Formed metal components and Non-metallic Parts

Sayyan.N Shaikh 4SN11MAR10 IAR,M-Tec

Metal Forming
It is a Large group of manufacturing processes in which plastic deformation is used to change the shape of metal workpieces. The tool, usually called a die,which applies stresses that exceed yield strength of metal. The metal takes a shape determined by the geometry of the die. Forming Process Classification. Bulk Metal forming Sheet Metalworking Wire forming

Bulk Metal Forming

It is characterized by significant deformations and massive shape changes. "Bulk" refers to work parts with relatively low surface area-to-volume ratios. Starting work shapes include cylindrical billets and rectangular bars. Rolling - compression process to reduce the thickness of a slab by a pair of rolls. Forging - compression process performing between a set of opposing dies. Extrusion - compression process squeezing metal flow a die opening. Drawing - pulling a wire or bar through a die opening.

Bulk Metal Forming

Sheet Metalworking
It is forming process on metal sheets, strips, and coils. The process is normally a cold working process using a set of punch, die and stamping. Often called press working because presses perform these operations. High surface area-to-volume ratio of starting metal, which distinguishes these from bulk deformation. Bending - straining of a metal sheet to form an angle bend. Drawing - forming a sheet into a hollow or concave shape. Shearing - not a forming process but a cutting process.

Sheet Metalworking

Wire forming
Wire forms are made by bending and forming wires of different diameters into different geometries which are resistance welded into structures. Wires are stronger then cast materials of equal rigidity. Wire form structure has least weight and is inexpensive to construct. Example of wire form structures are display racks, cages, trays, grills, fan guards, refrigerator racks, supermarket carts and baskets. Repeated usage of wire of a standardized geometry within the product can reduce tooling and fixture cost.

Wire form design

Non-metallic Parts
PLASTIC:
These are a group of synthetic chemical compounds which are high polymers and which are at some stage plastic and could be shaped by heat, with or without pressure into useful products. The word plastics is from the Greek word Plastikos, meaning able to be shaped and molded A polymer is composed of enlarged molecules or macromolecules which are formed by the recurring addition of monomers. This combining of many monomers to make macromolecules or polymer is known as polymerization.

Why Design with Plastics?

Corrosion resistance Low electrical and thermal conductivity, insulator Easily formed into complex shapes, can be formed, casted and joined. Wide choice of appearance, colors and transparency

Disadvantages of using Plastics:

Low strength Low useful temperature range (up to 600 oF) Less dimensional stability over period of time (creep effect) Aging effect, hardens and become brittle over time Sensitive to environment, moisture and chemicals Poor machinability

Classification of plastics
Plastics are classified into 3 categories. Synthetic resins Thermosetting resins Thermoplastic resins

Synthetic resins:
These plastics are complex organic materials made by the chemical reactions of relatively simple substance.

Thermosetting resins
All resins are either thermoplastics or thermosetting. Thermosetting resin is one that is hardened by heat, causing a chemical change which is irreversible. Thermosetting material are something called heat-setting materials.
General properties: more durable, harder, tough, light. Typical uses: automobile parts, construction materials. Examples: Unsaturated Polyesters: lacquers, varnishes, boat hulls, furniture Epoxies and Resins: glues, coating of electrical circuits,

Thermoplastic resins
These are the resins softened by heat,and some time called cold setting resins. This process may be repeated as many time as is required.
General properties: low melting point, softer, flexible. Typical uses: bottles, food wrappers, toys,
Examples: Polyethylene: packaging, electrical insulation, milk and water bottles, packaging film Polypropylene: carpet fibers, automotive bumpers Polyvinyl chloride (PVC): electrical cables cover, credit cards, car instrument panels

Plastics Processing: Extrusion

Plastics Processing: Blow molding

(a) The hollow piece of heated glass (parison) is first created by a blow mold (see text-book Fig 17.25) 3-piece mold heated glass

(b) The mold is put together

(c) Plunger and hot air push the glass up

(d) Hot air blows the glass out towards the mold surface

(e) Mold comes apart, bottle is removed

Plastics Processing: Thermoforming

Sheet of plastic Heated (soft) Molded using a shaped die

Plastics Processing: Compression and Transfer Molding

compression molding

transfer molding (more complex shapes)

Plastics Processing: Injection Molding

Cycle of operation for injection molding

DFM Design Guidelines Injection Molding

Provide adequate draft angle for easier mold removal.

Minimize section thickness, cooling time is proportional to the square of the thickness, It reduce cost by reducing the cooling time.

DFM Design Guidelines Injection Molding

Keep rib thickness less than 60% of the part thickness in order to prevent voids and sinks.

Avoid sharp corners, they produce high stress and obstruct material flow.

DFM Design Guidelines Injection Molding

Provide smooth transition, avoid changes in thickness when possible.

Keep section thickness uniform around bosses.

RUBBER PARTS
Rubber parts are formed to the desired shape mainly by moulding and extruding, with cutting and grinding being used less frequently. Most rubber products are vulcanized with sulphur at high temperatures during moulding or after extruding. An essential element of rubber behaviour is that it retracts forcibly and quickly from large deformations. This property makes it extremely useful in application of sealing or shock absorption. Extrusion is favoured for producing long rubber parts of uniform cross section, and the cross section may be simple, like tubing, or highly complex, like door seals for automobiles

Design Recommendation for rubber

Holes should be as shallow and as wide as possible.

Incorporate sufficient wall thickness around holes used for mounting to minimize the danger of the rubber part tearing from the hole. Use of stepped or tapered pins to form deep blind holes.

 Spacing between holes, and between holes and edges, should be at least one hole diameter to minimize tearing of rubber.

Avoid undercuts that make molding more difficult.

Ceramic and Glass Parts

Ceramics are defined as inorganic, nonmetallic materials. They can be classified into the following groups:
1. Whitewares. These include, in addition to mechanical and electrical components, earthenware, china, tiles, and porcelain. 2. Glass. It is a mutual solution of fused, inorganic oxides cooled to a rigid condition without crystallization. It is made into a variety of hard, transparent objects. 3. Refractories. These include heat-resistant and insulating blocks, bricks, mortar, and fireclay. 4. Structural-clay products. They consist of bricks, tiles, and piping made from natural clays. 5. Porcelain enamels. These are ceramic coatings on castiron, steel, and other metal products.

Ceramic Parts
To produce ceramic parts, refined powders of the basic raw materials are first thoroughly mixed with some water and small quantities of selected additives, normally metallic oxides that act as fluxing agents and inhibitors. Then the basic fabrication operation, such as pressing, extrusion, or casting, takes place. Depending on the shape and dimensions, machining or grinding of the formed part also may be involved.

Pressing methods and molds types

QUESTIONS???

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