Manufacturing Processes: Metal Forming & Sheet Metalworking PDF

METAL FORMING AND SHEET METALWORKING Manufacturing Processes Course Dr. Feras Kafiah 2020 1 METAL FORMING AND SHEET METALWORKING...

METAL FORMING AND SHEET METALWORKING Manufacturing Processes Course Dr. Feras Kafiah 2020 1 METAL FORMING AND SHEET METALWORKING 2 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). FUNDAMENTALS OF METAL FORMING Metal Forming includes a large group of manufacturing processes in which plastic deformation is used to change the shape of metal work pieces. Stresses applied Desirable properties The effect of temperature Strain rate & Sensitivity Classification of metal Friction and Lubrication forming operations. 3 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010).  FUNDAMENTALS OF METAL FORMING Bulk Deformation Processes Rolling Forging Extrusion Wire Drawing Thickness of a slab A workpiece is The work metal is The diameter of a or plate is reduced by compressed between forced to flow through round wire or bar is two opposing two opposing dies. a die opening. reduced by pulling it cylindrical tools called through a die opening. rolls. 4 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). FUNDAMENTALS OF METAL FORMING Sheet Metal Working Processes Sheets has a high surface area to volume ratio. Bending Drawing Shearing (Punching) Shearing (Cutting) Straining of a metal Forming of a flat metal A shearing operation cuts the work using a punch and die sheet or plate to take sheet into a hollow or an angle along a concave shape, such straight axis. as a cup, by stretching the metal 5 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). FUNDAMENTALS OF METAL FORMING Metal Forming includes a large group of manufacturing processes in which plastic deformation is used to change the shape of metal work pieces. Stresses applied Desirable properties The effect of temperature Strain rate & Sensitivity Classification of metal Friction and Lubrication forming operations. 6 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). FUNDAMENTALS OF METAL FORMING True Strain 1) MATERIAL BEHAVIOR IN METAL FORMING Flow Stress, Yf Flow stress is defined as the instantaneous value of stress required to continue deforming the material— to keep the metal ‘‘flowing.’’ Yf = Flow stress, MPa K = Strength coefficient, MPa The flow curve describes the stress–strain relationship in Average Flow Stress: n = Strain-hardening exponent. the region in which metal ε = True stain. forming takes place. 𝒀ഥf = Average flow stress 7 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). FUNDAMENTALS OF METAL FORMING 2) TEMPERATURE IN METAL FORMING Cold Working Forming at Room Temperature or slightly above Warm Working Forming at 0.3 Tm. Hot Working hot working temperatures are usually maintained within the range 0.5-0.75 Tm. 8 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). FUNDAMENTALS OF METAL FORMING 3) STRAIN RATE SENSITIVITY The rate at which the metal is strained in a forming process is directly related to the speed of deformation, v Strain Rate: 𝜖ሶ = Strain rate, s-1. At Elevated Temp. Log-Log v = Deformation speed, m/s. h = Instantaneous height of the workpiece, m. 9 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010).  FUNDAMENTALS OF METAL FORMING 3) STRAIN RATE SENSITIVITY The rate at which the metal is strained in a forming process is directly related to the speed of deformation, v Strain Rate: Yf = Flow stress, MPa At Elevated Temp. Log-Log 𝜖ሶ = Strain rate, s-1. m = strain rate sensitivity exponent, m/s. C = strength constant, determined at m=1. 10 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). FUNDAMENTALS OF METAL FORMING 3) STRAIN RATE SENSITIVITY Effect of temperature on flow stress for a typical metal. C decreases with increasing temperature m increases with increasing temperature. Log-Log 11 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). FUNDAMENTALS OF METAL FORMING 4) FRICTION AND LUBRICATION IN METAL FORMING Friction in metal forming arises because of the close contact between the tool and work surfaces and the high pressures that drive the surfaces together in these operations. Friction is undesirable: 1. Metal flow in the work is retarded, causing residual stresses and sometimes defects in the product. 2. Forces and power to perform the operation are increased. 3. Tool wear can lead to loss of dimensional accuracy. If the coefficient of friction becomes large enough  Sticking Tendency for the two surfaces in relative motion to adhere to each other rather than slide. 12 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). FUNDAMENTALS OF METAL FORMING 4) FRICTION AND LUBRICATION IN METAL FORMING Lubricants: are applied to the tool–work interface in many forming operations to reduce the harmful effects of friction. Selection of Lubricants Lubricants are good 1. Type of forming process. 1. Reduce the harmful effects of friction. 2. Whether used in hot working or cold working. 