Foundry Processes and Techniques Quiz

Introduction to Basic Manufacturing Technology

• Manufacturing is the application of science to provide society with desired products.
• Manufacturing is the backbone of industrialized nations.
• Modern manufacturing involves mechanization, automation, and computer-integrated manufacturing.
• It focuses on optimized manufacturing and product design to reduce manual labor.

Introduction to Manufacturing Technology

• Authors of the document are Dr. B. J. Olorunfemi and Engr. A. E. Olumilua.
• Document details various manufacturing technologies and their applications.

Copyright Information

• Copyright © 2024
• ISBN: 978 – 978 – 53907 – 8 - 7
• Permission required for reproduction.

Foreword

• No content.

Introduction to Manufacturing Technology (Chapter 1)

• Technology is the application of science to provide societal needs.
• Manufacturing is crucial in any industrialized nation.
• Manufacturing safety precautions, including safety rules and procedures, to avoid accidents are essential.
• Manufacturing is the application of tools, machines, labor, chemical and biological processing to produce goods.
• The process ranges from handicrafts to high-tech operations.
• Manufacturing is a significant aspect of industrial/economic development.

Five Technological Applications (Chapter 1)

• Additive Manufacturing/3D Printing: 1980's technology covering various processes for producing 3-dimensional goods. Technology is becoming more affordable.
• Advanced Materials: critical in future energy efficiency, new consumer devices, resource shortages, and chemical safety and security.
• Cloud Computing: uses network connected remote services to process data, increasing business decisions, and reducing production time.
• Internet of Things (IoT): connected equipment communicates, providing notifications about operating conditions and leading to less downtime and waste.
• Nanotechnology: deals with matter between 1 and 100 nanometers. Used in aerospace and biomedical arenas for lightweight components.

Production Processes (Chapter 1.5)

• Job production: one operator or group completes a single or different job. Very low volume.
• Batch production: Manufacturing of a number (200-800) of similar parts with minimal variation in size and shape.
• Mass production: High volume (over 50,000) identical or near-identical products.

Process Planning (Chapter 1.6)

• Process planning involves selecting tools, establishing operation sequence and specifying operator actions.
• This plan maximizes productivity and minimizes material handling cost.
• Includes various concepts like tooling, machining time, and required operator skill.

Manufacturing Processes (Chapter 1.7)

• Manufacturing processes directly change the form and dimensions of a manufactured part (e.g., machining).
• This doesn't include transport, storage, or handling of parts.
• Raw materials need to be understood.

Manufactured Products (Chapter 1.8)

• Manufactured products categorized as consumer (directly purchased by consumers) or capital goods (purchased by companies).
• Capital goods include aircraft, computers, trucks and buses, which are often bought by industrial/service companies.

Computers in Manufacturing Industries (Chapter 1.9)

• Computer use in manufacturing leads to increased productivity, accuracy, flexibility and reduced costs.
• Computer-assisted design (CAD) and computer-aided manufacturing (CAM) are used to improve efficiencies and product quality.

Primary Shaping Processes (Chapter 2)

• Casting: Molten metal poured into a mold (cavity).
• Forging: Shaping hot metal via hammering or squeezing.
• Plastic technology: Forming materials using heat and pressure.
• Gas cutting: Employing gas for cutting metal and producing desired shapes.
• Bending: Form metal into curves or angles.
• Powder metallurgy: Manufacturing of products from metallic powders.

Classification of Foundries (Chapter 2.2)

• Foundries are classified by the type of product (iron, steel, non-ferrous).
• Jobbing foundry: used for small order of work and usually poor financial support.
• Production foundry: large, mechanized shops (using automated tools and equipment).
• Semi-production foundry: combines elements of jobbing and and productive foundries.
• Captive foundry: part of a larger production.

Casting (Chapter 2.3)

• Casting is a process of pouring molten metal into a mold.
• Mold cavity shape determines the cast part shape.
• Casting methods include sand casting, permanent-mold casting, and die casting. These differ mainly by the type of mold.

Advantages of Casting (Chapter 2.3.1)

• Versatile in shape.
• Parts can be complex in shape.
• Can be used with large parts.
• Can be used with various types of metals (suitable for liquid metal types).
• Mass production is possible.

Disadvantages of Casting (Chapter 2.3.2)

• Limitations in physical/mechanical properties.
• Difficulty with dimensional accuracy.
• Safety hazards exist in handling hot metals.
• Environmental issues result from dealing with very hot metals.

