PROCESOS DE MANUFACTURA

PROCESOS DE MANUFACTURA
DEFINICION

CLASIFICACION

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA MACHINING PROCESSES SINGLE POINT MACHINING TURNING BORING FACING FORMING SHAPING, PLANNING MULTIPOINT MACHINING DRILLING MILLING SAWING, FILING BROACHING, THREAD CUTTING GRINDING SURFACE GRINDING CYLINDRICAL GRINDING CENTERLESS GRINDING INTERNAL GRINDING FORM GRINDING ABRASIVE WIRE CUTTING HONING LAPPING ULTRASONIC MACHINING BUFFING, POLISHING TUMBLING GRIT BLASTING CHEMICAL MACHINING ENGRAVING CHEMICAL MILLING CHEMICAL BLANKING ELECTROCHEMICAL MACHINING ELECTRICAL DISCHARGE MACHINING LASER MACHINING ELECTRON BEAM MACHINING PLASMA-ARC CUTTING FLAME CUTTING WATER JET CUTTING DEFORMATION PROCESSES OPEN- DIE FORGING IMPRESSION-DIE FORGING CLOSED-DIE FORGING PRECISION OR FLASHLESS FORGING COINING HEADING, PIERCING, HUBBING, COGGING, FULLERING, EDGING, ROLL FORGING, SKEW ROLLING ROLLING FLAT, RING, THREAD, GEAR, PIERCING EXTRUSION DIRECT, INDIRECT HYDROSTATIC, IMPACT, BACKWARD DRAWING ROD & WIRE, FLAT STRIP, TUBES SWAGING SHEARING BENDING PRESS- BRAKE FORMING, ROLL FORMING, TUBE FORMING BEADING, FLANGING, HEMMING, SEAMING STRECH FORMING BULGING DEEP DRAWING PRESS FORMING RUBBER FORMING SPINNING EXPLOSIVE FORMING ELECTROHYDRAULIC FORMING MAGNETIC- PULSE FORMING SUPERPLASTIC FORMING

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA METAL CASTING AND POWDER PROCESSES CASTING CASTING OF INGOTS CONTINUOUS CASTING SAND CASTING SHELL MOLDING SLURRY MOLDING INVESTMENT CASTING (LOW- WAX PROCESS) EVAPORATIVE CASTING DIE CASTING (GRAVITY- FEED, PRESSURIZED) CENTRIFUGAL CASTING SQUEEZE CASTING RHEOCASTING CRYSTAL GROWING CRYSTAL- PULLING ZONE MELTING Electro forming Plasma Spraying POWDER METALLURGY PRESSING ISOSTATIC PRESSING SINTERING

JOINING PROCESSES MECHANICAL JOINING BOLTS, SCREWS, RIVETS SOLID- STATE WELDING DIFFUSION, FORGING, FRICTION, DEFORMATION LIQUID STATE WELDING RESISTANCE WELDING ARC WELDING THERMAL WELDING HIGH- ENERGY BEAM WELDING ELECTRONIC BEAM, LASER LIQUID- SOLID STATE BONDING BRAZING SOLDERING ADHESIVE BONDING PLASTICS AND COMPOSITES JOINING (MECHANICAL, HEATING, SOLVENTS, ULTRASONICS) Mfg process, ..

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA

MACHINING PROCESSES

Honing

Superfinishing

Lapping Prof. M.A. Bjar

Ultrasonic Machining

Buffing

PROCESOS DE MANUFACTURA

Typical Material Removal Rate

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA Tolerances A tolerance is exactly as the word implies. It is the amount of deviation that can be tolerated in the SIZE and GEOMETRY of a component or assembly. Size Tolerances To have any chance of manufacturing components, the dimensions specified on drawings, need to show the acceptable upper and lower limits of size. Within reason, these limits should be as generous as possible in order to keep down manufacturing costs. Obviously there are times when it is necessary to quote very tight limits in order to provide a particular fit. For instance, it may be necessary for two components which fit together, to be assembled with a transition fit. On the other hand the components may need to be pressed together. Clearly the limits on the size of the components, will dictate the kind of fit obtainable. The draughtsperson producing the drawing cannot leave any dimension without a size tolerance. Most dimensions can be covered by an overall drawing tolerance, but areas where particular fits are necessary, need to be identified and given appropriate tolerances. As a guide, the table below gives tolerances which can be achieved by various manufacturing processes. Interchangeability is one of the major reasons for using tolerances. It is impossible to guarantee that production components will fit, without using comprehensive tolerancing on interfaces. It is necessary to be able to produce components in batches, at any time, in different locations and still be able to guarantee the fit. You imagine going to buy a spare part for your car or motor cycle and finding that it wont fit because the size is incorrect. The manufacturer must be able to rely on the tolerance specified on the drawing, in order to be able to produce fully interchangeable components, with the correct interfacing condition. On the other hand, one off or prototype components and assemblies do not necessarily need comprehensive tolerancing. It is often sufficient to allow one component to be machined to fairly relaxed tolerances whilst specifying the mating component to be machined to a specific fit, quoting only the clearance or interference required. Process Machining - close tolerance Machining general Sheet metal work (small components) Sheet metal work (large components) Hole centres and drilling Sand casting Flame cutting Plasma cutting Tolerance 0.1mm 0.25mm 0.5mm 1mm 0.25mm 3mm 3mm 1mm

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA

Geometrical Tolerances It is sometimes necessary to specify that the faces of a component are flat, parallel, perpendicular to others etc. This is done on drawings by quoting a geometrical tolerance. For instance, the cylinder head on an internal combustion engine does need to be flat, where it interfaces with the crankcase (which of course also needs to be flat). It does not need to have very accurate size tolerances - normal machining tolerances will suffice, but size tolerances will not guarantee flatness. In the case of the cylinder head, it is a fairly rough casting, so there is no datum surface to relate to and there is no point in creating one. The cylinder head does not have to be parallel to anything, or perpendicular to a face, within close limits. However a flatness band has to be created, within which the surface must remain, otherwise the result could be a distorted and leaking cylinder head. Cylindrical components may also need geometrical tolerances. Again using the internal combustion engine as an example, the crankshaft will almost certainly need geometrical tolerances.

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA There are several bearing surfaces which need to be concentric with one another. The only way to guarantee concentricity is to use one surface as a datum and use geometric tolerances, to ensure that the other surfaces do not deviate outside of the limits specified.

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA Rugosidad Superficial

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA

DEFORMATION PROCESSES

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA

Heading

Piercing

Hubbing

Cogging

Fullering

Edging

Roll-forging

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA

Skew-rolling

Beading

Flanging

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA

METAL CASTING AND POWDER PROCESSES

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA

JOINING PROCESSES

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA

Costs and Production Times

Prof. M.A. Bjar

PROCESOS DE MANUFACTURA

Prof. M.A. Bjar