Manufacturing Processes Training PDF

Manufacturing processes training El Ghandour, Said AVL Morocco Internal Manufacturing processes: Author(s): El Ghandour, Said Co-Author(s): Approved by: Project Leader: Version: 1.0 Release date: 01.10.2024 Security level: Inte...

Manufacturing processes training El Ghandour, Said AVL Morocco Internal Manufacturing processes: Author(s): El Ghandour, Said Co-Author(s): Approved by: Project Leader: Version: 1.0 Release date: 01.10.2024 Security level: Internal Customer: Project: Task ID: Department: MDS Copyright © 2024, AVL Morocco Internal /2 El Ghandour, Said | MDS | 01 October 2024 | Content Training schedule Training objective About manufacturing processes Quiz Internal /3 El Ghandour, Said | MDS | 01 October 2024 | Training schedule Timing Content From 9 am to 10:30 am Forming, Casting, Molding From 10:30 am to 10:40 am 10 min break From 10:40 am to 11:30 am Machining, Joining, Q/A From 11:30 am to 12 am Quiz Internal /4 El Ghandour, Said | MDS | 01 October 2024 | Training objective The objective of this training is to provide design team with a comprehensive understanding of key manufacturing processes used in industrial production. By the end of this session, you will be able to: 1. Identify and differentiate between various manufacturing techniques. 2. Understand the principles behind each process and its applications. 3. Recognize the ups and downs of each manufacturing process. 4. Apply learned concepts to improve the geometry of parts and decide if they are manufacturable. This training aims to equip individuals with the skills and knowledge necessary to enhance operational efficiency and product quality in manufacturing environments. Internal /5 El Ghandour, Said | MDS | 01 October 2024 | 1. Introduction to M.F: There are five main manufacturing processes that engineers, designers and manufacturers have to be aware of : 1. Forming 2. Casting 3. Molding 4. Joining 5. Machining Each of the mentioned manufacturing processes contains a number of manufacturing techniques that will be explored later on. Internal /6 El Ghandour, Said | MDS | 01 October 2024 | 2. Factors to be considered when selecting the right M.F There are a lot of different factors to be considered when selecting the right Manufacturing Process: 1. Material selection 2. Geometry of the object 3. The number of parts to be produced 4. Tool & Material costs 5. Required Level of Automation Internal /7 El Ghandour, Said | MDS | 01 October 2024 | Forming El Ghandour, Said AVL Morocco Internal  Forming involves applying forces or pressure & plastically deforming the material to produce the desired shape. Forming is typically used for metals. Most of Forming processes can be done when the metal is above or below its recrystallization temperature (Hot/Cold working). Forming includes 3 main manufacturing techniques (Modern forging, Extrusion, and Rolling.) Internal /9 El Ghandour, Said | MDS | 01 October 2024 | 1. Modern Forging : Modern forging is done using machines. The metal is placed between top & closed dies, Repeated strokes of the hammer are used to cause the metal to flow into the shape of the dies. Internal / 10 El Ghandour, Said | MDS | 01 October 2024 | 1. Modern Forging : Con rod example Internal / 11 El Ghandour, Said | MDS | 01 October 2024 | 1. Modern Forging : ✓Improved Mechanical properties. X Difficult to achieve tight tolerances. X Required equipment can be expensive. Internal / 12 El Ghandour, Said | MDS | 01 October 2024 | 2. Extrusion : Extrusion is a continuous process that involves placing hot metal in a chamber & using a ram to force it through a die, producing a long object with a constant cross-section. Internal / 13 El Ghandour, Said | MDS | 01 October 2024 | 2. Extrusion : ✓ Excellent surface finish ✓ Can achieve very tight tolerances X Only Suitable for 2D shapes Internal / 14 El Ghandour, Said | MDS | 01 October 2024 | 3. Rolling : Rolling is the most common technique used in forming process. It involves passing metal between 2 or more rollers which apply pressure and reduce thickness. Internal / 15 El Ghandour, Said | MDS | 01 October 2024 | 3. Rolling : Multiple Rollers used to form an I beam Internal / 16 El Ghandour, Said | MDS | 01 October 2024 | 3. Rolling : ✓Improved mechanical properties ✓Can be fully automated X High tooling costs X Cannot produce complex shapes Internal / 17 El Ghandour, Said | MDS | 01 October 2024 | Casting El Ghandour, Said AVL Morocco Internal  Casting involves pouring molten metal into a mold and allowing it to