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LECTURE 2
PROCESSES AND
PROCESS
SELECTIONS
Deformati
Casting Moulding
on
processes processes
processes
Powder Rapid
Composit
processin prototypin
e forming
g g
Machining
operations
THE PROCESSESS: SHAPING - Casting
a) Casting
In casting, a liquid is poured or forced into a
mould where it solidifies by cooling.
It fills and mould by flow under its own weight (as
in gravity sand and investment casting) or under
a modest pressure (as in die casting and pressure
sand casting).
Sand casting are cheap; metal dies for die casting
large batches can be expensive.
The shape is designed so that the pattern and the
finished casting can be removed from the mould.
THE PROCESSESS: SHAPING - Casting
b) Moulding
Adapted to material that are very viscous when
molten, particularly thermoplastics and glasses.
The hot, viscous fluid is pressured or injected into
a die under considerable pressure, where it cools
and solidifies.
The die must withstand repeated application of
pressure, temperature and the wera involved in
separating and removing the part, and therefore it
is expensive.
Moulds for thermo-forming are cheap.
THE PROCESSESS: SHAPING - Moulding
c) Deformation processing
The process can be hot, warm or cold
Cold, relative to the melting point Tm of the material being
processed
Warm working (0.35 Tm < T < 0.55 Tm) allows recovery but not
recrystallization.
Cold forging, rolling and drawing (Tm < 0.35 Tm) exploit work
hardening to increase the strength of final product, but at the penalty
of higher forming pressures.
Forged parts are designed to avoid suden changes in the thickness and sharp
radii of curvature since both require large local strain that can cause the
material to tear or to fold back on itself (tapping).
Cold forging gives greater precision and finish, but forging pressures are
higher and the deformations are limited by work hardening.
THE PROCESSESS: SHAPING Deformation processing
d) Powder methods
This method can create the shape by pressing and
sintering fine particles of the material.
Advantages;
It is economic in its use of material
It allows parts to be fabricated from materials that
cannot be cast, deformed, or machined; and
It can give a product that requires little or no finishing.
THE PROCESSESS: SHAPING Powder
methods
g) Machining operation
Almost all engineering components, whether
made of metal, polymer or ceramic, are subjected
to some kind of machining during manufacture.