Transcript Shape Rolling

Chapter 1 Introduction
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian • Schmid
Prentice Hall, 2003
FIGURE 1.1 Section of an automotive engine - the Duratec V-6 - showing various
components and the materials used in making them. Source: Courtesy Ford Motor Company.
Illustration by David Kimball.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian • Schmid
Prentice Hall, 2003
Duratec Engine
Shapes and Production Method
Shape or feature
Flat surfaces
Parts with cavities
Parts with sharp features
Thin hollow shapes
Tubular shapes
Tubular parts
Curvature on thin sheets
Openings in thin sheets
Cross-sections
Square edges
Small holes
Surface textures
Detailed surface features
Threaded parts
Very large parts
Very small parts
Production method
Rolling, planing, broaching, milling, shaping, grinding
End milling, electrical-discharge machining, electrochemical machining,
ultrasonic machining, casting
Permanent-mold casting, machining, grinding, fabricating, powder
metallurgy
Slush casting, electroforming, fabricating
Extrusion, drawing, roll forming, spinning, centrifugal casting
Rubber forming, expanding with hydraulic pressure, explosive forming,
spinning
Stretch forming, peen forming, fabricating, assembly
Blanking, chemical blanking, photochemical blanking
Drawing, extrusion, shaving, turning, centerless grinding
Fine blanking, machining, shaving, belt grinding
Laser, electrical-discharge machining, electrochemical machining
Knurling, wire brushing, grinding, belt grinding, shot blasting, etching,
deposition, laser texturing
Coining, investment casting, permanent-mold casting, machining
Thread cutting, thread rolling, thread grinding, chasing
Casting, forging, fabricating, assembly
Investment casting, machining, etching, powder metallurgy,
nanofabrication, LIGA, micromachining
TABLE 1.2 Shapes and Some Common Methods of Production
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian • Schmid
Prentice Hall, 2003
Engineering Materials
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian • Schmid
FIGURE 1.4 An outline of engineering materials
Prentice Hall, 2003
Aluminum Automobile
FIGURE 1.5 . (a) The Audi A8 automobile, an example of advanced materials construction;
(b) The aluminum body structure, showing various components made by extrusion, sheet
forming, and casting processes. Source: Courtesy of ALCOA, Inc.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian • Schmid
Prentice Hall, 2003
Production Methods for a Simple Part
FIGURE 1.6 Various methods of making a simple part: (a) casting or powder metallurgy,
(b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian • Schmid
Prentice Hall, 2003
Machining
of a Mold
Cavity
FIGURE 1.8 Machining a mold cavity for making sunglasses.
(a) Computer model of the sunglasses as designed and viewed
on the monitor. (b) Machining the die cavity using a computer
numerical control milling machine. (c) Final product produced
from the mold. Source: Courtesy Mastercam / CNC Software,
Inc.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian • Schmid
Prentice Hall, 2003
Flexible Manufacturing System
FIGURE 1.9 General
view of a flexible
manufacturing system,
showing several
machines (machining
centers) and an
automated guided vehicle
(AGV) moving along the
aisle. Souce: Courtesy of
Cincinnati Milacron, Inc.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian • Schmid
Prentice Hall, 2003