2. Reduce sticking, forces, power, and tool wear. 3. Work material. 3. Better surface finish on the product. 4. Chemical reactivity with the tool and work 4. Remove heat from the tooling metals 5. Ease of application. 6. Toxicity. Lubricants Types 7. Flammability. Cold Working: Hot Working: 8. Cost. Mineral oils, fats and Dry. fatty oils. Mineral oils. Water-based Graphite. emulsions, soaps. Molten glass. 13 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). FUNDAMENTALS OF METAL FORMING Summary Flow stress Average Flow Stress: Yf = Flow stress, MPa K = Strength coefficient, MPa n = Strain-hardening exponent. ε = True stain. Strain Rate: 𝒀ഥf = Average flow stress Flow Stress with Strain Rate: 𝜖ሶ = Strain rate, s-1. v = deformation speed, m/s. h = Instantaneous height of the workpiece. True Stress True Strain m = strain rate sensitivity exponent, m/s. C = strength constant, determined at m=1. 14 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). FUNDAMENTALS OF METAL FORMING 15 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). HOMEWORK NO. 5 Problem 1 Problem 2 Problem 3 Problem 4 16 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). Thanks 19 BULK DEFORMATION PROCESSES Manufacturing Processes Course Dr. Feras Kafiah 2020 1 BULK DEFORMATION PROCESSES 2 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES Metal Forming includes a large group of manufacturing processes in which plastic deformation is used to change the shape of metal work pieces. Stresses applied Desirable properties The effect of temperature Strain rate & Sensitivity Classification of metal Friction and Lubrication forming operations. 3 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 1) Rolling Is a deformation process in which the thickness of the work is reduced by compressive forces exerted by two opposing rolls. Most rolling processes are very capital intensive, requiring massive pieces of equipment, called rolling mills. Most rolling is carried out by hot working, called hot rolling. For steel, the desired temperature for rolling is around 1200C. 4 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 1) Rolling Some of the steel products made in a rolling mill. 5 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 1) Rolling FLAT ROLLING AND ITS ANALYSIS 1) Draft: 2) Reduction: 2) Maximum Draft: m, coefficient of friction 4) Conservation of matter: 5) Material Flow Consistency 6) Forward slip 7) True Strain 8) Ave. Flow Stress 6 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 1) Rolling FLAT ROLLING AND ITS ANALYSIS 6) True Strain 7) Ave. Flow Stress 9) Rolling Force 10) Contact Length 11) Torque for each roll 12) Power (W) required to drive both rolls The product of torque and angular velocity Angular velocity is 2πN Horsepower, hp = 745.7 W 7 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 1) Rolling SHAPE ROLLING In shape rolling, the work is deformed into a contoured cross section. Products made by shape rolling include construction shapes such as I- beams, L-beams, and U-channels; rails for railroad tracks; and round and square bars and rods 8 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 1) Rolling ROLLING MILLS 2-high 3-high 4-high Cluster mill Tandem ‫ بالتزامن‬rolling mill 9 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 1) Rolling OTHER DEFORMATION PROCESSES RELATED TO ROLLING Thread Rolling Ring Rolling 10 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 2) Forging 2) Forging A deformation process in which the work is compressed between two dies, using either impact or gradual pressure to form the part. Forging is an important industrial process used to make a variety of high-strength components for automotive, aerospace, and other applications:- 1. Engine crankshafts 2. Connecting rods. 3. Gears 1) Open-die 4. Aircraft structural components 5. Jet engine turbine parts Most forging operations hot or warm. Three types of forging operations: 3) Flashless 1. Open-die forging. Flash is excess metal that must be trimmed off later 2. Impression-die forging. 3. Flashless forging. 2) Impression-die 11 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 2) Forging 1) Open-Die Forging Analysis of Open-Die Forging- Without Friction If open-die forging is carried out under ideal conditions of no friction between work and die surfaces True Strain Flow Stress Maximum Force 12 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 2) Forging 1) Open-Die Forging Analysis of Open-Die Forging- With Friction Actually, friction opposes the flow of work metal at the die surfaces. This creates the barreling effect. True Strain Maximum Force Forging shape factor µ = coefficient of friction Barreling effect 13 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 2) Forging 1) Open-Die Forging Example True Strain Maximum Force Forging shape factor Volume Consistency rule 𝑉𝑜 = 𝑉𝑓 ⇒ 𝐴𝑜. ℎ𝑜 = 𝐴𝑓. ℎ𝑓 14 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 2) Forging 2) IMPRESSION-DIE FORGING Impression-die forging, sometimes called closed-die forging, is performed with dies that contain the inverse of the desired shape of the part Maximum Force 15 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 2) Forging 3) FLASHLESS FORGING The raw workpiece is completely contained within the die cavity during compression, and no flash is formed. Process requirements: 1. The work volume must equal the space in the die cavity within a very close tolerance. 