Matels

IDT 203MANUFACTURING

METAL ( TWO )BY:

MEOR SYUKRI BIN MEOR ARISHANIS RIDZHA MINARWAN BIN AHMAD ZUKI

SWAGING

› Used to reduce or expand metal pipe into tapers,joints or sealed.

› Two techniques of swaging: Hammering Pressing

Hammering techniques› Is the manipulation of metal tube,rod or wire in a die.› Is a rotaring operation known as rotary swanging and tube

tapering› Ideal angel of taper is no more than 30’› Possible to swage up to 45’ where necessary› Smaller angle is simpler,quicker and more cost effective to

produce.

Pressing techniques› Is a hydraulic operation.› Often referred to as ‘end forming’.› Pressing action is applied from multiple angles simultineously .

› Use to expand or reduce the diameter of pipe.

TYPICAL APPLACATION› Application for swaging is deverse.› Use to form a large part such as cylindrical

lampposts,connectors and joints for load bearing cables, and piping for gas and water.

› Widely employed for small and precise product such as ammunition casing,electrodes for welding torches and thermometer probes.

RELATED PROCESS› Arc welding› Tube and section bending› Hydroforming is a recently develop process that is

capable of forming complex hollow parts from tube.› More expensive and specialized.

QUALITY› High precision› Surface finish is very good› Can be improved with polishing

DESIGN OPPORTUNITY› Possible to rotary swage tapers along the entire length

of pipe. Exp:

If the length of swage on a particular machine is 350mm,the longer tapers are made in 2 or more stage.

› Precision parts,nozzles for MIG welding are formed in a rotary swage die over an internal die.

DESIGN CONSIDERATION› Swaging tends to draw out metal into longer lengths.› Material thickness is determined by the capabilities of

the swager.› The benefits of thicker wall sections is that there is

more meterial to manipulate.

COMPATIBLE MATERIALS› Almost all metal can be used

Include steel,aluminium,copper,brass and titanium

COST› Tolling is expensive. But depends on the length and

complexity of swage.› Labour costs are hight for manual operation

ENVIRONMENTAL IMPACTS› Very little waste made by swaging process› Rotary swaging is manually process. The vibration can

cause ‘white finger’ especially in large parts

ROLL FORMING

Is a continous operation that operates at speed up to 1.25m per second.

Capable to produce 4500m of rolled steel per hour. Sheet and strip metal can be former into ribbed

panels,channels,angle or polygons with progressive rollrs.

TYPICAL APPLICATION› Automotive and transportation› Construction› Enclosures of white goods.

RELATED PROCESS› Forging and extrusion; use to produce similar continous

profiles to roll forming› Metal stamping› Press braking

DESIGN OPPORTUNITIES› Used to make standard and costume-made products.› Can be used to produce a range of profiles, from ribbed

panels to channels and box sections.› The profiles is cut to length as it is rolled and it is

possible to reduce lengths as short as 0.02m at full speed.

COMPATIBLE MATERIALS› Most commonly used for matel that are not feasible to

extrude Stainless steel,carbon steel and galvanized steel.

COST› Tooling cost are generally equal to progressive tooling

for metal stamping

ENVIRONMENTAL IMPACT› No scrap is produced in roll forming

FORGING

The forming of metal by heating and hammering or pressing was traditionally performed by blackmiths on anvils.

Now ,forgings are made by hammering,pressing or rolling hot metal with sophisticated dies and extreme pressure.

Roll forging forms continous metal rollers Use to forge stright profiles and rings(washers),which can

up to 8.5m in diameter and 3m high.

TYPICAL APPLICATION› Automotive and aerospace› Hand tolls and metal implements› Heavy duty machinery

RELATED PROCESS› Casting › Machining› Tube bending ( ring rolling )› Suitable for one-offs and low volume product as well as

mass production runs.

QUATITY› Excellent grain structure› Metal billets go through plastic deformation as they are

forge and as result the metal grains align in the direction of flow.

DESIGN OPPORTUNITIES› Suitable for one-off› Its froduces parts with superior properties that cannot be

manufactured in any other way.› Undercuts are not posibble in forging› Wall thickness should be 5mm-250mm› Forge can be used to make a huge range of components

size and geometric

COMPATIBLE MATERIALS› Most ferrous metals,including carbon,alloy and stainless

steels can be forge.› Non-ferrous metal including titanium,copper and

aluminium are also suitable.

