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Manufacturing Processes

Keith Lee – kmlee@clemson.edu. Punching A metal forming process that uses a press to force a tool through the workpiece to create a hole via shearing. Used to make bicycle chains, bolts, and various metal rings. Die Casting Forces molten metal under high pressure into a mold cavity

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Manufacturing Processes

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  1. Keith Lee – kmlee@clemson.edu • Punching • A metal forming process that uses a press to force a tool through the workpiece to create a hole via shearing. • Used to make bicycle chains, bolts, and various metal rings • Die Casting • Forces molten metal under high pressure into a mold cavity • Used to make gearbox housing, oil pans, cylinder head covers • Hot Pressing • Simultaneous application of heat and pressure to powder creates hard, brittle material • Used to make cutting tools, brake pads, clutch discs Manufacturing Processes

  2. Keith Lee – kmlee@clemson.edu Patents Die Casting Hot Pressing Punching

  3. Punching http://en.wikipedia.org/wiki/Punching 2/3/2014 - Most cost effective process of making holes in strip or sheet metal for average to high fabrication - Very quick process http://www.thefabricator.com/article/punching/the-formula-for-successful-punching2/3/2014 - Four essential components: punch, stripper, die, and tool holder system - Optimizing the die clearance is a very important part of punching success http://www.manufacturelink.com.au/processes/fabrication-punching.aspx2/3/2014 - Punched material is most normally in sheets, but rolled material can also be punched - Some machines are able to change punches during the operation to punch different sized holes in the same piece Keith Lee – kmlee@clemson.edu Die Casting http://en.wikipedia.org/wiki/Die_casting 2/3/2014 - Excellent dimensional accuracy (between .1 and .02 mm) - Casting tensile strength as high as 60 ksi http://diecasting.org/faq 2/3/2014 - High speed production - Multiple finishing techniques available http://www.custompartnet.com/wu/die-casting 2/3/2014 - Can produce geometrically complex parts - Reusable molds help reduce production costs Hot Pressing http://en.wikipedia.org/wiki/Hot_pressing 2/3/2014 - Heats metal powder into a mold - Largely used to create diamond-metal composite cutting tools and technical ceramics http://www.bodycote.com/services/hot-isostatic-pressing/isostatic-pressing-services/hot-isostatic-pressing.aspx2/3/2014 - Enables blends of metal powder to be combined into solids that other processes can not achieve - Eliminates all internal voids in castings http://technoman.hubpages.com/hub/Isostatic-Pressing 2/3/2014 - Heat and pressure are applied simultaneously - The process must be closed from the atmosphere so that oxide films can be avoided

  4. Keith Lee – kmlee@clemson.edu Summary • Punching is the most cost effective way to make holes • Die casting is fast and has high dimensional accuracy • Hot pressing easily combines different types of metals

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