2. If the starting blank is too large, excessive pressures may cause damage to the die or press. 3. If the blank is too small, the cavity will not be filled. 4. Flashless forging is often classified as a precision forging process. 5. Work materials such as aluminum and magnesium and their alloys. Maximum Force 16 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 2) Forging FORGING HAMMERS, PRESSES, AND DIES Gravity drop hammers Power drop hammers 17 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). HOMEWORK NO. 6 Problem 1 Problem 2 18 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). Thanks 21 BULK DEFORMATION PROCESSES Manufacturing Processes Course Dr. Feras Kafiah 2020 1 BULK DEFORMATION PROCESSES 2 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES Metal Forming includes a large group of manufacturing processes in which plastic deformation is used to change the shape of metal work pieces. Stresses applied Desirable properties The effect of temperature Strain rate & Sensitivity Classification of metal Friction and Lubrication forming operations. 3 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 3) Extrusion ‫عملية البثق‬ Extrusion is a compression process in which the work metal is forced to flow through a die opening to produce a desired cross-sectional shape. Advantages: 1. A variety of shapes are possible. 2. Grain structure and strength properties are enhanced in cold and warm extrusion. 3. Fairly close tolerances are possible. 4. Little or no wasted material is created. 4 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 3) Extrusion ‫عملية البثق‬ 5 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 3) Extrusion TYPES OF EXTRUSION 1) Direct Extrusion 2) Indirect Extrusion Forward extrusion Backward or reverse extrusion Solid section Hollow section 6 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 3) Extrusion TYPES OF EXTRUSION Temperature Productivity Cold Extrusion Continuous Extrusion Warm Extrusion Discrete Extrusion Hot Extrusion 7 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 3) Extrusion ANALYSIS OF EXTRUSION No friction and no redundant work 1) Reduction Ratio: 2) True Extrusion Strain 3) Ave. Flow Stress 5) Ram force 4) Pressure applied by the ram 6) Extrusion Power 8 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 3) Extrusion ANALYSIS OF EXTRUSION With friction and no redundant work 1) Reduction Ratio: 2) True Extrusion Strain (Johnson Formula) a and b are empirical constants for a given die angle - Typical values of these constants are: a = 0.8 and b = 1.2 to 1.5 5) Ram force 3) Ave. Flow Stress 6) Extrusion Power 4) Pressure applied by the ram 2L/Do accounts for the Indirect extrusion Direct extrusion additional pressure due to friction at the container– billet interface 9 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 3) Extrusion Example 1) Reduction Ratio: 2) True Extrusion Strain (Johnson Formula) 3) Ave. Flow Stress 4) Pressure applied by the ram Direct extrusion 10 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 3) Extrusion Example 11 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 3) Extrusion ANALYSIS OF EXTRUSION For Complex Cross Section With friction and no redundant work Indirect pressure Direct pressure Where Kx = die shape factor in extrusion; Cx= perimeter Die shape factor of the extruded cross section, mm; and Cc = perimeter of a circle of the same area as the extruded shape, mm 12 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 3) Extrusion OTHER DEFORMATION PROCESSES RELATED TO ROLLING Impact Forward Extrusion Impact Backward Extrusion Impact Combination Extrusion Hydrostatic Extrusion 13 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 3) Extrusion DEFECTS IN EXTRUDED PRODUCTS Center burst Piping Surface cracking 14 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). HOMEWORK NO. 7 Problem 1 15 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). Thanks 17 BULK DEFORMATION PROCESSES: WIRE AND BAR DRAWING Manufacturing Processes Course Dr. Feras Kafiah 2020 1 BULK DEFORMATION PROCESSES 2 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES Continuous drawing 4) Wire and Bar Drawing ‫عملية سحب األسالك و القضبان‬ An operation in which the cross section of a bar, rod, or wire is reduced by pulling it through a die opening The basic difference between bar drawing and wire drawing is the stock size that is processed. Bar drawing is the term used for large diameter bar and rod stock, while wire drawing applies to small diameter stock. Area reduction Draft 3 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 4) Wire Drawing ANALYSIS OF DRAWING No friction and no redundant work 1) Area reduction 2) True Extrusion Strain 3) Draw Stress 4) Ave. Flow Stress 4 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 4) Wire Drawing ANALYSIS OF DRAWING With friction and no redundant work 1) Area reduction 2) True Extrusion Strain µ : Die-work coefficient of friction. 