MATERIALS SELECTION AND DESIGN

EBT 447 SEMESTER I, 2014/2015

MATERIAL SELECTION: PROCESS & PROCESS

SELECTIONS

LECTURE 2
PROCESSES AND
PROCESS
SELECTIONS

Lecture 1 CHAPTER 13 OF THE TEXTBOOK

 CONTENTS
Introduction
Classifying Processes
The Processes: Shaping, Joining & Finishing
Processing of properties
Systematic process selection
The selection strategy
Implementing strategy
Ranking: Process Cost
Summary and conclusions
 Introduction
A process
is a method of shaping, joining or
finishing a material (e.g. sand casting,
injection moulding, fusion welding &
electro-polishing).
The choice, for a given component,
design
depends
material on requireme
nts
Required
size shape precision
 Introduction
Processing has dual functions
The obvious one is that of shaping,
joining and finishing
The less obvious one is that of property
control.
Process selection
Finding the best match between
process attributes and design
requirements
The process attributes are used as criteria for selection.
Introduction

Material properties and shape limit the choice of

process.
Shape can influence the choice of process
Slender shapes can be made easily by rolling or drawing
but not by casting
Hollow shapes cannot be made by forging, but they can
by casting or moulding.
Conversely, processing affects properties.
Rolling and forging change the hardness and texture of
metals and align the inclusions they contain, enhancing
strength and ductility
Heat treatment allows manipulation of strength, ductility
and toughness.
The taxonomy of the SHAPING family
The taxonomy of the JOINING &
FINISHING family
THE PROCESSESS: SHAPING

Deformati
Casting Moulding
on
processes processes
processes
Powder Rapid
Composit
processin prototypin
e forming
g g

Machining
operations
THE PROCESSESS: SHAPING - Casting

a) Casting
In casting, a liquid is poured or forced into a
mould where it solidifies by cooling.
It fills and mould by flow under its own weight (as
in gravity sand and investment casting) or under
a modest pressure (as in die casting and pressure
sand casting).
Sand casting are cheap; metal dies for die casting
large batches can be expensive.
The shape is designed so that the pattern and the
finished casting can be removed from the mould.
THE PROCESSESS: SHAPING - Casting

The tolerance and surface finish of a casting

vary from poor for sand casting to excellent for
precision die casting.

When metal is poured into a mould, the flow is

turbulent, trapping surface oxide and debris
within the casting, giving casting defects.

These are avoided by filling the mould from

below in such a way that flow is laminar, driven
by a vacuum or gas pressure
THE PROCESSESS: SHAPING - Casting
THE PROCESSESS: SHAPING - Moulding

b) Moulding
Adapted to material that are very viscous when
molten, particularly thermoplastics and glasses.
The hot, viscous fluid is pressured or injected into
a die under considerable pressure, where it cools
and solidifies.
The die must withstand repeated application of
pressure, temperature and the wera involved in
separating and removing the part, and therefore it
is expensive.
Moulds for thermo-forming are cheap.
THE PROCESSESS: SHAPING - Moulding

Blow molding, too, uses a gas pressure to

expend a polymer or glass blank into a
split outer die.
It is a rapid, low-cost process well suited
for mass production of cheap parts mile
milk bottles.
Polymers, such as metals, can be
extruded; virtually all rods, tubes and other
prismatic sections are made in this ways.
THE PROCESSESS: SHAPING - Moulding
THE PROCESSESS: SHAPING Deformation processing

c) Deformation processing
The process can be hot, warm or cold
Cold, relative to the melting point Tm of the material being
processed

Extrusion, hot forging and hot rolling (T>0.55 T m) have

much in common with molding, though the material is
a true solid, not a viscous liquid.

The high temp. lowers the yield strength and allows

simultaneous crystallization, both of which lower
forming pressures
THE PROCESSESS: SHAPING Deformation processing

Warm working (0.35 Tm < T < 0.55 Tm) allows recovery but not
recrystallization.

Cold forging, rolling and drawing (Tm < 0.35 Tm) exploit work
hardening to increase the strength of final product, but at the penalty
of higher forming pressures.

Forged parts are designed to avoid suden changes in the thickness and sharp
radii of curvature since both require large local strain that can cause the
material to tear or to fold back on itself (tapping).

Hot forging of metals allows larger changes of shapes but generally

gives a poor surface and tolerence because of oxidation and warpage.

Cold forging gives greater precision and finish, but forging pressures are
higher and the deformations are limited by work hardening.
THE PROCESSESS: SHAPING Deformation processing

In forging, a slug of metal is shaped between two dies held

in the jaws of a press.
In rolling, a billet or bar is reduced in section by compressive
deformation between the rolls.
THE PROCESSESS: SHAPING Deformation processing

In extrusion, metal is forced to flow through a die aperture

to give a continuous prismatic shape. All three processes can
be hot (T > 0.85 Tm), warm (0.55 Tm > T > 0.85 Tm), or cold
(T < 0.35 Tm) .
In spinning, a spinning disc of ductile metal is shaped over a
wooden pattern by repeated sweeps of the smooth, rounded
tool.
THE PROCESSESS: SHAPING Powder methods

d) Powder methods
This method can create the shape by pressing and
sintering fine particles of the material.

The powder can be cold-pressed and then sintered

(heated at up to 0.8 Tm to give diffusion bonding);
It can be presses in a heated die (die pressing); or
contained in a thin preform,
It can be heated under a hydrostatic pressure (hot
isostatic pressing or HIP)
THE PROCESSESS: SHAPING Powder methods

Powder processing is most widely used for small

metallic parts like gears and bearings for cars
appliances.

