Metal Processes Flashcards
Properties of die casting?
Mould can be re-used, automated, suitable for high volume production, provides detai; and quality fnishes
Properties of piercing and blanking?
Highly automated, continuous, accurate, repeatable and scrap can be easily recycled
Properties of drop forging?
Hardens and strengthens components,improved grain size and continuous grain
Properties of welding?
required for welding, hence no reduction of area. So structural members are more effective in taking the load.
- In welding filler plates, gusseted plates, connecting angles etc, are not used, which leads to reduced overall weight of the structure.
- Welded joints are more economical as less labor and less material is required.
- The efficiency of welded joint is more than that of the riveted joint.
- The welded joints look better than the bulky riveted/butted joints.
- The speed of fabrication is faster in comparison with the riveted joints.
- Complete rigid joints can be provided with welding process.
- The alternation and addition to the existing structure is easy.
- No noise is produced during the welding process as in the case of riveting.
- The welding process requires less work space in comparison to riveting.
- Any space of joint can be made with ease.
Properties of Pressing?
Advantages: High strength in thin parts that can have complex shapes and for a ‘reasonable’ price. Easy to make parts in different colours and finishes (plated and painted
Properties of punching?
Characteristics of the punching process include:
◾ Its ability to produce economical holes in both strip and sheet metal during medium or high production processes.
◾The ability to produce holes of varying shapes - quickly.
The punching process forces a steel punch, made of hardened steel, into and through a workpiece. The punch diameter determines the size of the hole created in the workpiece.
The illustration that follows provides a two-dimensional look at a typical punching process. Note how the workpiece remains and the punched part falls out as scrap as the punch enters the die. The scrap drops through the die and is normally collected for recycling.
Properties of turning?
Economics, and Reasons to Ultimate Spinning
Inexpensive Tooling - Conventional casting or stamping dies are expensive. Spinning tooling is simple and less costly. Only a mandrel and a tool stop are needed along with a lever or a chest tool, which is typically fractionally less when compared to other forming methods. In some cases we can spin in the air. We design and build our own tooling to ensure the job is done right the first time. Our press department compliments our spinning operation.
Higher Strength (Improved Metallurgy) - Repeated passes with the tool work hardens the product and creates a stronger part (tensile strength) than a drawn product. In some cases lighter metal can be used.
Tailor-Made Tooling - Tooling costs can be kept in line with the parts’ life expectancy. If it is a one-time job, soft tools can be used. Long runs or repetitive jobs require more expensive hardened tooling.
Ease of Design Changes - These are easily made if the smaller tool is less expensive than other tooling. Parts can be refined and developed. Parts can be modified in-house without starting over. The constant changes often required in new product development make the low start up costs associated with metal spinning the ideal
Properties of milling?
- The metal is removed at a faster rate as the cutter has got multiple cutting edges and rotates at a higher speed.
- It is possible to perform machining by mounting more than one cutter at a time.
- The table of the machine can be moved to an accuracy of 0.02mm.2
- It is very useful since various cutters and precise tools can be machined.
- Special attachments can be mounted on the machine to perform operations that are performed in other machine tools.
- The quality of the shop is enhanced with the presence of this machine
Properties of sand casting?
- A very smooth surface finish.
- The ability to cast complex shapes with thin walls.
- The capacity for forming large parts with less expense than other processes, such as investment casting.
- A higher degree of dimensional accuracy than that of sand casting
Properties of stamping?
SPEED, SPEED, SPEED! – Progressive die metal stamping is based on the continuous feed of material through the different die stations of a tool. The nature of the process allows you to create more parts in a shorter period of time when compared with traditional fabrication or machining. For high volume parts, progressive stamping provides the lowest cycle times per part.
- Less Scrap Material – Progressive stamping is a metalworking method that can encompass punching, coining, bending and several other ways of modifying metal to produce your desired end part shape. The vast majority of material is used, hence, less scrap is produced. Progressive Die Metal Stamping may provide the most cost effective material option for manufacturing your parts.
- Quicker Setup – When compared to traditional fabrication or machining, the setup time may be much less for the progressive stamping process. What is achieved in multiple Setups and processes during traditional fabrication and machining, may be performed in one operation if Progressive Die Stamping is utilized. This reduction in Setup and processing will result in a more cost effective piece part.
- Create More Geometries with a Single Process – Progressive Die Metal Stamping allows you to create parts with many geometries within a single tool. This video shows a single part progressing through a die. All required geometries of the part are achieved in one Progressive Die operation.
- Longer Runs – The continuous material feed used in the progressive die stamping process allows for long runs. Longer runs between material changes and tooling adjustments mean your parts can be produced in a much shorter time.
- High Repeatability – The hard tooling die designs allow for high volume runs without die degradation. This means that part