3 Draw Stress α : Die angle (half-angle) φ: Factor that accounts for inhomogeneous deformation 4) Ave. Flow Stress 5) Draw force 6) Extrusion Power 5 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 4) Wire Drawing Example 1) Area reduction 2) True Extrusion Strain 3 Draw Stress 4) Ave. Flow Stress 5) Draw force 6) Extrusion Power 6 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 4) Wire Drawing ANALYSIS OF DRAWING Maximum Reduction per Pass Maximum draw stress must be less than the yield strength of the exiting metal Without friction With friction 0.50 for single-draft bar drawing 0.30 for multiple-draft wire drawing 7 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 4) Wire Drawing DRAWING PRACTICE Metal bars Hydraulically operated draw bench Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 4) Wire Drawing DRAWING PRACTICE Wire Continuous drawing Continuous drawing of wire Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BULK DEFORMATION PROCESSES 4) Wire Drawing Tube Drawing Fixed mandrel Floating Plug Tube drawing with mandrels Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). HOMEWORK NO. 8 Problem 1 Problem 2 11 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). Thanks 14 SHEET METALWORKING Manufacturing Processes Course Dr. Feras Kafiah 2020 1 SHEET METALWORKING Blanking Operation Bending Operation Punching Operation Drawing Operation 2 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). SHEET METALWORKING Sheet Metalworking Sheet metalworking includes cutting and forming operations performed on relatively thin sheets of metal. Sheet-metal thicknesses are between 0.4 mm and 6 mm. When thickness exceeds about 6 mm, the stock is usually referred to as plate rather than sheet. The most commonly used sheet metal is low carbon steel (0.06%–0.15% C typical). Sheet-metal processing is usually performed at room temperature (cold working). Most sheet-metal operations are performed on machine tools called presses (Stamping presses). The sheet-metal products are called stampings. 3 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). SHEET METALWORKING 1) Cutting Operations Cutting of sheet metal is accomplished by a shearing action between two sharp cutting edges. The shearing action can be divided into four steps shown in figures. Sheared edge Four steps of shearing process 4 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). SHEET METALWORKING 1) Cutting Operations Following are the types of cutting operations performed in sheet metal working: 1. Shearing 7. Perforating 2. Blanking 8. Notching 3. Punching 9. Trimming 4. Cut off 10 Shaving 5. Parting 11. Fine blanking 6. Slotting 5 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). SHEET METALWORKING 1) Cutting Operations 1-3) SHEARING, BLANKING, AND PUNCHING 1 SHEARING 2 BLANKING 3 PUNCHING It is a sheet metal cutting Punching is similar to It involves cutting of sheet metals operation along a straight line along a single step to separate the blanking except that the between two cutting edges. piece from the surrounding stock. piece that is cut out is scrap called the slug. It is typically used to cut large sheets into smaller sections for subsequent press working operations. 6 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). SHEET METALWORKING 1) Cutting Operations 4-6) CUTOFF, PARTING AND SLOTTING 4 CUTOFF 5 PARTING 6 SLOTTING It is a shearing operation in which Parting involve cutting a sheet Slotting is a punching blanks are separated from a sheet metal strip by a punch with two operation that cuts out an metal strip by cutting the opposite cutting edges that match the elongated or rectangular side of the part in sequence. opposite sides of the blank. hole. 7 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). SHEET METALWORKING 1) Cutting Operations 7-9) PERFORATING, NOTCHING AND TRIMMING 7 PERFORATING 8 NOTCHING 9 TRIMMING Perforating involves the Notching involves cutting out a Trimming is a cutting simultaneous punching of a portion of a metal from the side of operation performed on a pattern of holes in a sheet sheet or strip. formed part to remove metal. For decoration purposes excess metal and establish size. 8 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). SHEET METALWORKING 1) Cutting Operations 10, 11) SHAVING, AND FINE BLANKING 10 SHAVING 11 FINE BLANKING It is a shearing operation performed with very It is a shearing operation used to blank sheet small clearance to obtain accurate dimensions metal parts with close tolerances and smooth, and cut edges that are smooth and straight. straight