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Chapter II Summary

Chapter II discusses manufacturing processes that do not involve material removal, classifying them into deformation, fusion, and assembly processes. It details deformation techniques like forging and rolling, fusion methods including various casting types, and sheet metal working techniques. Additionally, it covers powder metallurgy and the production of profiles and pipes, highlighting their advantages, applications, and common defects.

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5 views2 pages

Chapter II Summary

Chapter II discusses manufacturing processes that do not involve material removal, classifying them into deformation, fusion, and assembly processes. It details deformation techniques like forging and rolling, fusion methods including various casting types, and sheet metal working techniques. Additionally, it covers powder metallurgy and the production of profiles and pipes, highlighting their advantages, applications, and common defects.

Uploaded by

Älaâ Å Rã
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Chapter II: Materials Processes for Obtaining Parts

Without Removing Material

1. Classification
Manufacturing processes without material removal are classified into:
• Deformation processes (forging, rolling, extrusion, wire drawing, stamping)
• Fusion processes (casting, welding, soldering)
• Assembly processes (welding, fastening, adhesives, coating)

2. Deformation Processes
These processes shape materials through plastic deformation.
• Elastic domain: reversible deformation.
• Plastic domain: permanent deformation, ending with necking.
• Higher temperature lowers the elastic limit, easing deformation.

Main Techniques
• Forging: Improves strength and fatigue resistance; low precision.
• Stamping (Die forging): Better precision, used for series production.
• Rolling: Reduces thickness of metal sheets, bars, and tubes.
• Wire drawing: Cold process to produce wires through a die.
• Extrusion: Heated material forced through a die to create profiles.

3. Fusion Processes – Casting


Casting involves pouring molten metal into a mold.
• Sand casting: Low cost, mold destroyed after use.
• Permanent mold casting: Reusable metal molds.
• Lost-wax casting: High precision and surface quality.
Common defects include porosity, shrinkage cavities, and inclusions.

4. Sheet Metal Working


• Cutting processes: Oxy-fuel, plasma, laser, waterjet.
• Bending and rolling: Permanent deformation beyond elastic limit.
• Stamping: Fast, low-cost shaping of metal sheets.

5. Powder Metallurgy (Sintering)


Powder metallurgy consists of compressing metal powders and heating them below melting
temperature.
Advantages: good tolerance, surface quality, low cost for mass production.
Disadvantages: expensive equipment, suitable mainly for large series.
Applications: brakes, electrical parts, prostheses, filters.

6. Profiles and Pipes


Steel pipes are produced from rolled metal strips and welded by high-frequency welding.
The process includes shaping, welding, inspection, heat treatment, calibration, and finishing.
Common profiles: U, T, H, square and rectangular tubes.

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