Basic Machine Processes

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Basic Machine Processes

• Competency D403.00
• Identify the basic concepts of the manufacturing
  processes.

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Basic Machine Processes

• Objective D403.01
• Explain the concepts of the manufacturing process.

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Manufacturing

• Arrived from the Latin word manu factus,
  meaning made by hand.
• Manufacturing is the process of converting raw
  materials into products.

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WHY STUDYMANUFACTURING PROCESSES?

• The designer and the drafter must have a working
  knowledge of the various processes that could
  produce a part in order to lower cost and reduce
  production time.

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Three Phases Of The Manufacturing Process

1. Product design.
2. Selection of materials.
3. Selection of production methods and techniques.

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The information needed to produce a part, most
often comes in the form of a

• Working Drawing

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Three Main Stages Of The Production Of A Machined
Part

• Rough Forming
• Casting, Forging, Welding
• Finishing
• Drilling, machining, surfacing
• Assembling
• The assembly of parts

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The Casting Process

• First a pattern is made.
• Then a cavity is made by placing a pattern in wet
  sand.
• Next molten metal is poured into the cavity of
  damp sand.

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The Casting Process
Machined Finish
Rough Casting

• The rough casting is now ready for the machine
  shop.
• Holes are then bored and reamed.
• Top and bottom surfaces are machined
• Smaller holes will be drilled and counterbored.
• All corners on cast parts are fillets and rounds.

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Forging Process

• Forging is produced by using heavy mechanical
  presses or hammering heated bars of metal between
  dies.
• Advantages of forging over sand casting are that
  forged parts are much stronger and less brittle.

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Welding
Welded
Cast

• Welding is the fusion or joining of two pieces
  of metal by means of heat, with or without the
  application of pressure.

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Manufacturing Materials

• Fall into three general categories
• Metal
• Plastic
• Inorganic materials

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Metals are classified as

• Ferrous - contain iron and steel.
• Nonferrous - do not have iron content (such as
  copper and aluminum).
• Alloys - mixture of two or more metals.

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Inorganic Materials Include

• Carbon and graphite - have low tensile strength
  (ability to be stretched).
• Ceramics are clay and glass materials. (resistant
  to heat, chemicals, corrosion).

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Heat-Treating

• Annealing is the process generally used to
  soften metal by heating followed by slow cooling.
• Hardening requires heating and then rapid
  cooling in oil or water.

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Plastics Processing
The plastics industry represents one of the
major manufacturing segments.

• Thermosetting becoming permanently hard and
  unmoldable when once subjected to heat.

• Thermoplastic becoming or remaining soft and
  moldable when subjected to heat.

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Typical Plastic Processing Operations Include

• Extrusion
• Blow Molding
• Injection Molding
• Thermoforming

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Extruding

• The process of producing shapes by forcing hot
  metal through a die that has and opening of the
  desired shape.

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Blow Molding

• Used in the production of bottles, automotive
  ductwork, hollow toy components, and door panels.

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Injection Molding
.    
 

• Used to manufacture products such as housings
  for electronic implements, automotive components,
  food storage containers, and components for
  medical applications.

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Thermoforming

• Used in the manufacturing of thin-walled packages
  for the food industry.
• Manufactured primarily by injection molding.

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CAD in Manufacturing

• The process of developing a design drawing on a
  CAD system and producing it on a computerized
  machine is called CAD/CAM.
• The process of converting the CAD drawing into a
  preprogrammed, coded instructions is called
  Computer Numerical Control (CNC).
• The advantages of the (CNC) is, better production
  and control, increased productivity, decreased
  labor and lower production costs.

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The Machinist Steel Ruler

• Commonly used measuring tool for getting rough
  measurements on a part.
• The smallest division on the fractional scale is
  1/64 (.016).

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Vernier Caliper

• Precise measuring.
• Decimal, fractional, or metric.
• Often used by drafters to record dimensions from
  a machined prototype or part.

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6 Dial Caliper
Step
Depth
Inside
Inside
4-way Measurement
Outside
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6 Dial Caliper Three Scales
METRIC (mm)
FRACTIONAL (1/64)
DECIMAL (.XX)