edges in one step. 9 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). SHEET METALWORKING 1) Cutting Operations ANALYSIS OF SHEET METAL CUTTING CLEARANCE Process parameters in sheet-metal cutting are: The clearance, c in a shearing operation Clearance between punch and die is the distance between the punch and die. Stock thickness Typical clearances range between 4% Type of metal and its strength and 8% of the sheet-metal thickness t. Length of the cut. c = clearance, mm; Ac = clearance allowance; t = stock thickness, mm Clearance too small Clearance too large 10 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). SHEET METALWORKING 1) Cutting Operations ANALYSIS OF SHEET METAL CUTTING CUTTING FORCES Process parameters in sheet-metal cutting are: Estimates of cutting force are important Clearance between punch and die because this force determines the size Stock thickness (tonnage) of the press needed Type of metal and its strength Length of the cut. S = shear strength of the sheet metal, MPa. TS = ultimate tensile strength MPa t = stock thickness, mm L = Length of cut edge, mm 11 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). SHEET METALWORKING 1) Cutting Operations Example Around disk of 150-mm diameter is to be blanked from a strip of 3.2 mm, half-hard cold rolled steel whose shear strength = 310 MPa. Determine (a) clearance, and (b) blanking force. S = shear strength of the sheet metal, MPa. TS = ultimate tensile strength MPa t = stock thickness, mm L = Length of cut edge, mm c = clearance, mm; Ac = clearance allowance; t = stock thickness, mm 12 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). HOMEWORK NO. 9 Problem 1 A blanking operation is to be performed on 2.0 mm thick cold rolled steel (half hard). The part is circular with diameter = 75.0 mm. a) Determine the appropriate punch and die sizes for this operation, b) Determine the blanking force required, if the steel has a shear strength = 350 MPa. Problem 2 The foreman in the press working section comes to you with the problem of a blanking operation that is producing parts with excessive burrs. What are the possible reasons for the burrs, and what can be done to correct the condition? 13 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). Thanks 16 MATERIAL REMOVAL PROCESSES Manufacturing Processes Course Dr. Feras Kafiah 2020 1 THEORY OF METAL MACHINING 2 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF METAL MACHINING Material Removal Processes The material removal processes are a family of shaping operations in which excess material is removed from a starting workpart so that what remains is the desired final geometry. A sharp cutting tool is used to mechanically cut the material to achieve the desired geometry. Machining is a manufacturing process in which a sharp cutting tool is used to cut away material to leave the desired part shape. 3 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF METAL MACHINING OVERVIEW OF MACHINING TECHNOLOGY Two motions Primary motion  Cutting speed Secondary motion  Feed 4 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF METAL MACHINING Material Removal Processes Advantages Disadvantages Machining can be applied to a wide variety Wasteful of material. of work materials. Variety of part shapes and geometric Time consuming. features Dimensional accuracy (tolerances of ±0.025 mm) Good surface finishes (Roughness values less than 0.4 microns) 5 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF METAL MACHINING Types of Machining Operations There are many kinds of machining operations, each of which is capable of generating a certain part geometry and surface texture. Turning Drilling Peripheral Milling Face Milling 6 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF METAL MACHINING Types of Machining Operations Drilling Turning Milling 7 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF METAL MACHINING The Cutting Tool A cutting tool has one or more sharp cutting edges and is made of a material that is harder than the work material. There are two basic types, (a) single-point tools and (b)multiple-cutting-edge tools A single-point tool Multiple-cutting-edge tools 8 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF METAL MACHINING Cutting Conditions Two motions Primary motion  Cutting Speed, v Secondary motion  Cutting Feed, f Penetration of the cutting tool  Cutting Depth, d RMR= material removal rate,mm3/s Material removal rate v = cutting speed, mm/s f = feed, mm d = depth of cut, mm. A cutting fluid is often applied to the machining operation to cool and lubricate the cutting tool. A machine tool is used to hold the workpart, position the tool relative to the work, and provide power for the machining process at the speed, feed, and depth that have been set. Lathes, drill presses, and milling machines 9 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF CHIP FORMATION IN METAL MACHINING Rake angle THE ORTHOGONAL CUTTING MODEL The geometry of most