...initially at awakening your interest in the processes used for the shaping, joining and finishing of materials both manually and within the CES EduPack database. Next week, there will be a second section aimed at developing your skills in the selection of processes for the shaping, joining and finishing of materials both manually and within the CES EduPack database. 1. Browsing processes Open up CES EduPack in the level 3 database. 1.1 Within the process universe under ‘joining’, ‘thermal welding’ and ‘metals’, determine how Soldering and brazing differ from true welding processes such as Manual Metal Arc welding (also known as Shielded Metal Arc welding). 1.2 Have a look at the four most common electric arc welding processes Manual Metal Arc, Submerged Arc, Gas Metal Arc (or Metal Inert Gas – MIG) and Gas Tungsten Arc (or tungsten Inert Gas – TIG). Summarise the essential differences in the space below. 1.3 Compare the mass range, minimum section, dimensional tolerance and surface roughness for Automated Green Sand casting, Standard Automated Investment casting and High-Pressure Die casting. 1.4 Now compare the same attributes for ALL of the casting techniques by plotting graphs in CES (under the selection menu – just like in the Materials Universe database). Paste your graphs here. 1.5 Outline the essential differences between the deformation processes Hot Metal Extrusion, and Wire Drawing. ...
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...Lasers in Micro-manufacturing Laser processes have continued to be used for a considerably long time for specific micro-manufacturing processes. This is because there have been several decades of such applications in development through which conventional manufacturing approaches could not satisfy the major demands relating to accuracy and flexibility. On the other hand, the outstanding share of micro applications across the entire laser market has extensively been a minor segment through which laser cutting as well as welding have proven to be dominant within the laser application sector.1 As a result of the increasing trend towards miniaturization, as well as higher integration for diverse consumer products, laser processes are well becoming more important under which laser micro manufacturing continues to show a considerably high market increase.7 These developments are both fostered by the strong market pull and the availability of lasers that are very high quality. This consequently allows a specific deposition of energy across a micrometer scale which remains at high processing speeds. On the other hand, laser technology greatly lowers operational costs, enables easy installation as well as lowering maintenance costs which continue making lasers a more versatile tool for application within industrial micro manufacturing processes. Apart from the existing areas of application for laser micro processing across fine mechanics and defined electronics, there are current...
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...exothermic reactions between metal oxides and a metal reducing agent * is used in this process to melt the metal. After the metal is in a liquid state, it is poured between the two workpieces to form the joint | * Apply force and current through electrodes contacted metal parts to be welded; and resistance heat is generated at the interface of metal parts and makes a nugget, resulting in melt joint * the coalescence of metals is the result of the heat obtained from resistance offered by the work piece to the flow of electrical current | * is the solid state welding process which produces coalescence of material by the heat obtained from a mechanically induced sliding motion between the rubbing surfaces of two cylindrical work pieces under pressure. | APPLICATIONS | * for butt welding pipes end to end * for welding broken frames of machines * replacing broken pieces or large gears | * is used for joining vehicle body part * for joining wire end * pipes of gas oil & water pipeline | * used in shipbuilding industries * Widely being used in shipbuilding industry to join sheet and plate material. * Used with thermoplastics. | 1)The difference between thermit welding, resistance, & friction welding 2)Comparison between Cold Isostatic Pressing (CIP) & Hot Isostatic Pressing (HIP) Isostatic pressing is a powder processing process that falls in the category of forming under the general category of manufacturing processes. * Cold Isostatic...
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...AENG 11 Engineering Shop Asst. Prof. Mark Keylord S. Onal VI. METAL WORK MATERIALS General Classification of Metals Used in Bench Metal Work: 1. Ferrous Metals (wrought iron, steel, and cast iron) 2. Non-ferrous Metals (copper, brass, bronze, and aluminum) *All these material come in various forms and shapes such as sheets, rods, bars, and wires. Common Metals and Their Major Use • Cast Iron - origin: iron ore - characteristics: forms into any shape; brittle - major use: machinery parts; engine blocks • Wrought Iron - origin: iron ore - characteristics: malleable; tough; rust-resistant - major use: decorative fences; railings • Mild Steel - origin: iron ore - characteristics: malleable; ductile; tough - major use: structural steel • Tool Steel - origin: iron ore - characteristics: high carbon; heat treatable; expensive - major use: tools; tool bits • Stainless Steel - origin: iron ore, nickel, and chromium - characteristics: corrosion resistant; bright appearance; tough - major use: food handling equipment; restaurant equipment • Galvanized Steel - origin: steel, zinc - characteristics: zinc-coated steel - major use: water tanks; towers; fencing; roofing - 33 - AENG 11 Engineering Shop Asst. Prof. Mark Keylord S. Onal • Aluminum - origin: ore - characteristics: light; relatively soft; good electrical conductor; tough; silver-white color - major use: truck bodies; automobiles; electrical wires/cables • Copper - origin: ore - characteristics: malleable; corrosion-resistant;...
