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Lec A01

Good ferrous metallurgy lecture

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111 views14 pages

Lec A01

Good ferrous metallurgy lecture

Uploaded by

utsho das
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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MME 345

Foundry Engineering
July 2018 Term

MME 345
Lecture A:01

Introduction
1. Materials processing technology
Ref: M.F. Ashby, Materials Selection and Alloy Design, Elsevier, 2011
Ch 13: Process and Process Selection
Topics to discuss today ….

1. Introduction
2. Classification of process
3. Selection of process

1. Introduction

 Process is a method of shaping, joining, or finishing material.


 sand casting, injection molding, fusion welding, and electro-polishing
are all processes;
 there are hundreds of them.

 The choice of a process, for a given component depends on


the design requirements i.e.
 the material of which it is to be made;
 its size, shape, and required precision; and
 how many are to be made

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 Processing has dual functions:
 The obvious one is that of shaping, joining, and finishing.
 The less obvious one is that of property control.
 metals are strengthened by rolling and forging
 steels are heat-treated to enhance hardness and toughness
 polymers are drawn to increase modulus and strength
 ceramics are hot-pressed, again to increase strength

5/28

2. Classification of process
 Primary shaping processes - create shapes
casting
moulding
deformation process
powder methods
methods for forming composites
special methods (e.g., rapid prototyping)

 Secondary processes - modify shapes or properties


machining (which adds features to an already shaped body)
heat treatment (which enhances surface or bulk properties)

 Below these come joining and surface treatment or finishing

6/28
FIGURE 1.1 The classes of process. 7/28

FIGURE 1.2
The taxonomy of the kingdom of process with part of the shaping family expanded. Each member
is characterized by a set of attributes. Process selection involves matching these to the requirements
of the design.
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FIGURE 1.3
The taxonomy of the process kingdom again, with the families of joining and finishing partly expanded.

9/28

FIGURE 1.4 Casting process 10/28


FIGURE 1.5 Moulding process 11/28

FIGURE 1.6 Deformation process 12/28


FIGURE 1.7 Powder process 13/28

FIGURE 1.8 Composite forming methods 14/28


FIGURE 1.9 Rapid prototyping 15/28

FIGURE 1.10 Machining operations 16/28


FIGURE 1.11 Joining operations 17/28

FIGURE 1.12 Finishing processes to protect and enhance properties. 18/28


FIGURE 1.13 Finishing processes to enhance appearance. 19/28

3. Selection of process

 A process has certain attributes;


they describe the things the process can do.
they can be thought of as the "properties" of a process, just as the material attributes
of strength, ductility, conductivity and so on are the properties of a material.

 The common process attributes are: size, shape, complexity,


precision, surface roughness, etc. (Table 1.1).

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Table 1.1 Attributes of processes.

Process attributes Definition

Materials class Material to be processed, characterised by melting point Tm and hardness H.

Size Minimum and maximum overall size, measured by volume V or weight W.

Shape Aspect ratio, web thickness-to-depth ratio; surface-to-volume ratio.

Complexity Information content, symmetry, etc.


Tolerance Dimensional accuracy or precision T.

Roughness Surface finish measured by RMS surface roughness R.

Surface details Smallest radius of curvature at corner.

Minimum batch size Minimum number of components to be made.

Production rate Time to produce one component; cycle time.


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Cost Cost per component.

 A design for a component or assembly calls for a certain


profile of these attributes, not for a process per se;
any process which meets the profile will do.

 The problem, then, is that of matching the attribute profiles


of available processes to that specified by the design.

 The correct process selection involves finding the best match


between process attributes and design requirements.
 This depends on how material, shape and processing interact with
each other (Fig. 1.14).

22/28
FIGURE 1.14
Processing selection depends on materials and shape.
The “process attributes” are used as criteria for selection.
23/28

Examples of Material - Shape - Property - Process Interaction

Rolling
Ductile Brittle
Forging
materials materials
Extrusion
MATERIALS
Low melting-point materials Casting process
High melting-point materials Powder process

Deformation processes Slender shape Casting processes


SHAPE
Deformation processes Hollow shape Casting processes

High precision Machining


PROPERTIES Directional properties Deformation processes (rolling, etc.)
Anisotropic properties Casting
24/28
Examples of Process - Property Interaction

FIGURE 1.15 Enhancement of properties using different processes.

25/28

FIGURE 1.16 The process-material matrix. A colored dot indicates that the pair are compatible.
26/28
FIGURE 1.17 The process-shape matrix. 27/28

Next Class
MME 345, Lecture A:02

Introduction
2. Casting as a metal forming process

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