practical machining operations is somewhat complex.. Shear Plane A simplified model of machining is available that neglects many of the geometric complexities Clearance angle to= chip thickness prior to cutting Chip thickness ratio tc = chip thickness chip ratio (r) will always be less than 1.0 Shear Strain 10 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF CHIP FORMATION IN METAL MACHINING ACTUAL CHIP FORMATION For the material to behave in a realistic way, the shear deformation must occur within a thin shear zone. This more realistic model of the shear deformation process in machining. Brittle materials Ductile materials Ductile materials Difficult-to-machine metals such Low cutting speed High cutting speed Low to medium cutting speed as titanium alloys, nickel-base superalloys Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). EXAMPLE 1 Chip thickness ratio Shear Strain 12 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF CHIP FORMATION IN METAL MACHINING FORCE RELATIONSHIPS AND THE MERCHANT EQUATION On the Chip: Coefficient of friction F= friction force on the chip N = The normal force to friction Coefficient of friction R = Resultant force Fs = Shear force Fn = Normal force to shear Shear stress As = Area of the shear plane R’ = Resultant force of the shear On the tool: Fc = Cutting Force In order for the forces acting on the Ft = thrust Force chip to be in balance, this resultant R’ must be equal in magnitude, opposite in direction, and collinear with the resultant R. Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF CHIP FORMATION IN METAL MACHINING Force diagram FORCE RELATIONSHIPS AND THE MERCHANT EQUATION On the Chip: Coefficient of friction F= friction force on the chip N = The normal force to friction Shear stress R = Resultant force Fs = Shear force Fn = Normal force to shear Trigonometric relationships: As = Area of the shear plane R’ = Resultant force of the shear On the tool: Fc = Cutting Force Ft = thrust Force Dynamometer Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). EXAMPLE 2 In a machining operation that approximates orthogonal cutting, the cutting tool has a rake angle = 10 and shear angle φ = 25.4. The cutting force and thrust force are measured during an orthogonal cutting operation: Fc = 1559 N and Ft = 1271 N. The width of the orthogonal cutting operation w = 3.0 mm. determine (a) the friction angle and (b) the coefficient of friction. On the Chip: Shear stress F= friction force on the chip N = The normal force to friction R = Resultant force Fs = Shear force Fn = Normal force to shear As = Area of the shear plane R’ = Resultant force of the shear On the tool: Fc = Cutting Force Ft = thrust Force 15 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF CHIP FORMATION IN METAL MACHINING THE MERCHANT EQUATION Shear force On the Chip: F= friction force on the chip N = The normal force to friction Shear stress R = Resultant force Fs = Shear force Fn = Normal force to shear As = Area of the shear plane Shear stress R’ = Resultant force of the shear On the tool: Force diagram Fc = Cutting Force Ft = thrust Force Merchant: Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). dynamometer EXAMPLE 3 In a machining operation that approximates orthogonal cutting, the cutting tool has a rake angle = 10 and shear angle φ = 25.4. The cutting force and thrust force are measured during an orthogonal cutting operation: Fc = 1559 N and Ft = 1271 N. The width of the orthogonal cutting operation w = 3.0 mm. Based on these data, determine the shear strength of the work material. On the Chip: Coefficient of friction F= friction force on the chip N = The normal force to friction R = Resultant force Fs = Shear force Merchant: Fn = Normal force to shear As = Area of the shear plane R’ = Resultant force of the shear On the tool: Fc = Cutting Force Ft = thrust Force 17 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF CHIP FORMATION IN METAL MACHINING LESSON LEARNED FROM MERCHANT EQUATION It defines the general relationship between rake angle, tool–chip friction, and shear plane angle. The shear plane angle can be increased by: Increasing the rake angle. Decreasing the friction angle (and coefficient of friction) Shear stress between the tool and the chip. Merchant: Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). THEORY OF CHIP FORMATION IN METAL MACHINING POWER AND ENERGY RELATIONSHIPS IN MACHINING The power (energy per unit time) required to perform a machining operation Pc = cutting power, N-m/s Fc = cutting force, N v = cutting speed, m/s Horsepower Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). HOMEWORK NO. 11 Pick one of the nontraditional machining operations: 1) Do research about it. 2) Prepare a short presentation 20 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). Thanks 21 JOINING AND ASSEMBLY PROCESSES Manufacturing Processes Course Dr. Feras Kafiah 2020 1 JOINING AND ASSEMBLY PROCESSES 2 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). JOINING AND ASSEMBLY PROCESSES The term joining is generally used for welding, brazing, soldering, and adhesive bonding, which form a permanent joint between the parts. Welding is a materials joining process in which two or more parts are coalesced at their contacting surfaces by a suitable application of heat and/or pressure Many welding processes are accomplished by heat alone, with no pressure applied. In some welding processes a filler material is added to facilitate coalescence. 