Advantages;
It is economic in its use of material
It allows parts to be fabricated from materials that
cannot be cast, deformed, or machined; and
It can give a product that requires little or no finishing.
THE PROCESSESS: SHAPING Powder
methods

In die-pressing and sintering, powders are compacted in a

die, often with a binder, and the green product(s) compact is
then fired to give a more less dense product(s).
In hot isostatic pressing, powder in a thin, shaped shell or
preform is heated and compressed by an external gas
pressure..
THE PROCESSESS: SHAPING Powder
methods

In powder injection molding, powders and binder are

forced into a die to give a green blank that is then fired.
In slip casting, a water-based powder slurry is poured into a
porous plaster mold that absorbs the water, leaving a powder
shell that is subsequently fired.
 Ceramics, difficult to cast and impossible to deform, are
routinely shaped by powder methods.

In a slip casting, a water-based slurry is poured into a

plaster mould. The mould wall absorbs water, leaving a
semi-dry skin of slurry over its inner wall. The remaining
liquid is drained out, and the dried slurry shell is fired to
give a ceramic body.

In powder injection moulding, ( the way spark plug

insulators are made) a ceramic powder in a polymer
binder is moulded in a conventional way; the moulded
part is fired, burning the binder and sintering the powder.
THE PROCESSESS: SHAPING Composite forming

e) Composite forming methods

The figure shows the polymer-matrix composites reinforced with
continuous or chopped fibers.

Large compounds are fabricated by filament winding or by laying up pre-

impregnated mats of carbon, glass or Kevlar fiber (pre-preg) to the
required thickness, pressing and curing.

Parts of the process can be automated, but it remains a slow

manufacturing route; and, if components is a critical one, extensive
ultrasonic testing may be necessary to confirm its integrity.

Higher integrity is given by vacuum-bag or pressure-bag molding, which

squeezes bubbles out of the matrix before it polymerizes. Lay up
methods are the best suited to a small number of high-performance,
tailor made components.
THE PROCESSESS: SHAPING Composite
forming

In filament winding, fibers of glass, Kevlar, or carbon are

wound onto a former and impregnated with a resin-hardener
mix.
In roll and spray lay-up, fiber reinforcement is laid up in a
mould onto which the resin-hardener mix is rolled or sprayed.
THE PROCESSESS: SHAPING Composite
forming

In vacuum-bag and pressure-bag, laid-up fiber

reinforcement impregnated with resin-hardener mix, is
compressed and heated to cause polymerization.
In pultrusion, fibers are fed through a resin bath into a
heated die to form continuous prismatic sections.
THE PROCESSESS: SHAPING Rapid prototyping System (RPS)

f) Rapid Prototyping System (RPS)

Allow single examples of complex shapes to be made from
numerical data generated by CAD solid modeling software.

The motive may be that of visualisation: The aesthetics of

an object may be evident only when reviewed as a
prototype.

All RPSs can create shapes of great complexity with

internal cavities, overhangs, and transverse features,
though the precision, at present, is limited to + 0.3 mm at
the best.
THE PROCESSESS: SHAPING Rapid prototyping System (RPS)

In deposition modeling and ballistic particle

manufacture (BPM), a solid body is created by the layer-by-
layer deposition of polymer droplets.
In stereo-lithography (SLA), a solid shape is created layer-
by-layer by laser-induced polymerization of a resin.
THE PROCESSESS: SHAPING Rapid prototyping System (RPS)

In direct mold modeling, a sand mold is built up layer-by-

layer by selective spraying of a binder from a scanning print-
head..
In laminated object manufacture (LOM), a solid body is
created from layers of paper, cut by a scanning laser beam
and bonded with a heat-sensitive polymer.
THE PROCESSESS: SHAPING Machining operation

g) Machining operation
Almost all engineering components, whether
made of metal, polymer or ceramic, are subjected
to some kind of machining during manufacture.

Metals differ greatly in their machinability, a

measure of ease of chip formation, the ability to
give a smooth surface and the ability to give
economical tool life (evaluated in a standard test).

Poor machinability means higher cost.

THE PROCESSESS: SHAPING Machining
operation

Most polymers are molded into a final shape. When

necessary they can be machined but their low moduli
mean that they deflect elastically during the machining
operation, limiting tolerance.

Ceramics and glasses can be ground and lapped to high

tolerance and finish (think of the mirrors of telescopes).

There are many special machining techniques with

particular applications including; electro-discharge
machining (EDM), ultrasonic cutting, chemical milling and
cutting by water and sand jets and electron and laser
beams.
THE PROCESSESS: SHAPING Machining operation

In turning and milling, the sharp, hardened tip of a tool

cuts a chip from the work piece surface.
In drawing, blanking and stretching, sheet is shaped and
cut to give flat and dished shapes.
THE PROCESSESS: SHAPING Machining operation

In electro-charge machining, electric discharge between a

graphite electrode and the work piece, submerged in a
dielectric such as paraffin, erodes the work piece to the
desired shape.
In water-jet cutting, an abrasive entrained in a high-speed
water-jet erodes the material in its path.
THE PROCESSESS: SHAPING Machining
operation

Machining is often a secondary operation

applied to castings, moldings, or powder
products to increase finish and tolerance.

Higher finish and tolerance mean higher

cost.
Any questions..???