The CES EduPackThe CES EduPack

© MFA 2009

Izbor postupaka:oblikovanje, spajanje i površinska obrada

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Sadržaj

• Tehnološki postupci i njihova svojstva

• Pretraga po svojstvima

• Izbor postupaka za oblikovanje proizvoda

• Izbor postupka za spajanje

• Izbor postupka toplinske obrade

• Vježbe

Više informacija:• “Materials: engineering, science, processing and design”, Poglavlja 18 i 19

• “Materials Selection in Mechanical Design”, Poglavlja 7 i 8

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Proizvodni postupci

SpajanjeZavarivanjeLijepljenjeRastavljivii nerastavljivispojevi

Zavarivanje

PrimarnooblikovanjeLijevanjePrešanjeMetalurgijapraha

Heater Screw

Granular PolymerMould

Nozzle

Cylinder

No.8-CMYK-5/01Injekcijsko prešanje

SekundarnooblikovanjeStrojna obradaBušenjeRezanje

Strojna obrada

PovršinskaobradaBojanjePoliranjeToplinskaobrada

Bojanje

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Svaka grupa ima različite atribute.

Grupa

Spajanje

Oblikovanje

Površinskaobrada

Organizacija podataka: Podjela postupaka

Baza

“ProcessUniverse”

Vrsta

LijevanjeDeformiranje

Prešanjepolimera

Oblikovanje

kompozita

Metalurgija praha

Brza izrada prototipa

Član

Tlačno

Rotacijsko

Injekcijsko

RTM (prešanje tekuće smole)

Puhanje

Atributi

Zapisi o postupcima

RTMMaterialShapeSize RangeMin. sectionToleranceRoughnessEconomic batchDocumentation-- specific-- general

RTMMaterialShapeSize RangeMin. sectionToleranceRoughnessEconomic batchDocumentation-- specific-- general

PuhanjeMaterialShapeSize RangeMin. sectionToleranceRoughnessEconomic batchDocumentation-- specific-- general

PuhanjeMaterialShapeSize RangeMin. sectionToleranceRoughnessEconomic batchDocumentation-- specific-- general

Injekcijsko preš.MaterijalOblikOpseg veličinaMin. presjekTolerancijaHrapavostIsplativa vel. serijeDokumentacija-- specifična-- opća

Injekcijsko preš.MaterijalOblikOpseg veličinaMin. presjekTolerancijaHrapavostIsplativa vel. serijeDokumentacija-- specifična-- opća

Teško !

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Klasifikacija oblika

Vučenje žice, ekstrudiranje, valjanje,

profiliranje:oblici prizme

Lijevanje,prešanje,

metalurgija praha:3-D oblici

Utiskivanje,savijanje,

duboko vučenje:oblici ploha

Nekim postupcima mogu se dobiti samo jednostavni oblici, a nekima i složeni:

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Strukturirani podaci za injekcijsko prešanje*

INJECTION MOULDING of thermoplastics is the equivalent of pressure die casting of metals. Molten polymer is injected under high pressure into a cold steel mould. The polymer solidifies under pressure and the moulding is then ejected.

Injekcijsko prešanje (plastomeri)

*Dobiveni pomoću CES EduPack Level 2 DB

Process characteristicsDiscrete TruePrototyping False

Economic AttributesEconomic batch size 1e+004 - 1e+006Relative tooling cost highRelative equipment cost high

+ links to materials

ShapeCircular Prism TrueNon-circular Prism TrueSolid 3-D TrueHollow 3-D True

Physical attributesMass range 0.01- 25 kgRoughness 0.2 - 1.6 µmSection thickness 0.4 - 6.3 mmTolerance 0.1 - 1 mm

Cost modelingRelative cost index fxfx

Typical usesInjection molding is used ……….

