Manufacturing Processes

laser machining

A nontraditional process that uses the intense light a laser generates to cut material

Injection Molding

A process during which plastic is heated in a machine and forced into a cavity by a screw or ram. The material solidifies and is then ejected.

Electrochemical Grinding (ECG)

is used to shape and sharpen carbide cutting tools- uses a rotating metal disk electrode with diamond dust

Chip formation- Ductile materials form

long, helix-coiled string chips, known as continuous chips or two-type chips

Gravity Molding

molten metal is poured into a metal or graphite mold

high-energy-rate forming (HERF)

process that plastically deform metals with blasts of high-pressure shock waves

Swaging

reduce workpiece area by cold flowing the metal into a die cavity by high compressive forces or impact

Electrochemical Machining (ECM)

removes metal by electrolysis in a high current deplating operation

Forging

repeated hammering of a workpiece to obtain the desired shape

Blanking

sheet metal cutting to separate piece from surrounding stock

Die Casting

the process or product of forcing molten metal into a metallic mold under hydraulic pressure to give it a particular shape or form.

3 common types of failure

(1) flank wear, (2) crater wear, (3) nose failure

arc welding

The joining of metal parts by fusion, in which the necessary heat is produced by means of an electric arc.

Punching

The operation of cutting a hole in sheet metal using a die. The hole material is scrapped.

Sand Molding

a mold produced by packing sand around a pattern

Gas welding

Welding with the heat from an oxy-fuel flame, with or without the addition of filler metal or pressure.

Ultrasonic Machining (USM)

an ultrasonically vibrating tool is used to impel the abrasives in a slurry at high velocity against the workpiece

continuous casting

any process in which molten material is continuously poured into a mold

Forming Dies

bend and form the blank along a curved axis

Shearing Operations

blanking- punching- notching

Soldering and Brazing

both use a molten dissimilar metal as glue between the two pieces

Honing

describes grinding in which very little material 0.023mm-.13mm is removed

Snagging

describes very rough grinding

Chip Formation-Brittle materials produce

discrete fragments known as discontinuous chips, segmented chips, or type-one chips

Embossing

forms shallow raised letters or other designs in relief on the surface of sheet metal blanks

Presswork

general term used to denote the blanking, bending, forming, shearing of thin-gage metals

Drawing

is a cold-forming process that converts a flat blank into hollow vessel

Chemical Milling

is selective removal of material not protected by a mask

T (life of a tool)

is the length of time it will cut satisfactorily before requiring resharpening and depends on the conditions of use

Grinding

is used as a finishing operation since very fine and dimensionally accurate surface finishes can be produced

Bending Dies

used in press brakes to bend along a straight axis

Coining

used in production of coins

Lapping

used to product dimensionally accurate surfaces by removing less than 0.025 mm

Purpose of cutting fluids

used to reduce friction, remove heat, remove chips, and protect against corrosion

Electrical Discharge Machining (EDM)

uses high energy electrical discharges (sparks) to shape an electronically conducting workpiece

Taylor Tool Life Equation

vT^n = C