COST› Tooling cost are moderate to hight depending to the size

and geometric of the parts.› Labour cost are moderate to high due to the level of

skill and experience required

ENVIRONMENTAL IMPACT› A great deal of energy is required to heat metal billets

to working temperature and hammer or press them into shape.

› No metal is waste because all scrap and off cuts can be recyeled.

SAND CASTING

Manual process to shaped molten ferrous metals and non-ferrous alloys.

Use regular sand to make molds Molten metel is here cast in expendable sand molds, which

are broken apart to remove the solidified part.

TYPICAL APPLICATION use in :

- architectural fittings- automotive- furniture and lighting

RELATED PROCESS.- centrifugal casting- die casting

-( produce part more accurately and rapidly )-( generally reserved for high volume

production )- forging

All this process are altenatives to sand casting metals. Sand casting is often combined with forging or CNC

machining and arc weldingnto create more complex parts.

QUALITY› Poor surface finish ang high level of porosity.› Depend largely on the quality of the foundry.› Varying grits are used to produce the highest quality finish.

DESIGN OPPORTUNITIES› This process is less expensive than die casting and investment casting

for low volume production.› Sand casting cab ne used to produce much larger casting methods

( up to several tonnes )

COMPATIBLE MATERIALS› Can be used to cast ferrous metal and non-ferrous alloys.› Most commonlt materials include iron,steel,copper alloy ( brass,bronze

)

COST› Low tooling cost› Moderate tooling cost

ENVIRONMENTAL IMPACT› This meterial can directly recycled in most case.› The mold sand can be reused by mixing it with vergin meterial.› Energy requirements for sand casting are quite high because the

metal has to be raised to several hundred degrees above its melting temperature.

DIE CASTING

die casting is a precise method of forming parts from metal.

Techniques in die casting is high pressure, low pressure and gravity.

> the high pressure mean that small parts, thin wall sections, intrecate details and fine surface finishes can be achieved.

> low pressure is very little turbulence as the the

materials flows in and so the parts have good mechanical properties.

> gravity is also known as permeant mold casting. The

mold can be use manually operated or outomated.

TYPICAL APPLICATIONS >Automotive > Furniture > Kitchenware

> high pressure used to produce outomotive industry, white goods, consumer electronics packaging, furniture lighting, jelwelry and toys.

> low pressure widely utilized in the outomotive industry to make wheel and engine parts.

RELATED PROCESSES >Forging > invesment casting > sand castingo Die casting is process for large volume productions of metal

parts due to its versatility, speed quality, minimum wall section, high strength to weight and repetability.

QUALITY > Very high Surface finish > Variables mechanical propertieso DESIGN OPPORTUNITIES >advantages * economic * strength * reduced weighto DESIGN CONSIDERATIONS > has technical considerations similar to injection molding > MORE SUITABLE FOR SMALL PART

o COMPETABLE MATERIALS >particular propetis to be exploited. > suitable for non ferrous metals. * aluminium, magnesium, zinc, copper, lead and tin.

o COST > high because tool have to be made in steel > depending on size of casting

o INVIRONMENT IMPACTS > can be directly recyled. > use a great deal of energy to melt the alloys and

maintaint them at high temperature for casting.

INVESTMENT CASTING

Liquid metal are formed into complex and intricate shapes More expensive from die casting. Made up of 3 element. > expandable pattern > non permanent ceramic mold > metal casting

o TYPICAL APPLICATIONS > aerospace > construction > consumer electronics and appliances > furniture > outomotive > jewelry industries

o RELATED PROCESSES > die casting > metal injections molding > sand casting

o QUALITY > very high > Complex shapes with high integrity

o DESIGN OPPORTUNITIES > not have the same shape limitations as other casting

techniques. > complex internal shapes are feasible in the injections

molding of the wax pattern > injections molded wax is still the most commonly used

pattern material.

o DESIGN CONSEDERATIONS > wall section do not have unifform thickness > possible to feed metals to the cavity through multiple

gates, ensuring good distributions around even complex parts.

