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.