solidify. It is a primary shaping process it means that it requires a secondary shaping process such as machining to achieve the desired surface finish. Like forming casting is most commonly used for metals. is mostly used for non-ferrous metals like Aluminum & Zinc which require a low melting temperature. Internal / 19 El Ghandour, Said | MDS | 01 October 2024 | 1. Die Casting : Die Casting involves forcing molten metal into reusable metal dies at high pressure. Once the molten metal is solidified it is removed from the mold. Internal / 20 El Ghandour, Said | MDS | 01 October 2024 | 1. Die Casting : ✓ Excellent surface finish ✓ Can achieve very tight tolerances X High start-up costs so it is only suitable for larger production runs. Internal / 21 El Ghandour, Said | MDS | 01 October 2024 | 2. Sand Casting : In Sand Casting a pattern is used to create a single-use mold from damp sand then molten mold is poured into the mold through a channel formed in the sand. When the metal has solidified, the cast object can be removed from the sand. Internal / 22 El Ghandour, Said | MDS | 01 October 2024 | 2. Sand Casting : ✓ Can be used for a wide range of metals. ✓ Can produce large & complex parts. ✓ Very low initial costs. X Poor surface finish. X Not as accurate as other casting techniques Internal / 23 El Ghandour, Said | MDS | 01 October 2024 | 3. Investment Casting : Investment Casting involves creating several wax patterns of the same object and attaching them to a sprue, then the wax tree is dipped into a slurry to form a ceramic mold. Later on, heat is applied to melt out the wax. Molten metal is then poured into the ceramic mold. Internal / 24 El Ghandour, Said | MDS | 01 October 2024 | 3. Investment Casting : ✓ Good for complex geometry. ✓ Can achieve tight tolerances. X Relatively expensive & time-consuming. Internal / 25 El Ghandour, Said | MDS | 01 October 2024 | Molding El Ghandour, Said AVL Morocco Internal  Molding is very similar to casting it invloves shaping a liquid or a pliable material using a mold. Most of the time molding is used for plastic. There are three manufacturing techniques included in molding: Injection molding Compression molding Blow molding Internal / 27 El Ghandour, Said | MDS | 01 October 2024 | 1. Injection Molding : Injection molding is the most commonly used manufacturing technique for plastic. Polymer granuels are fed into the hopper and a screw is used to pass material through a heated cylinder before forced at pressure into a mold. Injection molding is mostly used for thermoplastics which are polymers that soften when heated and solidified when cooled. Internal / 28 El Ghandour, Said | MDS | 01 October 2024 | 1. Injection Molding : Internal / 29 El Ghandour, Said | MDS | 01 October 2024 | 1. Injection Molding : ✓ Very fast process ✓ Can be fully automated X High start-up costs due to expensive molds Internal / 30 El Ghandour, Said | MDS | 01 October 2024 | 2. Compression Molding : Compression molding involves placing a precise amount of material into a mold. The mold is closed then pressure & temperature are applied. Compression molding is mainly used for thermosets. (Polymers that irreversibly harden when heated) Internal / 31 El Ghandour, Said | MDS | 01 October 2024 | 2. Compression Molding : ✓ Low tooling costs X Relatively slow process X Not well suited for complex designs Internal / 32 El Ghandour, Said | MDS | 01 October 2024 | 3. Blow Molding : Blow molding involves forming hollow plastic parts. It is also used for forming glass bottles and other hollow shapes. It starts by softening the material by heating a preform (parison). The material workpiece is then clamped into a mold and air is blown into it. The air pressure inflates the material which conforms to the mold. Once the material has cooled and hardened it is ejected. Preform (Parison) : The parison is a tube-like piece of plastic with a hole in one end through which compressed air can enter. Internal / 33 El Ghandour, Said | MDS | 01 October 2024 | 3. Blow Molding : Internal / 34 El Ghandour, Said | MDS | 01 October 2024 | 3. Blow Molding : ✓ Low tooling costs ✓ Highly automated process ✓ Time-saving process for large productions X Only for hollow parts X Thick parts cannot be manufactured Internal / 35 El Ghandour, Said | MDS | 01 October 2024 | Machining El Ghandour, Said AVL Morocco Internal  Machining is a material removal process where a tool is used to remove material from a larger object. It is often used as a secondary shaping process when the part has already been formed using