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Selecting processes:
shaping, joining and surface treatment
New approaches to Materials Education - a course authored by Mike Ashby and David Cebon, Cambridge, UK, 2008
MFA and DC 2008
Outline
!
! Screening by attributes ! Selecting shape-forming processes ! Selecting joining processes ! Selecting surface-treatment processes ! Exercises
Manufacturing processes
Mould
Primary shaping
Casting Molding PM methods
Secondary shaping
Screw
Heater
Injection moulding
No.8-CMYK-5/01
Joining
Welding Adhesives Fasteners
Surface Treating
Painting Polishing Heat treating Welding Painting
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Kingdom
Family
Class
Casting
Member
Attributes
Difficult !
Joining
Process
data-table
Shaping
Surfacing
Powder
Rapid prototyping
Process records
Shape classification
Some processes can make only simple shapes, others, complex shapes.
!!
!!
Shape
Circular Prism Non-circular Prism Solid 3-D Hollow 3-D True True True True
Economic Attributes
Economic batch size Relative tooling cost Relative equipment cost 1e+004 - 1e+006 high high
Physical attributes
Mass range Roughness Section thickness Tolerance Discrete Prototyping 0.010.2 0.4 0.1 25 1.6 6.3 1 kg !m mm mm
Cost modeling
Relative cost index
fx
Process characteristics
True False
+ links to materials
Typical uses
Injection molding is used """.
Mould
Heater
Screw
No.8-CMYK-5/01
Design guidelines. Injection moulding is the best way to mass-produce small, precise, plastic parts with complex shapes. The surface finish is good; texture and pattern can be moulded in, and fine detail reproduces well. The only finishing operation is the removal of the sprue. The economics. Capital cost are medium to high; tooling costs are high, making injection moulding economic only for large batch-sizes (typically 5000 to 1 million). Production rate can be high particularly for small mouldings. Multicavity moulds are often used. The process is used almost exclusively for large volume production. Prototype mouldings can be made using cheaper single cavity moulds of cheaper materials. Quality can be high but may be traded off against production rate. Process may also be used with thermosets and rubbers. Typical uses. The applications, of great variety, include: housings, containers, covers, knobs, tool handles, plumbing fittings, lenses, etc. The environment. Thermoplastic sprues can be recycled. Extraction may be required for volatile fumes. Significant dust exposures may occur in the formulation of the resins. Thermostatic controller malfunctions can be extremely hazardous.
*Using the CES EduPack Level 2 DB
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Toolbar
Browse
Select
Search
Search web
ProcessUniverse
+ + +
Selection of processes
Process selection has the same 4 basic steps
!!
Step 1 Translation: express design requirements as constraints & objectives Step 2 Screening: eliminate processes that cannot do the job Step 3 Ranking: find the processes that do the job most cheaply Step 4 Documentation: explore pedigrees of top-ranked candidates
1. Selection data
Edu Level 2: Processes - shaping Shape
2. Selection Stages
Graph Limit Tree
Physical attributes
Results
X out of 60 pass
0.2
Batch size B
Process 2
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Body shell
Insulator Material class Shape class Mass Section Tolerance Roughness Batch size Alumina 3-D, hollow 0.05 kg 3 - 5 mm < 0.5 mm < 100 m >2,000,000
Central electrode
Design requirements
Make 2,000,000 insulators from alumina with given
"! shape "! dimensions "! tolerance "! surface
and
roughness
Free variable
Choice of process
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Materials
Translation Constraints
"! "! "! "! "! "! "!
Physical attributes
Mass range Range of sect. thickness Tolerance 0.04 3
Material class Alumina Shape class 3-D, hollow Mass Section Tolerance Roughness Batch size 0.05 kg 3 5 mm < 0.5 mm < 100 m >2,000,000
Roughness
0.06 kg 5 mm
0.5 mm 100 m
Economic attributes
Economic batch size 2e6
Shape
Hollow, 3 D
b
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Joining
Welding Fasteners
Processes
Joint geometry
A joining record*
Gas Tungsten Arc (TIG)
Tungsten inert-gas (TIG) welding, the third of the Big Three (the others are MMA and MIG) is the cleanest and most precise, but also the most expensive. In one regard it is very like MIG welding: an arc is struck between a non-consumable tungsten electrode and the work piece, shielded by inert gas (argon, helium, carbon dioxide) to protect the molten metal from contamination. But, in this case, the tungsten electrode is not consumed because of its extremely high melting temperature. Filler material is supplied separately as wire or rod. TIG welding works well with thin sheet and can be used manually, but is easily automated.
Joint geometry
Lap Butt Sleeve Scarf Tee True True True True
Materials
Ferrous metals
True
non-restricted True False 0.7 - 8 mm
Physical Attributes
Component size Watertight/airtight Demountable Section thickness
Economic Attributes
Relative tooling cost Relative equipment cost Labor intensity low medium low
+ links to materials
Typical uses
TIG welding is used """.
