Manufacturing Processes and Metal Surface Metrology - Report Example

Manufacturing Processes and Metal Surface Metrology Insert Insert Manufacturing Process Casting: The process of manufacturing is metal casting, and it is the oldest. Filling of a mold with a molten material is involved in casting and brings an essential activity. Upon the solidification, the material takes the shape of t the mold. Permanent and expandable are the basic types of metal casting process. As per the requirement of this final product, depending on the shape of the final product, the cast can be made into the same shape. In multi-process manufacturing part, casting can sometimes be being the first manufacturing process. In both internal and external geometry, metal casting can be used to make parts in the complicated geometry. From a single piece with the cast, intricate parts can be made. Components of enormous machinery and great parts weighing several hundred tons, metal casting can also use to produce tiny parts like jewelry. Control of material properties can be obtained through careful parameter and technique (Muralikrishnan, Venkatachalam, Raja & Douglass, 2005). The presence of more flaws and the lower strength and ductility, when compared to the final product, is the general disadvantage of metal casting. Forming: The using of force for induction of shape is an inclusion of a large group of the process, mechanical working and plastic deformation resulted from the category of manufacturing from metal forming. The measure to be used in metal forming process is measured in terms of high ductility and malleability and lower yield of strength in the material. Greater flexibility and lower yield strength are resulted from increased temperature when working with metals. Elevated temperatures are usually used on metals in manufacturing industries. The metal forming process will change the mechanical properties of the material’s parts, this happens besides addition to shape. Establishment of new, stronger grain vacancies from close up boundaries of metal forming within the metal break ups, led to the distribution of impurities (Muralikrishnan, Venkatachalam, Raja & Douglass, 2005). Production of the superior mechanical properties of metal forming process impacted from the above reason. There three types of temperature in relation to establishing. These forms are cold working (room temperature), warm working, and hot working. In the other perspective, there are two main categories in relation to surface area to volume of a material. Powder processing: Production of powder from certain materials is a technique used in manufacturing process. Into different shapes, (called pressing) the powder is pressed and heated sufficiently causing the bonding of the particles together into solid components (called sintering). However, the subjectivity of ceramics to powder processing technique, powder processing is standard for metal materials. Powder processing has many advantages. Consistent dimensions control of the product that keeps tight tolerance relatively, (+/-.005”) can be obtained with the use of powder processing. Finishing of parts with the good surface can be produced. With no further requisition in the process of manufacturing, therefore parts can be made into different final shapes (Paulraj & Paul, 2011). Minimal waste of materials can be experienced in powder processing. The flexibility of powder processing to be automated can minimize the need for labor that requires little amount of skilled labor. Metals that easily shaped are very difficult to work with another process. Production using this technique is applicable to particular alloy combination and cements which has no other form of processing. Lastly, depending upon the nature of the process, some parts can be produced with a controlled level of porosity. A number of disadvantages are found in this powder process. The foremost is the high cost, compared to solid material, the powder is expensive, and its storage is also difficult. Compared to conventional machinery, sintering furnaces, and special presses are more complicated to process. Tooling also is very expensive (Paulraj & Paul, 2011). There is a Geometric Limitation to parts to be manufactured since powder does not easily flow in a die when pressed. Inferior mechanical properties may be found in powder parts. Finally, more intricate geometries when variations in material density through the part might be a problem. Machining: In this format, manufacturing of desired part take the form of wanted geometric dimensions via the removal of materials that are in excess by exerting force. For this purpose, qualities of a desired manufacturing material would be: 1) Shear strength lowered 2) Shock resistant 3) The material must not possess tendency to stick to the cutting tool 4) Separation from the work easily and completely from the removed material (Paulraj & Paul, 2011) Machinability is the ability of a material to be processed. The nature and difficulty to cut in ceramics comes from the high