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...techniques of manufacturing are being used in FNSS; * Chip Removal * Joining * Metal Forming * Testing * Chemical Operations 3.1.1 CHIP REMOVAL PROCESSES Metal cutting, commonly called machininh, is the removal of unwanted portions from a block,plate of material in the from o chips so as to obtain a finished product of desired dimensions, finish.Most of the manufactured products require machining at some stage of their production, ranging from rough work to high precision work.Hence metal cutting is the most important of the basic manufacturing processes. In all metal cutting operations an edged tool driven in to the material to remove chips from the main body and reach the desired geometry.Other actions that occurs are related to that action. In cutting operations, there are three cutting conditions; namely speed, feed and depth of cut.Speed is the primary cutting motion, which relates the velocity of the tool relative to work.Feed is the amaount of material removed per revolution.The depth of cut is the depth of cutting edge engaged in the workpiece. The properties of the workpiece are important in chip formation.High strength materials require larger forces than do materials of lower strength, causing greater tool and work deflection, increased friction and heat generation and operating temperatures,and requiring greater work input.The structure and composition also affect metal cutting.Hard or abrasive constituents, such as carbides in steel, accelerate...
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...The process is used with shielding gas and without the application of pressure. The shielding gas that usually used were argon and helium. The process may be used with or without the addition of filler metal. GTAW has become indispensable as a tool for many industries because of the high-quality welds produced and low equipment costs. The GTAW process can be used to weld steel, stainless steel, Al, Mg, Cu, Ni, Ti, and others. The primary variables in GTAW are arc voltage (arc length), welding current, travel speed, and shielding gas. The amount of energy produced by the arc is proportional to the current and voltage. The amount transferred per unit length of weld is inversely proportional to the travel speed. The arc in helium (He) is more penetrating than that in argon (Ar). However, because all of these variables interact strongly, it is impossible to treat them as truly independent variables when establishing welding procedures for fabricating...
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...2013 Manufacturing Technologies – Assignment 1 Producing engineering housings: examination of the manufacturing-materials-design issues I. Introduction This assignment is an examination of the manufacturing-materials-design issues involved in producing engineering housings. A housing can be defined as an “envelope designed to retain and position a range of mechanical or electrical components”1. More specifically, the aim of this essay is to discuss what aspects need to be considered when determining which materials and processes are to be used in the manufacture of a car engine cylinder block (which is considered to be a housing). First of all, an identification of the developments, difficulties and constraints introduced by the design requirement to cast (or mould) a housing will be done. Secondly, a comparison of the material/process choices between ferrous alloys and light alloys for housing applications will be developed. Thirdly, the finishing, joining and assembly aspects will be identified and finally, this essay will be ended by a discussion about how the overall organisation of the manufacturing system might be expected to change with production from cast iron to aluminium alloy engine blocks and how the manufacturer has accommodated these changes within their overall manufacturing strategy. Source : http://howautowork.com/list_of_contents/part_1/ch_1/images/cylinder%20block%202.JPG ...
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...Table of Contents 1 Introduction to Riveting 3 2 General Rivet Facts and Applications 4 3.1 Solid Shank Rivets 6 3.2 Special Rivets 8 4 Riveting Processes 10 4.1 Manual Process 10 4.2 Automated Process 12 4.3 Counter-sinking 13 4.4 Applying Special Rivets 14 References 17 List of Figures Figure Number Figure Description Page Number 2.11 Riveted metal sheets under shear loads …………………………………. 3 2.12 AN270 Mushroom Head Rivet, AN426 Countersunk Rivet .…… 3 2.13 Before and after of rivet being set into a drilled hole …………... 4 3.11 Example of a Solid Shank Rivet ……………………………..……………... 5 3.12 Example of a rivet Identification Number …………………………….. 6 3.13 Examples of other Rivet heads …………………………………………….. 6 3.14 Markings on Rivet Heads ……………………………………………………… 7 3.21 Example of a friction lock rivet …………………………………………….. 8 3.22 Example of a mechanical lock rivet ………………………………………. 8 4.11 Example of a Rivet Gun ………………………………………………………… 9 4.12 Example of a Bucking Bar ………………………………………….…………. 9 4.13 A depiction of the riveting operation ………………………………….. 10 4.14 Example of Riveting in teams ……………………………………...
