Lecture 10 Mass Production 2 v3

IDES 2101 Lecture 10: Mass Production

Today's Class Topics

  • Permanent Mold-Die Casting

  • Mass manufacturing processes in sheet metal

  • Wire Forming

  • Final Lab and deliverables

Metal Casting Processes

  • Expendable and Permanent Mold Casting

  • Types include:

    • Sand Casting

    • Investment Casting

    • Die Casting

    • Hot and Cold Chamber processes

Die Casting Overview

  • High volume casting process for various metal parts.

  • Utilizes steel molds filled with molten metal at high pressure.

  • Ensures high precision and good finish/tolerances.

Benefits of Die Casting

  • Capable of producing complex shapes and thin walls.

  • More durable than plastic parts.

  • Offers integration of multiple functions in a single part.

  • Requires little to no machining.

  • High production rates and cost-effectiveness for non-ferrous metals.

Cold Chamber Die Casting

  • Involves ladling molten metal into an unheated chamber.

  • Best for metals with high melting points (e.g., magnesium, aluminum).

  • Cost-effective, but longer cycle times and potentially lower product quality due to gas entrapment.

Hot Chamber Die Casting

  • Hydraulic cylinder submerged into molten metal for faster production.

  • Suitable for metals with low melting points.

Die Casting Tools

  • Complex and expensive, built to withstand high pressures.

  • Incorporates stationary cavity and retractable core.

  • Mold design is critical and often proven with prototyping beforehand.

Material Flow in Die Casting

  • Metal flows through a sprue and runners into the mold.

  • Excess material is discarded but can be recycled.

Common Materials in Die Casting

  • Zinc, Aluminum, and Magnesium used for strength and durability.

  • Choice of material impacts costs and properties.

Design Considerations

  • Undercuts require special inserts that can slow production.

  • Parting lines and draft angles must be decided early for mold design.

  • Wall thickness should be uniform to avoid distortion and voids.

Bosses and Features in Cast Parts

  • Used for mounting and reinforcement.

  • Should be designed with rounded edges to prevent stress concentrations.

Vacuum Impregnation

  • Seals porosity in castings, making them watertight.

Finishing Processes

  • Techniques include painting, powder coating, plating, anodizing, and PVD coating.

  • Finishing improves appearance, durability, and corrosion resistance.

Mass Production of Sheet Metal

  • Methods include:

    • Laser Cutting

    • Stamping

    • Deep Drawing

    • Spinning

    • Slide Forming

Stamping and Drawing

  • Utilizes mechanical action to form parts, primarily in automotive manufacturing.

  • Deep drawing involves multiple stages to achieve desired shapes.

Additional Processes

  • Slide forming for small complex parts.

  • Wire forming using CNC machines for rapid production of various wire shapes.