quality in shear strengths. The result loading between the tool and workpiece caused by the inability to be shock resistant results to their fracture. From the heat, generate in the process, polymers melt, although having low yields causing them to stick to the tool. Material difficulty in removal comes because of high ductility in polymers later prompting its removal to be machine oriented. Ceramic and polymers have reduced Machinability because of this reason. Metals are applied to machining. Among metals, machinery varies. A particular problem is presented to hardened metals, due to a high level of shear strength. Before metals being hardened, they are machined to as close to their final shape as possible. From this case, the hardened materials only have to undergo little finishing operations. Many advantages are contained in this process. Accurate dimensions in machining can be produced; usually more so than any other process alone (tolerance of less than .001”) (Suriano, Wang & Hu, 2012). Material Surface Metrology Areas covered 1. The acceptance of units of measurements internationally defined. 2. Measures units by scientific methods realization 3. Determining and documenting the value and accuracy of measurements and discriminating that knowledge through establishment of traceability chains Categories Scientific metrology: organization and development of measurements standards and their maintenance are handled in this metrology. Industrial metrology: limited functioning of measurement instruments used in industrial production and testing process is ensured. One of the initiations of industrial quality control is the systematic analysis of known levels of uncertainty. Legal metrology: ensuring of fair trade was its origin; in areas of weights and measures is its area of specification. Assuring the citizens of the correct measurements results when used in official land transactions is its primary objective (Suriano, Wang & Hu, 2012). The fundamental features of a solid material, from the view of materials science, are as follows; Material atomic nature: the chemical composition of a material is highlighted in atomic nature of periodic table Material’s atomic bonding: classification of the type of cohesive electronic interactions between the atoms (or molecules) in a material is as follows; -Electron transfer and the development of anions and cations resulted from the formation of different electron negativity between chemical elements (the tendency to gaining electrons). Between the atoms, bonding occurs through electrostatic forces (Suriano, Wang & Hu, 2012). -Elements of the same electron negativity form covalent bonds. The lead to spatiality directed angular relationships come because of localized electrons and share equality between them. -Elements with low electron negativities form metallic bonds, loose attachment to the ionic nuclei by the electrons. A set of positively charged electrons embedded in a sea of electrons forms a metal. The difference in internal electronic polarities between adjacent atoms or molecules those results to weak (secondary) forms van der Waals bond (Zamashchikov, 2006). -Materials spatial atomic nature: the long range or short range force result from the amorphous arrangement of atoms. They are characterized by unit cells in a crystalline structure that are repeated severally in a space within a crystal. Grains: separated by space, they are made up of unit identical areas that are separated by grain boundaries. Phrase: this is a uniform crystal structure formed through the homogeneous aggregation of matter with respect to chemical composition (Zamashchikov, 2006). Lattice defects: deviation of ideal crystal structure -Point defects: vacancies and substituted atoms -Line defects: dislocations -Area defects: phase boundaries -Volume defects: these are the cavities (Zamashchikov, 2006) -Microstructure: microscopic collection of grains and lattice defects Material Properties and substantial performance make up for extrinsic characteristics. Reference methods have to be used in testing and metrology in order to determine their characteristics and non-destructive evaluation (NDE). References Muralikrishnan, B., Venkatachalam, S., Raja, J., & Douglass, M. (2005). Process mapping and functional correlation in surface metrology: a sheet metal case study. Int J Adv Manuf Technol, 27(1-2), 75-82. doi:10.1007/s00170-004-2144-1 Paulraj, P., & Paul, B. (2011). Metal microchannel lamination using surface mount adhesives for low-temperature heat exchangers. Journal of Manufacturing Processes, 13(2), 85-95. doi:10.1016/j.jmapro.2011.01.001 Suriano, S., Wang, H., & Hu, S. (2012). Sequential monitoring of surface spatial variation in automotive machining processes based on high definition metrology. Journal of Manufacturing Systems, 31(1), 8-14. doi:10.1016/j.jmsy.2011.04.006 Zamashchikov, Y. (2006). Duality in Metal Cutting: Impact of the Surface Layer Residual Stress. Materials And Manufacturing Processes, 21(5), 551-566. doi:10.1080/10426910500471706 Read More