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...Joined together with fire 1.So you may ask yourself who likes to play with fire so much that they do it for their job? well welders do so now you may be asking yourself what's a welder? well a welder is someone who fuses two pieces of metal together or disconnects using a welder or welding torch. the reason I chosen this is because not only is it an exciting job but it pays well and is just something I've been interested in for a long time. it is a dangerous job but is also well worth it. 2. This job also comes with quite a few responsibilities and task to accomplish for instance you may need to examine a joint to see if it needs repairing or bind to pieces of metal together or cut a specific shape or figure out of a large piece of metal...
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...Engineering Address: Unit 2, No. 15, East Rose St., Salimi Jahromi St., Ferdows Blvd., 2nd Sadeqiyeh Sq., Tehran, Iran E-Mail: mkokabi1003@yahoo.com Office: 0098 21 44071350 Mobile: 0098 912 2096826 1 Cored Wires with different Depositions, Compositions and Applications Abstract: Cored Wires (CW) are used in a wide range of applications such as joining and hard facing. These kinds of filler metals are generally categorised in “Flux C.W”, “Self Shielded Flux C.W” and “Metal C.W”. Researches on C.Ws used for hardfacing on plane carbon steels, showed that hypo eutectic and eutectic compositions can increase the abrasion resistance. On the other hand addition of “Mn” shows some reductions in abrasion resistance and increasing in impact energy. Special coated electrodes with metal C.Ws had developed for welding of Ductile Cast Iron. This C.W can deposit weld metal same as base metal and also reduce costs in compare with E-Ni. C.Ws produced with “Ti” strip as tube and “Carbon” or “TiC” as inside powder used for hardfacing of Ti can increase the hardness, wear resistance and reduce friction coefficient. Keywords: cored wire, hardfacing, joining, wear...
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...Cast iron is difficult, but not impossible, to weld. In most cases, welding on cast iron involves repairs to castings, not joining casting to other members. The repairs may be made in the foundry where the castings are produced, or may be made to repair casting defects that are discovered after the part is machined. Mis-machined cast iron parts may require repair welding, such as when holes are drilled in the wrong location. Frequently, broken cast iron parts are repaired by welding. Broken cast iron parts are not unusual, given the brittle nature of most cast iron.While there are a variety of types of cast iron, the most common is gray cast iron, and these guidelines are directed toward this type of material. A few facts about cast iron help in understanding the welding challenges. Cast iron typically has a carbon content of 2% - 4%, roughly 10 times as much as most steels. The high carbon content causes the carbon to form flakes of graphite. This graphite gives gray cast iron its characteristic appearance when fractured.When castings are made, molten iron is poured into a mold and allowed to slowly cool. When this high carbon material is allowed to cool slowly, crack free castings can be made. Remembering this is helpful when welding cast iron: during and after welding, the casting must either be allowed to cool slowly, or should be kept cool enough that the rate of cooling is not important.A critical temperature in most cast iron is about 1450 degrees F. When at this temperature...
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...BODY WELDING - CAN IT BE FLEXIBLE? BODY WELDING - CAN IT BE FLEXIBLE? Some 250~300 pressed panels from in-house and vendor facilities are brought to different subassembly stations of Body Weld Shop. Subassemblies of pressed components are carried out mainly by resistance welding and other joining methods in a planned sequence at number of stations. Some subassemblies are done in off-line manufacturing cells and fed in at appropriate locations into the main assembly line. Fig. 6.1 shows a layout of a typical Body Weld Shop. Front end, rear floor, and front floor, are transported to underbody body line, where all these are welded together in sequence to form the floor structure. Underbody is then transferred to main body welding station. Right hand and left hand body side panels are brought from two sides to main body weld station, after completion of all subassembly operations in separate lines. Preframing of body structure is carried out on special fixture. At same or next station, roof is added to form the body shell, Fig. 6.2. Thereafter, rear doors, front fenders, hood and decklid/ tailgate fitments are carried out to complete the body-inWhite. If necessary, a metal finish line may be added for minor repair of Body-in-White before it moves for painting. Fig. 6.3 illustrates the sequences of subassemblies and the main body weld. Typically, Body weld shop activities cover fixturing, welding, and transportation between the work stations, and the related support services....
