Chapter 1-Introduction
Chapter 1-Introduction
Chapter 1-Introduction
b. Nonferrous metals: All other metallic elements and their alloys, such as Al, Cu, Au, Mg,
Ni, Ag, Sn, Ti. Examples are:
- Brass: 65% Cu and 35% Zn
- Bronze: 90% Cu and 10% Sn
- Monel: Ni-Cu alloy
- AZ91: Mg-Al-Zn alloy
Manufacturing processes:
Figure 3 summarizes the manufacturing processes. Details and discussion are in the following
section to describe the figure contents.
Figure 4: Illustration of solidification process (1) pouring the fluid into a mold cavity and (2)
allowing the fluid to solidify, after which the solid part is removed from the mold.
Figure 5: Particulate processing: (1) the starting material is powder; the usual process consists of
(2) pressing and (3) sintering.
Figure 6: Common machining operations: (a) turning, in which a single-point cutting tool
removes metal from a rotating workpiece to reduce its diameter; (b) drilling, in which a rotating
drill bit is fed into the work to create a round hole; and (c) milling, in which a workpart is fed
past a rotating cutter with multiple edges.
Bulk Deformation Processes are generally characterized by significant deformations and massive
shape changes, and the surface area-to-volume of the work is relatively small. Starting work shapes
for these processes include cylindrical billets and rectangular bars.
Figure 8: Basic bulk deformation processes: (a) rolling, (b) forging, (c) extrusion, and (d)
drawing. Relative motion in the operations is indicated by v; forces are indicated by F.
Figure 9: Basic sheet metalworking operations: (a) bending, (b) drawing, and (c) shearing: (1) as
punch first contacts sheet, and (2) after cutting. Force and relative motion in these operations are
indicated by F and v.
Bending involves straining of a metal sheet or plate to take an angle along a (usually) straight
axis.
Drawing is the forming of a flat metal sheet into a hollow or concave shape, such as a cup, by
stretching the metal. A blank holder is used to hold down the blank while the punch pushes into
the sheet metal, as shown in Figure 9(b). To distinguish this operation from bar and wire drawing,
the terms cup drawing or deep drawing are often used.
Shearing. This process involves cutting the sheet metals rather than forming. A shearing
operation cuts the work using a punch and die, as in Figure 9(c). Although it is not a forming
process, it is included here because it is a necessary and very common operation in sheet
metalworking.