Casting Processes (Chapter 2.4)

• Initial phase is mold creation.
• Melting and pouring (heating the metal to liquid states and pouring it into the mold).
• Gating system (a passageway for the flow of the metal).
• Subsequent mold cooling and solidification in the mold cavity.
• Removal of casting from the mold.
• Post-processing (cleaning surface or inspecting).

Mould and Mould Making (Chapter 2.5)

• Moulding: the preparation of a mold for the metal.
• Sand molds are common in casting, bonded by clay or other substances.
• Green sand casting: Bonded with clay.
• Dry sand casting: Sand undergoes baking prior usage.
• Various other molding methods (as needed).

Core Sands and Core Binders (Chapter 2.5.3)

• Green sand is used for making cores, sometimes strengthened by binders.
• Dry sand cores are made from silica sand.
• Core binders are either organic (e.g., oils) or inorganic (e.g., minerals).

Organic binders (Chapter 2.5.3)

• These include common materials (e.g. core-oil from linseed oil, resins, and kerosene)
• These enhance qualities of a material (e.g. workability, oxidation characteristics).

Core Making Methods (Chapter 2.5.3.1)

• Core blowers and extrusion machines are used.
• Screw feed machines are used for creating uniform cylindrical cores.
• Core driers are used for holding/supporting cores during baking.

Melting and Pouring (Chapter 2.5.4)

• Melting is the process of transforming metal into liquid form.
• Pouring is carefully placing molten metal inside the mold.
• Cleaning removes excess materials from the casting.
• Inspection is done to ensure quality and specifications.

Melting and Heat Treating Furnaces (Chapter 2.5.4.1)

• Various types of furnaces are used in metal casting (e.g. electric arc, induction, and crucible furnaces are prevalent).
• Furnace type is dependent on scale of operation.
• Traditional, electric arc, induction and crucible are used.

Vacuum Melting and Refining (Chapter 2.5.4.2)

• Used for exceptionally pure metals in high-strength/high-temperature applications (e.g. turbine blades)
• Involves locating furnace in an evacuated chamber to remove gases from the melted metal.
• Expensive due to vacuum chamber/equipment.

Cleaning and Inspection (Chapter 2.5.5)

• Tumbling barrels: removes sand/scale using hard iron balls.
• Air-blast cleaning units: use compressed air to remove materials from the casting.
• High-pressure water cleaning methods are also used.

Casting Design (Chapter 2.6)

• Casting design is influenced by factors like metal solidification characteristics, foundry practices, and the metallurgy of the metal.

Computers in Manufacturing Industries (Chapter 1.9)

• Computer use in manufacturing is significant.
• Increased efficiency through CAD-CAM.

Forging (Chapter 3)

• Forging is the oldest metal shaping process (used to make small objects where accuracy is not so important).
• Forging is done using hammers.
• Methods include hand forging, drop forging and machine forging.

Applications of Forging (Chapter 3.2)

• Forging is commonly used for carbon and alloy steels, wrought iron, copper-base, aluminum and magnesium alloys, stainless steel, nickel-based alloys and titanium).
• Primarily used for aerospace grade materials.

Common Hand Forging Tools (Chapter 3.3)

• Tools used in hand forging (eg. Tongs, flatters, fullers, punches, rivet headers, chisels, hammers and swage blocks) for performing tasks such as cutting, moving or shaping the metal.

Forging Operations (Chapter 3.4)

• Drawing-down: Reduction of bar thickness.
• Upsetting: Increasing cross-section of metal piece.
• Flattening: producing a flat surface.
• Swaging: Reducing the cross-section to size and shape.
• Bending: Forming metal into an angle or curve.
• Twisting: Shaping metal into a spiral shape.
• Cutting: Using chisels to cut metals (hot or cold).

Forge Welding (Chapter 3.5)

• Joining two metal pieces by heating to plastic condition, followed by hammering/pressing them together.
• Usually requires a flux to prevent oxide formation.

Drop Forging (Chapter 3.6)

• Using dies to produce high volumes of similar parts.
• A cost-effective method for large quantities.

Machine Forging (Chapter 3.7)

• Larger jobs than drop forging
• Uses power hammers for shaping and forming metal parts.

Safety in Forging (Chapter 3.8)

• Safety precautions are essential during forging operations. These include wearing aprons, using correct tongs and tools etc.
• Avoiding loose hammer heads and leaving hot metal where people can touch it.