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...e i n f o a b s t r a c t Electromagnetic forming is an impulse or high-speed forming technology using pulsed magnetic field to apply Lorentz’ forces to workpieces preferably made of a highly electrically conductive material without mechanical contact and without a working medium. Thus hollow profiles can be compressed or expanded and flat or three-dimensionally preformed sheet metal can be shaped and joined as well as cutting operations can be performed. Due to extremely high velocities and strain rates in comparison to conventional quasistatic processes, forming limits can be extended for several materials. In this article, the state of the art of electromagnetic forming is reviewed considering: Article history: Received 10 September 2010 Received in revised form 7 December 2010 Accepted 15 December 2010 Available online 23 December 2010 Keywords: Electromagnetic forming Impulse forming High-speed forming • basic research work regarding the process principle, significant parameters on the acting loads, the • application-oriented research work and applications in the field of forming, joining, cutting, and process combinations including electromagnetic forming incorporated into conventional forming technologies. Moreover, research on the material behavior at the process specific high strain rates and on the...
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...BTME306 BTME307 Course Name Load Allocation L 3 3 1 4 4 3 18 T 1 1 1 3 P 6 2 2 2 1 13 Contact Hours: 34 Hrs. Marks Distribution Internal 40 40 40 40 40 40 30 30 30 60 390 External 60 60 60 60 60 60 20 20 20 40 460 Total Marks 100 100 100 100 100 100 50 50 50 100 850 Credits Strength of Materials- I Theory of Machines-I Machine Drawing Applied Thermodynamics -I 4 4 4 5 4 3 1 1 2 1 29 Manufacturing Processes – I Engineering Materials & Metallurgy Engineering Materials & Metallurgy Lab BTME308 Strength of Materials Lab. BTME309 Applied Thermodynamics Lab Advisory Meeting BTME 310 Workshop Training* Total * Workshop Training will be imparted in the Institution at the end of 2 nd semester for Four (04) weeks duration (Minimum 36 hours per week). Industrial tour will also form part of this training. Fourth Semester Course Code BTME401 BTME402 BTME403 BTME404 BTME405 BTME406 BTME407 Course Name Strength of Materials – II Theory of Machines – II Fluid Mechanics Applied Thermodynamics - II Manufacturing Processes-II Fluid Mechanics Lab Manufacturing Processes Lab Load Allocation L T P 4 1 4 1 4 1 4 2 4 Total 2 2 2 1 - Contact Hours: 32 Hrs. Marks Distribution Internal External 40 60 40 60 40 60 40 60 40 30 30 30 100 60 20 20 20 Total Marks 100 100 100 100 100 50 50 50 100 Credits 5 5 5 5 4 1 1 1 - BTME408 Theory of Machines Lab Advisory Meeting General Fitness 20 05 07 390 360 750 27 2 Punjab Technical University...
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...A wear resistant tool is plunged first at the interface of the plates and move forward to form the weld. The advantages of FSW technique is no necessity for gas shielding for welding aluminium. Mechanical properties are proven to be excellent by FSW process. There is no fume, no porosity, no spatter and low thermal shrinkage of the metal. Welding dissimilar metals can be attempted by this unique process. Friction Stir Welding can be used to join aluminum sheets and plates without filler wire or shielding gas. Material thicknesses ranging from 0.5 to 60 mm can be welded from one side at full penetration, without porosity or internal voids. Nowadays welding materials is chosen for non-ferrous materials and it has a broad range of materials. In this paper we have identified the effects of different process parameters on friction stir welding of aluminium 1100 and aluminium 6082 which is mostly used in aircrafts, aluminium 6082 is used in wing ribs which is costly and more weight when compared to aluminium 1100. So aluminium 1100 can be welded with aluminium 6082 by friction stir welding...
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