition, manufacturing processes, properties, and applications. GRP consists of glass fibers embedded in a thermosetting plastic matrix. It offers advantages over other materials like steel due to its light weight, corrosion resistance, strength, and low maintenance. GRP can be manufactured through filament winding or centrifugal casting processes and is used in applications like pipes where its properties make it suitable for transporting chemicals and fluids.
Polystyerene
Polystyrene is a hard, transparent synthetic resin produced from styrene monomer. It can be solid or foam and is used widely in food packaging, construction insulation, and other applications. Polystyrene has good insulation properties but is flammable and allows oxygen and water vapor to pass through. It is produced in various forms including sheets, molded blocks, and extruded foam boards. Common uses include below-grade foundation insulation, cavity wall insulation, and roof insulation. However, polystyrene is non-biodegradable and can harm wildlife if released into the environment.
Plastics
Plastics are polymers that can be molded into various shapes. There are two main types: thermoplastics, which can be reshaped upon heating, and thermosetting plastics, which permanently harden during molding. Common thermoplastics include polyethylene, PVC, and nylon, while popular thermosetting plastics include bakelite, melamine, and epoxy. Plastics are used in a wide range of applications from piping to electronics due to their lightweight, corrosion resistance, and low cost compared to other materials. Fiber reinforced plastics combine polymers with fibers for increased strength.
Fire retardant and environmental impact of polymer additives
This document discusses polymer additives and their environmental impacts. It begins by defining polymer additives as substances added to polymers to modify their properties. It then outlines the main functions of additives such as improving processability, resistance to degradation, mechanical properties, and performance. Some examples of commonly used additive types are provided. The document notes that while additives enhance polymer performance, some can have environmental and health impacts. It gives examples of carcinogenic antioxidants and issues with certain plasticizers like DEHP. Overall, the document provides a high-level overview of polymer additives and highlights some of their benefits to properties and drawbacks regarding environmental impact.
plastics-140928093734-phpapp02.pptx
The document discusses plastics, including their definition, properties, types (thermoplastics and thermosetting plastics), manufacture, applications, disadvantages, and latest developments. Plastics are synthetic or semi-synthetic organic solids that are moldable and consist of large chain-like molecules containing carbon. They have properties like corrosion resistance, light weight, and heat resistance. The two main types are thermoplastics, which can be remolded, and thermosetting plastics, which set permanently. Plastics are manufactured through processes like polymerization, compounding, and molding/shaping techniques. They have various applications but also disadvantages like low strength and sensitivity to environment. New developments include bulletproof polymers
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Plastics and Rubbers-Introduction, Types, Uses and Examples
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Structural foam molding
- 2. INJECTION MOLDING To produce the parts by injecting a material. Performed with metals, , thermoplastic and thermosetting polymer.
- 3. STRUCTURAL FOAM MOLDING low pressure injection molding inert gas into the melted polymer Reduces density and weight Increases strength
- 4. Materials used Thermoplastic material: •Polycarbonate •ABS •Polyphenylene oxide-PPO •Polybutylene terephthalate
- 5. Design Benefits Reduced part weight Thick sections up to 5 inches Lower cost tooling Chemical and corrosion resistance
- 6. Performance Benefits Increased strength to weight ratio Chemical and corrosive resistance Improved acoustical and electrical insulation characteristics Can be recycled and reused.
- 7. APPLICATIONS •Tool boxes •Trash cans •Commercial laundry bins •Pallets •Replace wood,concrete,metals,fiberglass
- 10. SANDWICH MOULDING Two or more polymers are injected one after another through the same gate in one or more cavities. Core and skin material different or same. Also called as co-injection molding
- 11. PROCESS INJECTION 1-FORM THE SKIN MATERIAL INJECTION 2- FORM THE CORE INJECTON 3-TO SEAL THE GATE AND FINISH THE PART
- 13. PROPERTIES OF SKIN MATERIAL Will be thin Surface structure of the material. Transparent material Paintable surface E.g.: glass, thermoplastics, thermosets , sheet material , plywood
- 14. PROPERTIES OF CORE MATERIAL Thick but will be lightweight. Low density material High bending stiffness. Recycled material. E.g. :PVC, polyethylene ,polystyrene , metal foams.
- 15. APPLICATIONS • Door handles in car industry(strengthening) • Electronic housings • Decks in ships • In aerospace, making doors in airplane • Antennas
- 16. METHODS: Autoclave molding Adhesive bonding Liquid molding Continuous lamination Compression molding
Editor's Notes
- Is a manufacturing process for producing the parts by injecting a material into the mould Can be performed with a host of materials including metals, elastomers, thermoplastic and thermosetting polymer.
- Is a low pressure injection molding process where an inert gas or a chemical blowing agent is introduced into the melted polymer for the purpose of reducing density and weight of the finished product while increasing the strength.
- Design-Part weight reduced to 10% to 30%,larger parts lower pressure,thick sections upto 5 inches, increased strength and stiffness due to honeycomb structure, capable of molding large complex parts without sink marks.product or performance- highest strength to weight ratio compared to alternative manufactuing methods and materials, can replace concrete, sheet material,metal castings, wood , fiberglass, rotational and blow molding, superior impact resistance, more rigid than a solid part ,cleanability,chemical and corrosive resistance , sound deadening characteristics, electrical and thermal insulating properties, reduced part stress. Parts can be screwed, nailed or stapled like woods.production – high dimensional stability, multiple molds can be made at the same time, two differnt materials or colours can be molded simultaneously.cost-low raw material cost,parts are recyclable and reusable
- Custom plastic enclosures, toolboxes, truck bedliners, roll around carts, pallets, commercial laundry bins, wine hopper bins, trash cans, in ground pool form, pet carriers