3 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). OVERVIEW OF WELDING TECHNOLOGY TYPES OF WELDING PROCESSES 50 different types of welding operations have been cataloged by the American Welding Society. We can divide the welding processes into two major groups: (1) fusion welding and (2) solid-state welding. A) Fusion Welding B) Solid-state Welding Fusion-welding processes Solid-state welding refers to joining use heat to melt the base processes in which coalescence results metals. from application of pressure alone or a A filler metal is added to the combination of heat and pressure. molten pool to facilitate the No filler metal is utilized process 4 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). OVERVIEW OF WELDING TECHNOLOGY A) Fusion Welding TYPES OF WELDING PROCESSES 1) Arc welding (AW) Arc welding refers to a group of welding processes in which heating of the metals is accomplished by an electric arc 5 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). OVERVIEW OF WELDING TECHNOLOGY A) Fusion Welding TYPES OF WELDING PROCESSES 2) Resistance welding (RW) Resistance welding achieves coalescence using heat from electrical resistance to the flow of a current passing between the faying surfaces of two parts held together under pressure. Seam Welding Spot Welding 6 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). OVERVIEW OF WELDING TECHNOLOGY A) Fusion Welding TYPES OF WELDING PROCESSES 3) Oxyfuel gas welding (OFW) These joining processes use an oxyfuel gas, such as a mixture of oxygen and acetylene, to produce a hot flame for melting the base metal and filler metal, if one is used. 7 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). OVERVIEW OF WELDING TECHNOLOGY A) Fusion Welding TYPES OF WELDING PROCESSES Other Fusion Welding Processes Other welding processes that produce fusion of the metals joined include electron beam welding and laser beam welding. Electron beam welding Laser beam welding 8 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). OVERVIEW OF WELDING TECHNOLOGY B) Solid-state Welding TYPES OF WELDING PROCESSES 1) Diffusion welding (DFW) Two surfaces are held together under pressure at an elevated temperature and the parts coalesce by solid-state diffusion. 9 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). OVERVIEW OF WELDING TECHNOLOGY B) Solid-state Welding TYPES OF WELDING PROCESSES 2) Friction welding (FRW) Two surfaces coalescence is achieved by the heat of friction between two surfaces. 10 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). OVERVIEW OF WELDING TECHNOLOGY B) Solid-state Welding TYPES OF WELDING PROCESSES 3) Ultrasonic welding (USW) Moderate pressure is applied between the two parts and an oscillating motion at ultrasonic frequencies is used in a direction parallel to the contacting surfaces. The combination of normal and vibratory forces results in shear stresses that remove surface films and achieve atomic bonding of the surfaces. 11 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). OVERVIEW OF WELDING TECHNOLOGY B) Solid-state Welding WELDING AS A COMMERCIAL OPERATION Automation in Welding Automatic welding Robotic welding 12 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). OVERVIEW OF WELDING TECHNOLOGY B) Solid-state Welding THE WELD JOINT Butt Joint Corner Joint Lap Joint Tee Joint Edge Joint TYPES OF WELDS Fillet weld Groove welds 13 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). OVERVIEW OF WELDING TECHNOLOGY B) Solid-state Welding FEATURES OF A FUSION-WELDED JOINT 1) Fusion Zone. 2) Weld Interface. 3) Heat-affected Zone (HAZ) 4) Unaffected base metal zone 14 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). Thanks 15 JOINING AND ASSEMBLY PROCESSES II Manufacturing Processes Course Dr. Feras Kafiah 2020 1 BRAZING, SOLDERING, AND ADHESIVE BONDING 2 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). JOINING AND ASSEMBLY PROCESSES The term joining is generally used for welding, brazing, soldering, and adhesive bonding, which form a permanent joint between the parts. Welding is a materials joining process in which two or more parts are coalesced at their contacting surfaces by a suitable application of heat and/or pressure Many welding processes are accomplished by heat alone, with no pressure applied. In some welding processes a filler material is added to facilitate coalescence. 