Hog cycle Flashcards
Chemical Etching
Definition:
A process that uses chemicals to remove material from the surface of a workpiece to create intricate designs or patterns.
Key Points:
Involves masking the areas that shouldn’t be etched.
Commonly used for thin metal parts.
Suitable for complex shapes and fine details.
No mechanical stress or heat is applied to the material.
Blanking
Definition:
A sheet metal forming process where a punch and die are used to cut out a piece of material from a larger sheet, producing a “blank.”
Key Points:
The blank is the desired part, while the remaining sheet is scrap.
Often used in mass production.
The process requires precise dies.
Common in manufacturing automotive parts, cans, and electronic components.
Chemical Machining
Similar to chemical etching, masking protects certain areas, but in chemical machining, the chemical solution removes material over a larger area or to a greater depth. It’s commonly used to lighten parts, create complex shapes, or produce variable thicknesses in metals.
Shaping
Definition:
A manufacturing process that involves removing material to form a desired shape, often using a cutting tool or press.
Key Points:
Suitable for creating parts with specific contours or forms.
Can be done manually or with machines.
Often used for metals, woods, and plastics.
Examples include forging, casting, and machining.
Spinning
Definition:
A metalworking process where a disc or tube of metal is rotated at high speed and formed into an axially symmetric part using a tool.
Key Points:
Ideal for making hollow, round shapes (e.g., cymbals, bowls).
Typically used with metals like aluminum, brass, or steel.
A cost-effective method for low-volume production.
Produces strong parts with excellent surface finish.
Pressing
Definition:
A process in which material (often sheet metal) is compressed or shaped by being forced into a die or mold under high pressure.
Key Points:
Can be used for mass production of components.
Common in forming, stamping, and punching operations.
Produces precise and repeatable shapes.
Frequently used in automotive, aerospace, and electronics industries.
Drawing
Definition:
A metal forming process in which a sheet, bar, or tube is pulled through a die to reduce its cross-section/diameter and increase length.
Key Points:
Used to produce thin-walled tubes, wires, and rods.
Can be done cold or hot, depending on material properties.
Produces high-strength, precision components.
Commonly used for making wires and long metal components.
Most failure due to misaligned tools/fitment
Hemming
Definition:
A metalworking process used to fold the edge of sheet metal onto itself to reinforce it or create a smooth edge.
Key Points:
Often used in automotive body parts to join metal sheets.
Creates a safe edge free of sharpness.
Can be done manually or by machine.
Provides additional strength and rigidity to parts.
High-speed steel
Description:
Cutting materials at high speed
Features:
Good for cutting harder materials.
Retains hardness even when heated.
Affordable and widely used in standard drills.
High rake angle
Key Features:
Reduces cutting resistance and improves efficiency - less force required.
Commonly used in tools for softer materials.
Promotes smoother cutting action.
Carbide cutter
Key Features:
Excellent for cutting tough or abrasive materials.
Carbide tips last longer than HSS tools.
More expensive but suitable for high-speed and high-performance applications.
Honing
Definition:
A precision machining process used to improve the surface finish or refine the shape of a bore.
Key Points:
Uses abrasive stones.
Achieves high dimensional accuracy and surface finish. Leaves cross hatched surface. Useful for retaining oil and lubrication.
Common in cylinder finishing and engine parts.
Broaching
Definition:
A machining process that uses a toothed tool (broach) to remove material, usually for making holes or cutting keyways.
Key Points:
Efficient for producing complex shapes.
High material removal rate.
Used for internal and external surfaces.
Reaming
Definition:
A finishing process that enlarges a hole to an exact diameter with a smooth finish using a reamer.
Key Points:
Ensures precise hole diameter.
Used after drilling.
Produces smooth, accurate holes.
Hobbing
Definition:
A gear manufacturing process using a hob (special cutting tool) to cut teeth into a gear blank.
Key Points:
Used for producing gears and splines.
Fast and efficient for mass production.
Provides accurate, repeatable results.
Lapping
Definition:
A machining process where two surfaces are rubbed together with an abrasive to achieve an extremely fine surface finish or precise flatness.
Key Points:
Ultra-fine finishing technique.
Commonly used for optical and precision components.
Achieves tight tolerances.
Slot drill
Definition:
A type of milling cutter with two or more cutting edges used to create slots or pockets in materials.
Key Points:
Can plunge directly into the material.
End Mill
Definition:
A cutting tool used in milling operations to cut in all directions.
Key Points:
Versatile tool for cutting, profiling, and slotting.
Bull Nose Mill
Definition:
A milling tool with a rounded edge, also called a corner radius end mill, used to create smooth contours or fillets in a workpiece
Fly Cutter
Definition:
A single-point cutting tool used in milling for producing a flat surface.
Key Points:
Efficient for machining large, flat surfaces.
Adjustable cutting diameter.
Material Extrusion (MEX)
Definition:
An additive manufacturing process where material is extruded layer-by-layer to build a part.
