INDUSTRIAL MATERIALS AND PROCESSES
IE 2A1
SHAPING PROCESSES
Solidification Processes & Particulate Processing
Written Output
Group 1
ABUCAY, MA. ELINA
DUNGOG, CYBEL
PABULAR, GISELLE ANN
TAMPUS, LAUREN GIE
TESALUNA STACY KATE
July 30, 2019
SHAPING PROCESSES
-apply mechanical force or heat or other forms and combinations of energy to effect
a change in geometry of the work material.
Four categories of Shaping Operations
-Solidification Processes
-Particulate Processing
-Deformation processes
-Material Removal
SOLIDIFICATION PROCESSES
-The starting material is heated to liquid or semi fluid that cools and solidifies to
form the part geometry
-Nearly all materials can be processed this way if it has relatively low melting point,
such as polymers, metals and glass ceramics
-The molted material is forced or poured into a mold to form the required shape
-Processes under this category include;
Casting (for metals)
Molding (for plastics )
Glassworking.
GLASSWORKING
-Refers collectively to a wide range of techniques and artistic styles that use glass as the
primary medium.
-In glassworking, the starting material is silica. This is heated to transform it from solid into
a viscous liquid; it is the shaped into the desired geometry while in this fluid condition
When cooled and hard, the material remains in the glassy state rather than
crystallizing
The typical process sequence;
(1.) preparation of raw materials and melting
(2.) shaping
(3.) heat treatment
CASTING
is a manufacturing process generally used for mass production in which materials in a
molten state are poured into a mold where they solidify
-Casting materials are metals or various cold setting materials that cure after mixing two
or more components together
-most often used for making complex shapes that would be otherwise difficult or
uneconomical to make by other methods
*Pattern
-in casting, pattern is a replica of the object to be cast, used to prepare the cavity into
which molten material will be poured during the casting process
(insert pics of patterns-to be explained further)
Casting can be divided into two basic categories:
1. Expendable-mold processes
a. A generic classification that includes sand, plastic, shell, plaster, and investment
(lost-wax technique) moldings.
b. This method of mold casting involves the use of temporary, non-reusable molds.
2. Non-expendable-mold processes
a. In metalworking, casting means a process, in which liquid metal is poured into
a mold that contains a hollow cavity of the desired shape, and then allowed to cool
and solidify.
b. Differs from expendable processes in that the mold need not be reformed after
each production cycle.
Types of Casting
-Sand Casting
-Die Casting
-Shell mold casting
-Permanent mold casting
-Investment casting (lost wax casting)
-Lost-foam casting
-Centrifugal Casting
Sand Casting
Most widely used casting process utilizes expandable solid molds to form complex metal
parts that can be made nearly any alloy
Die casting
A manufacturing process that can produce geometrically complex metal parts through the
use of reusable molds called die
Shell holding casting
Shell molding techniques is used for making thin sections and for acquiring surface finish
and dimensional accuracy
Permanent mold casting
A metal mold that is typically made from steel/cast iron and can be reused for several
thousand cycles
Investment casting
One of the oldest manufacturing processes. In which molten metal is poured into an
expandable ceramic mold by using a wax pattern.
Lost foaming casting
The pattern evaporates when the metal is poured into the mold
Centrifugal Casting
It is typically used to cast thin-walled cylinders
ADVANTAGES AND DISADVANTAGES OF EACH TYPE OF CASTING
Types of Casting Advantages Disadvantages
Low cooling and equipment cost Poor material strength
Sand Casting Can produce very large parts Poor surface finish and
Can form complex shapes tolerance
Easy availability of raw material
High production rate Trimming is required
Die Casting Very good surface finish and
accuracy
Low labor cost High equipment cost
Shell mold casting Low tooling cost
High production rate
Permanent mold Low labor cost High tooling cost
casting Reducing manufacturing
expenditure
Scrap can be recycled
-Investment casting Many material option High labor cost
(lost wax casting) Little need for secondary Time consuming
machining process
Lost-foam casting Dimensionally accurate Patterns cost can be
Maintains excellent surface finish high for low volume
and can easily be
damaged due to low
strength
Centrifugal Casting Good mechanical properties Secondary machining is
often required for inner
diameter
MOLDING
-primarily used during the manufacturing process of plastics
3 Stages of molding process
Application of heat to soften the molding material
Forming to the required shape in the mold
Removal of heat
Types of molding Process
1. Compression Molding
-used for thermosetting plastics
-process is carried out in a hydraulic press with heated platens
(products-toilet seats, bottle tops, tablewares)
2. Transfer molding
- used for thermosetting plastics
-this process is suited to the production of parts incorporating small metal inserts,
and those products having variation of section thickness can be produced
(products-motor-car distributors cap and domestic electric plugs)
3. Injection Molding
-a process in which a polymer is heated to a highly plastic state which is then solidified in a
mold cavity
-for small parts, the mold can be built to contain multiple cavities, also making the mold
expensive. Thus, injection molding is economical only for large production quantities.
PARTICULATE PROCESSING
-starting raw materials are powders of metals or ceramics.
-the process includes pressing the powder into the designed die and then goes through
sintering
Sintering-the process of heating materials below its melting point to make the particle stick
together to form one piece
Ceramics Particulate Processing
Usually for traditional ceramics the powders are mixed with water which is used as a
binding agent to achieve the proper consistency for shaping before it is fired (sintered).
Advantages
-Use of automated operation with low energy consumption
-High material utilization
Disadvantages
-Health hazard to the operator due to very fine powder being processed
-Limited part size and complexity