> thicknes depend on the alloys. * aluminium and zinc = 2mm 3mm * stell and copper = grater than 3mm

o COMPETIBLE MATERIALS > ferrous and non ferrous metal alloys can be investment

cast. > the most commonly cast materials are carbon and low

alloys steels, stainless steels, aluminium, titanium, zinc, copper alloys and percius metal.

o COST > low to moderate cost wax injections tooling > non-permanent molds > moderate to high unit cost o ENVIRONMENTAL IMPACTS > very little metal is wasted in operation and any scrap

and offcuts can be directly recycled in the furnances.

METAL INJECTIONS MOLDING

Combaines powder metallury with injections molding technology.

Suitable for small parts in steel, stainless steel, magnetic alloys, bronze, nikel alloys, cobalt alloys.

TYPICAL APPLICATIONS > caplable of producing a wide range of geometric > the accuracy and speed of the process make it ideal for

manufacturing components for the aerospace, outomotive and consumer electronics industries

o RELATED PROCES * die casting * forging * investment casting > can be use to produce similar geometries > investment casting and MIM are often interchangeable,

depending on tolerances and intrcacy of features. > MIM reduces or eliminates, the need for secondary

operations sush as machining.

o QUALITY > very high quality surface > high level of density

o DESIGN OPPORTUNITIES > can reduce the number of component > can produce complex and intricate geometries in a

single operations. > complex tooling, because it comperises moving parts,

may increase tool cost significantly.

o COMPATIBLE MATERIALS > common metalic materials for MIM are ferrous metals

including low alloys steels, tool steels, stainless steels, magnatic alloys and bronze.

COST > high tooling cost > moderate to low units cost

o INVIRONMENTAL IMPACT > Scrap matrerial in the injections molding cyle, including

feeders, can be directly recycled.

ELECTROFORMING

Same as electroplating but it is carried out on non-conductive or non-adherent metal surface (such as stainless steel)

Builds up the matel layer in a gradual and precise manner.

o TYPICAL APPLICATIONS > architecture and interiors > biomadecal > jelwelry, silversmithing and sculpture

o RELATED PROCESSES > CNC maching > investment casting > laser cutting and engrawing

o QUALITY > very high: exact replica of the mold with relatively

uniform wall thickness

o DESIGN OPPORTUNITIES > mandrels can be made from semi-flexible rubber,

intricate shapes and re-entrant angles can be produced with a single manderals.

> electroformed products can be manufactured in a relatively inexpensive material

o COMPATIBLE MATERIALS > almost any materials * wood * ceramics * plastic

o COST > low tooling costs generally > high unit cost, partly dependent on electroforming

material

o ENVIRONMENTAL IMPACTS > additive rather than reductive process > plenty of hazardous chemicals are used in the process.

CENTRIFUGAL CASTING

Cavers a range of spining processes used to shape materials in their liquid state.

Suitable for metals plastic, composites and glass.

o TYPICAL APPLICAIONS > bathroom fitting > jewelry > prototyping and model making

o RELATED PROCESSES > die casting > investment casting > sand casting

o QUALITY > very good reproduction of fine detail and surface

texture

o DESIGN OPPORTUNITIES > can produce from 1 to 100 parts in a single cycle. > large part are cast around the central core. > using semi-rigid silicons means complex details and re-

entrant angles that are not suitable in hard tooling can be cast.

COMPITABLE MATERIALS > silicone molds can be used to cast > metal molds are used to shape most other metals

powders and metal matrix composites.

o ENVIRONMENTS IMPACTS > all scrap metal thermoplastic and glass can be directly

recycled .

PRESS BRAKING

o simple and versatile technique is utlized to bend sheet metal profile for prototypes and batch productions.

o A range of geometries can be formed including bend, continuous and sheet.

TYPICAL APPLICATIONS > consumer electronics and appliances > packaging > transport and outomotive

RELATED PROCESSES > extrusion > metal stamping > roll forming

o QUALITY > high quality and accurate bends to within 0.1 mm

o DESIGN OPPORTUNITIES > using an air bending die, it is posible to bend a range of

angles very quickly by depressing the ram only as much as necessary.

> press brakes have the capability of producing long, tapered and segment profile.

COMPATIBLE MATERIALS > almost all metals can be formed using press braking,

including steel, aluminium, copper and titanium.

o COSTS > no cost for standard tooling > low to moderate unit cost

o ENVIRONMENTAL IMPACTS > bending is an efficient use of materials and energy > no scrap in the bending operations.