a primary shaping process such as casting. Machining can be used for a wide range of materials including metals, plastic & wood. Machining includes 3 main manufacturing techniques: 1. Milling 2. Turning 3. Reaming 4. Boring Internal / 37 El Ghandour, Said | MDS | 01 October 2024 | 1. Milling : Milling is a process where a milling tool cuts away the material in a rotary motion. As drilling, this is possible with a wide array of different tools with different diameters and different hardness. Milling is commonly used for prismatic parts. Internal / 38 El Ghandour, Said | MDS | 01 October 2024 | 2. Turning/lathing : Turning is simply the use of a cutting tool to shape a rotating workpiece. It is meant for cylindrical parts. Internal / 39 El Ghandour, Said | MDS | 01 October 2024 | 3. Reaming : Reaming is a turning technique that involves using a rotary cutting tool (a reamer) to create smooth interior walls in an existing hole in a workpiece Internal / 40 El Ghandour, Said | MDS | 01 October 2024 | 4. Boring : Boring is a cutting process that involves using a single-point cutting tool or boring head to enlarge an existing hole in a workpiece unlike drilling which consists of creating an initial hole in a workpiece. Internal / 41 El Ghandour, Said | MDS | 01 October 2024 | The difference between drilling, reaming & boring : Internal / 42 El Ghandour, Said | MDS | 01 October 2024 | Joining El Ghandour, Said AVL Morocco Internal  Joining involves combining many separate components into a larger assembly. Just like machining, joining is a secondary process. Joining involves many techniques: 1. Welding 2. Brazing 3. Soldering 4. Riveting 5. Fastening Internal / 44 El Ghandour, Said | MDS | 01 October 2024 | 1. Welding : Welding uses extremely high heat to fuse distinct metal parts together, unlike soldering & brazing (will be explored later on) the base metal melts during welding. Internal / 45 El Ghandour, Said | MDS | 01 October 2024 | 1. Welding : Internal / 46 El Ghandour, Said | MDS | 01 October 2024 | 1. Welding : Friction welding Internal / 47 El Ghandour, Said | MDS | 01 October 2024 | 1. Welding : Laser welding Internal / 48 El Ghandour, Said | MDS | 01 October 2024 | 2. Brazing : Brazing is a metal joining process in which 2 or more metal items are joined together by melting and flowing a filler metal into the joint. The filler metal must have a lower melting temperature than the adjoining metal. Brazing differs from welding as it does not melt the workpiece. Internal / 49 El Ghandour, Said | MDS | 01 October 2024 | 2. Brazing : Torch brazing Flux is applied to the parts’ surfaces and a torch is used to focus flame against the work at the joint. Internal / 50 El Ghandour, Said | MDS | 01 October 2024 | 2. Brazing : Furnace brazing The workpieces and filler material are allowed into a furnace (heat- producing area); due to the heat, the filler material will melt down and deposits over the joining spots to join them permanently. Internal / 51 El Ghandour, Said | MDS | 01 October 2024 | 3. Soldering : The joining of metals using a filler metal. Soldering is very similar to brazing. While brazing is used for hard materials, soldering is applied to softer and more delicate materials like the ones used in electronics & jewelry. (Copper wires, printed circuits boards etc..) Internal / 52 El Ghandour, Said | MDS | 01 October 2024 | 4. Riveting : Riveting is a forging process that may be used to join parts together by way of a metal part called a rivet. The rivet acts to join the parts through adjacent surfaces. A straight metal piece is connected through the parts. Then both ends are formed over the connection, joining the parts securely. The metal workpiece used to form the connection may be hollow or it may be solid. Rivets have many uses, such as in the construction and sheet metal industries. Internal / 53 El Ghandour, Said | MDS | 01 October 2024 | 4. Riveting : Internal / 54 El Ghandour, Said | MDS | 01 October 2024 | 5. Fastening : Fastening is one temporary joining process that employs additional elements to mechanically assemble or attach two or more parts together. Additional mechanical elements that are used in fastening are called fasteners. However, threaded elements like nut-bolt, screw, etc. are commonly considered as fasteners as they can provide a reliable and secure joint. Internal / 55 El Ghandour, Said | MDS | 01 October 2024 | 5. Fastening : Some types of fasteners Internal / 56 El Ghandour, Said | MDS | 01 October 2024 | Q/A Internal Thank you www.avl.com Internal