Key Points:
Common for thermoplastics like PLA and ABS.
Requires support structures for overhanging parts.
Inexpensive and widely accessible for hobbyists.
Photopolymerisation (VAT)
Definition:
An additive manufacturing process where liquid photopolymer is cured using light to create solid layers.
Key Points:
High accuracy and fine details.
Material only cures where exposed to light.
Ideal for intricate and precise parts.
Can use thermoset
Material Jetting MJT
Definition:
An additive process where droplets of material are deposited layer by layer and cured with UV light.
Key Points:
Allows full color and multiple materials.
High detail and surface finish.
Similar to an inkjet printer but for 3D parts.
Can use thermoset
Binder Jetting BJT
Definition:
A process similar to material jetting, but instead of material, a binder is deposited onto a powder bed.
Key Points:
Uses powder as both material and support.
Ideal for metals and ceramics.
Produces complex geometries with minimal material waste.
Powder Bed Fusion PBF
Definition:
An additive manufacturing process where powder is selectively fused using a heat source like a laser.
Key Points:
Used for both metals and polymers.
Support material is fused and can be difficult to remove.
Produces strong, high-quality parts.
Wave Soldering
Definition:
A bulk soldering process where a printed circuit board (PCB) is passed over a wave of molten solder to connect components.
Key Points:
Common in mass production of PCBs.
Fast and efficient for through-hole components.
Ensures consistent soldering of multiple joints.
Ultrasonic Soldering
efinition:
A soldering method that uses ultrasonic vibrations to break down oxides and bond materials without flux.
Key Points:
Ideal for difficult-to-solder materials (e.g., glass, ceramics).
No need for chemical flux.
Reflow Soldering
Definition:
A soldering process where solder paste is applied to a PCB, and components are attached and then heated in an oven to melt the solder.
Key Points:
Common in surface-mount technology (SMT).
Allows precise placement of components.
Low Rake Angle
Definition:
A low rake angle in a cutting tool means the angle between the tool’s face and the cutting surface is small, resulting in a more blunt edge.
Key Points:
Ideal for cutting tough, hard materials.
Requires more force to cut and may result in a rougher finish compared to tools with a high rake angle.
Extrusion
A manufacturing process where material is pushed through a die to create long parts with a consistent cross-section.
Rotational Moulding
Definition:
A moulding process where a hollow mold is filled with material and rotated in multiple axes to form hollow parts.
Key Points:
Produces large, hollow, lightweight parts.
Often used for plastic tanks, toys, and containers.
Low tooling cost, but slower cycle time compared to other molding methods.
Powder Metallurgy
Definition:
A process where metal powders are compacted into a desired shape and then sintered (heated) to create a solid part - has pores, metal infiltration can fill.
Key Points:
Suitable for materials that are difficult to machine.
Commonly used in producing gears, bearings, and filters - oil impregnation.
Shell Molding
Definition:
A casting process that uses a thin shell of sand and resin as the mold for producing metal parts.
Key Points:
Provides excellent surface finish and dimensional accuracy.
Used for complex shapes and thin-walled sections.
Die Casting
Definition:
A metal casting process where molten metal is forced into a mold cavity under high pressure.
Key Points:
Produces high-precision, smooth-surface parts.
Suitable for mass production of metal components.
Compression Moulding
Definition:
A moulding process where a preheated material is placed into a heated mold cavity and compressed into shape.
Key Points:
Commonly used for thermoset plastics and rubber.
Ideal for large, flat parts with simple geometries.
What gasses have RH thred on weld gas
Non Flammable (argon, oxygen, nitrogen)
What weld gas have LH thread
Flammable (Acetelyne, Hydrogen)
Thermoforming
Definition:
A process where a plastic sheet is heated until pliable and then formed into a shape using a mold and vacuum.
Key Points:
Commonly used for packaging, trays, and disposable cups.
Selective Laser Sintering
Definition:
Additive manufacturing process that uses laser to sinter small particles of powder into a solid structure. Can create items of plastics, metals, or ceramics.
Key Points:
No need for support but typically requires post-process machining to improve finish
Transfer Moulding
Definition:
A process where a pre-measured amount of material is heated in a chamber and then forced into a mold to form a part.
Key Points:
Used for thermosets and some elastomers.
Steriolithography (SLA)
Form of additive manufacturing (3D printing) that uses a photosensitive resin and an ultraviolet (UV) laser to create parts layer by layer. SLA works by curing liquid resin into solid objects.
fine detail, thermoset
Laser Cutting
A high-powered laser is used to cut precise and detailed cuts. It is used with a CNC machine and is good for small to medium runs.
Plasma Cutting
High-temperature electrodes are generated to cut materials. Can be hand-held or operated by CNC. Good for stainless steel
Oxyacetylene Cutting
Oxyfuel Gas cutting process good for cutting ferrous metals. Portable and cost-effective. Can cause heat damage.