forging

Forging is a product of hammering heated bars or billets of material between dies In forging hammers are used to exert the tremendous pressure that forces the metal into the dies.

Types of forging
Drop forging- it is when the pressure during the forming process was exerted by heavy impact. Press forging- it is when the pressure is from a slow squeezing action.

Advantages of forging over sand casting

Forging is better over sand casting because when you sand cast it is not smooth as if you were forging, because when you forge it leave it smooth and less brittle.

Die Casting

Die Casting is forcing a molten alloy or zinc into a cavities between metal dies It is the fast casting process It is used to make automobile, carburetors, toys, and door handles.

Dry sand cores: used when green sand is not strong enough to from some shapes; a mixture of sand and biding substance Core box: a box in which dry sand cores are made. The core is removed and baked in a core oven to make it solid. A core is used to extend through a casting and make a core hole.

Core prints: made by a core to form openings in the sand to support the ends of the core. Metal is poured into mold, flows around core, leaves hole in casting. After cooling, it is removed from sand. Dry sand core is broken out. Casting is then cleaned. Any projected fins are ground off on a grinder.

The casting is sent to the machine shop.

There, cored hole will be enlarged by boring and reaming. The top and bottom surfaces will be machined. Small holes will be drilled and counter bored.

The Milling Machine

Fastened by clamp and fed into rotating milling cutter. A wide variety of cuts are available by using different shapes. Accuracy is better when the machine is set up properly and maintained. Laser-based milling is the most accurate and has pinpoint abilities. It can be used to design edges or cut inserts or slots in boards to slide in properly with an object.

Grinding Machine
Removes small amount of metal to bring work to a very fine & accurate finish. Operator can tell machine exactly how much to take off. In cylindrical grinding the work revolves on centers and moves past the grinding wheel. The machine automatically compensates for abrasiveness on the grinding wheel.

Lathe
Used to shape cylinders, cones, and other rounded shapes.

Stock held at centers between face plate and chuck.

Individual Uses:

1. Turning
2. Facing 3. Drilling

4. Boring
5. Reaming 6. Knurling

Turning
Facing Cutting external parts of cylindrical surfaces.

Boring

Cutting flat surfaces.

Drilling Cutting a hole thru an object.

Cutting a hole partially thru an object.

Reaming
Knurling Cutting groves in surface to allow better grip.

Lathe

Drill Press
Used to make holes in a non-moving object.
Usually followed by boring for improved roundness and straightness.

1. Boring
2. 3. Reaming Counterboring

4. Spotfacing
5. Countersinking

Boring
Enlarges the hole slightly rounder and straighter. Reaming

Enlarges hole slightly and smoothes the surface.

Counterboring The cutting of an enlarged cyulindrical protion at the top of an existing hole. Spotfacing The cutting of a shallow Counterbore. Countersinking The cutting of an enlarged conical portion at one end of a hole

Drill Press

The points of tangency must be found in the top view. They must be projected to the other views where runouts are carefully drawn freehand.

Point of Tangency

For Example , the upper top view in Fig A would in each case be completely blank, if lines were not used to represent rounded edges. The drawing then would be misleading

No!

Correct

Fig. A

Bronze Alloy of copper and tin Brass Alloy of copper and zinc Aluminum lightweight, corrosion resistant and very malleable. Titanium Strong as steel but light as aluminum

Changed from paper to electronic based Info from CAD programs are sent straight to the machine CAD/CAM CNC: vector-based drawing into tool movement Problems are created with a bad drawing

Draft: A taper given to patterns to make it easier to withdraw from sand mold without damaging shape of mold. Injection molding- used to manufacture products such as housings for electronic implements, automotive components, food storage containers, and a variety of other items Fillet - Inside corners in particular should have fillets as large as possible Round - A rounded outside corner

Boss