Documentation
*Using the CES EduPack Level 1 DB
Class
Member
Processes
Material Material Why treatment? Why treatment? Function of Coating thickness treatment Coating thickness Surface hardness Coating thickness Surface hardness Relative cost ... Surface hardness Relative cost ... Documentation Relative cost ... Documentation Documentation
Process records
"! Increased hardness "! Thermal insulation "! Electrical insulation "! Color "! Texture "! Decoration !.
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Function of treatment
"! Wear resistance "! Fatigue resistance "! Corrosion resistance "! Oxidation resistance
A surface-treatment record*
Induction and flame hardening
Take a medium or high carbon steel -- cheap, easily formed and machined -- and flash its surface temperature up into the austenitic phase-region, from which it is rapidly cooled from a gas or liquid jet, giving a martensitic surface layer. The result is a tough body with a hard, wear and fatigue resistant, surface skin. Both processes allow the surface of carbon steels to be hardened with minimum distortion or oxidation. In induction hardening, a high frequency (up to 50kHz) electromagnetic field induces eddy-currents in the surface of the workpiece, locally heating it; the depth of hardening depends on the frequency. In flame hardening, heat is applied instead by hightemperature gas burners, followed, as before, by rapid cooling.
Function of treatment
Fatigue resistance Friction control Wear resistance Hardness
Economic Attributes
Relative tooling cost Relative equipment cost Labor intensity Very good 300 - 3e+003 !m 727 - 794 K 420 - 720 Vickers low medium low
Physical Attributes
Curved surface coverage Coating thickness Processing temperature Surface hardness
Documentation
links to materials
Typical uses
Induction hardening is used "..
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5.1 Find, by browsing, the Level 2 record for the shaping process Resin transfer molding (RTM) in Shaping: Composite forming. What products, typically, is it able to make? 5.2 Find the Level 2 record for shaping process Abrasive jet machining and cutting in Shaping: Machining: non-conventional machining. Can it be used to cut glass? 5.3 Find the Level 2 record for the joining process Friction-stir welding in Joining: Mechanical welding. How does the process work? 5.4 Find the Level 2 record for the surface coating process Metal flame spraying in Surface treatment: Surface coating. What are its principal uses?
Browse
Select
Search
Table: Table: ProcessUniverse ProcessUniverse Subset: Subset: Edu Edu Level Level 2 2
ProcessUniverse
+ + +
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File
Edit
View
Select
Tools
Browse
Select
Search
5.6 Find, by searching, the record for Flexible adhesives. Which polymers are used for flexible adhesives?
Find what:
SLS
5.7 Find, by searching, the record for Vitreous enameling. What Functions can it perform?
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1. Selection data
Edu Edu Level Level2: 2: Processes Processes -- shaping shaping
2. Selection Stages
Graph Shape
Solid 3-D Process
Limit
Tree
Cast Deform Molding Composite Powder Prototype
Economic attributes
Economic batch size > 10 6
Results:
#! Compression molding #! Injection molding, thermoplastics
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1. Selection data
Edu Edu Level Level2: 2: Processes Processes -- shaping shaping
2. Selection Stages
Graph Shape
Flat sheet Material
Limit
Tree
Ceramic Hybrid Metal Polymer
Physical attributes
Section thickness <>4 mm
Process characteristics
Cutting processes
Results:
#! Abrasive jet machining and cutting #! Band sawing #! Laser cutting #! Water-jet cutting
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1. Selection data
Edu Edu Level Level2: 2: Processes Processes -- joining joining
2. Selection Stages
Graph Limit Tree
Materials to be joined
5.10. A process is required to join 0.6 mm steel blades onto aluminum sheet carriers to form a lap joint. Use the Level 2 Joining data-table to find them. The requirements are "! "! "! "! Materials to be joined: metals Joint geometry: lap joint Section thickness: 0.6 mm Demountable: No (X)
Metals
Joint geometry
Lap joint
Physical attributes
Section thickness <> 0.6 mm
Function
Demountable
Results:
#! #! #! #!
Brazing Power beam (laser, electron beam) Resistance welding Rivets and staples
Blades
#! Ultrasonic welding
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1. Selection data
Edu Edu Level Level2: 2: Processes Processes -- surface surface
2. Selection Stages
Emerson Transmission Corp
Limit
Tree
Ceramic Material Hybrid Metal Polymer
Ferrous Non-ferrous
5.11. A process is required to improve the wear resistance and fatigue resistance of steel gears. The requirements are "! Materials: steel "! Purpose of treatment: wear resistance fatigue resistance "! Curved surface coverage: very good
Physical attributes
Curved surface coverage: v. good
Results:
#! Carburizing and carbo-nitriding #! Nitriding #! Induction hardening and flame hardening
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