3 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING BRAZING, SOLDERING, AND ADHESIVE BONDING Brazing and soldering both use filler metals to join and bond two (or more) metal parts to provide a permanent joint. No melting of the base metals occurs Brazing and Soldering Compared to welding under circumstances where: (1) The metals have poor weldability, (2) Dissimilar metals are to be joined. (3) The intense heat of welding may damage the components being joined. (4) The geometry of the joint does not lend itself to any of the welding methods (5) High strength is not a requirement. 4 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING 1) BRAZING Brazing is a joining process in which a filler metal is melted and distributed by capillary action between the faying surfaces of the metal parts being joined. No melting of the base metals occurs in brazing; only the filler melts. Advantages: 1. Any metals can be joined, including dissimilar metals 2. Certain brazing methods can be performed quickly and consistently. 3. Some methods allow multiple joints to be brazed simultaneously. 4. Brazing can be applied to join thin-walled parts that cannot be welded. 5. Less heat and power are required than in fusion welding. 6. Problems with the heat-affected zone in the base metal near the joint are reduced. 7. Joint areas that are inaccessible by many welding processes can be brazed 5 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING 1) BRAZING Brazing is a joining process in which a filler metal is melted and distributed by capillary action between the faying surfaces of the metal parts being joined. No melting of the base metals occurs in brazing; only the filler melts. Disadvantages: 1. Joint strength is generally less than that of a welded joint. 2. Although strength of a good brazed joint is greater than that of the filler metal, it is likely to be less than that of the base metals. 3. High service temperatures may weaken a brazed joint 4. The color of the metal in the brazed joint may not match the color of the base metal parts 6 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING BRAZED JOINTS Butt JOINTS Scarf Conventional joint butt joint Stepped butt Increased cross joint section of the part at the joint. 7 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING BRAZED JOINTS LAP JOINTS Cylindrical Conventional parts lap joint Sandwiched parts Use of sleeve to convert butt joint into lap joint 8 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING Common Fillers 9 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING 2) SOLDERING A joining process in which a filler metal with melting point (liquidus) not exceeding 450C is melted and distributed by capillary action between the faying surfaces of the metal parts being joined. No melting of the base metals occurs in brazing; only the filler melts. JOINT DESIGNS IN SOLDERING Flat lock seam Bolted or riveted joint Copper Crimping pipe fittings 10 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING 2) SOLDERING SOLDERS AND FLUXES 11 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING 3) ADHESIVE BONDING Adhesive bonding is a joining process in which a filler material is used to hold two (or more) closely spaced parts together by surface attachment. Adhesive bonding was probably the first of the permanent joining methods. Carvings 3300 years old show a glue pot and brush for gluing veneer to wood planks. Adhesives are used in a wide range of bonding and sealing applications for joining similar and dissimilar materials such as metals, plastics, ceramics, wood, paper, and cardboard. 12 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING 3) ADHESIVE BONDING The filler material that binds the parts together is the adhesive. It is a nonmetallic substance—usually a polymer. Curing refers to the process by which the adhesive’s physical properties are changed from a liquid to a solid. The curing or hardening of the adhesive takes time, called curing time or setting time. In some cases this time is significant—generally a disadvantage in manufacturing. 13 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING 3) ADHESIVE BONDING JOINT DESIGN Tension Shear Cleavage Peeling 14 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING 3) ADHESIVE BONDING JOINT DESIGN 15 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING 3) ADHESIVE BONDING ADHESIVE TYPES A large number of commercial adhesives are available. They can be classified into three categories: (1)Natural. (2)Inorganic (3)Synthetic. 16 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). BRAZING, SOLDERING, AND ADHESIVE BONDING 3) ADHESIVE BONDING ADHESIVE APPLICATION TECHNOLOGY Surface Preparation Application Methods Brushing Flowing Manual rollers Silk screening Spraying Automatic applicators Roll coating 17 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). Thanks 18 JOINING AND ASSEMBLY PROCESSES III Manufacturing Processes Course Dr. Feras Kafiah 2020 1 MECHANICAL ASSEMBLY 2 Figures and Tables are adopted from Groover, M. P. "Fundamentals-of-Modern-Manufacturing-4Th-Edition-By-Mikell-P-Groover." (2010). JOIN