(isplativost uvijek važna)

Ključni uvjeti pri izboru postupka oblikovanja

7

Nestrukturirani podaci za injekcijsko prešanje*

Design guidelines. Injection moulding is the best way to mass-produce small, precise, plastic parts with complex shapes. The surface finish is good; texture and pattern can be moulded in, and fine detail reproduces well. The only finishing operation is the removal of the sprue.

The economics. Capital cost are medium to high; tooling costs are high, making injection moulding economic only for large batch-sizes (typically 5000 to 1 million). Production rate can be high particularly for small mouldings. Multi-cavity moulds are often used. The process is used almost exclusively for large volume production. Prototype mouldings can be made using cheaper single cavity moulds of cheaper materials. Quality can be high but may be traded off against production rate. Process may also be used with thermosets and rubbers.

Typical uses. The applications, of great variety, include: housings, containers, covers, knobs, tool handles, plumbing fittings, lenses, etc.

The environment. Thermoplastic sprues can be recycled. Extraction may be required for volatile fumes. Significant dust exposures may occur in the formulation of the resins. Thermostatic controller malfunctions can be extremely hazardous.

The process. Most small, complex plastic parts you pick up – children’s toys, CD cases, telephones – are injection moulded. Injection moulding of thermoplastics is the equivalent of pressure die casting of metals. Molten polymer is injected under high pressure into a cold steel mould. The polymer solidifies under pressure and the moulding is then ejected.

Various types of injection moulding machines exist, but the most common in use today is the reciprocating screw machine, shown schematically here. Polymer granules are fed into a spiral press like a heated meat-mincer where they mix and soften to a putty-like goo that can be forced through one or more feed-channels (“sprues”) into the die.

Heater Screw

Granular PolymerMould

Nozzle

Cylinder

No.8-CMYK-5/01

*Dobiveni pomoću CES EduPack Level 2 DB

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VrstaCasting

DeformationMolding

Composite

Powder

Rapid prototype

Član

CompressionRotationInjectionRTMBlow

Joining

Shaping

Surface treatment

ProcessUniverse

+++

Process UniverseProcess Universe

Edu Level 2Edu Level 2

Tablica:

Podskup:

Browse SelectSearch Alatna traka

Print Search web

File Edit View Select Tools Window Help Feature request

Pronalaženje informacija pomoću CES-a

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Joining

Shaping

Surface treatment

ProcessUniverse

+++

Process UniverseProcess Universe

Edu Level 2Edu Level 2

Tablica:

Podskup:

Browse SelectSearch Alatna traka

Print Search web

File Edit View Select Tools Window Help Feature request

Pronalaženje informacija pomoću CES-a

VrstaCasting

DeformationMolding

Composite

Powder

Rapid prototype

Član

CompressionRotationInjectionRTMBlow

Injection molding The process No other process has changed product design more than INJECTION MOLDING. Injection molded products appear in every sector of product design: consumer products, business, industrial, computers, communication, medical and research products, toys, cosmetic packaging and sports equipment. The most common equipment for molding thermoplastics is the reciprocating screw machine, shown schematically in the figure. Thermoplastics, thermosets and elastomers can all be injection molded. Co-injection allows molding of components with different materials, colors and features... Shape Circular prismatic True Non-circular prismatic True Solid 3-D True Hollow 3-D True Physical attributes Mass range 0.001 - 25 kg Range of section thickness 0.4 - 6.3 mm Surface roughness (A=v. smooth) A Tolerance 0.07 - 1 mm Economic attributes Relative tooling cost very high Relative equipment cost high Labor intensity low Economic batch size (units) 1e4 - 1e6 Typical uses Extremely varied. Housings, containers, covers, knobs, tool handles, plumbing fittings, lenses, etc.

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Browse SelectSearch Alatna traka

Print Search web

File Edit View Select Tools Window Help Feature request

Resin transfer molding (RTM) The process RESIN TRANSFER MOLDING (RTM) allows manufacture of complex shapes in fiber-reinforced composites without high tooling costs. It uses a closed mold, in two or more parts, usually made of glass-reinforced polymers or light metal alloys, with injection points and vents to allow air to escape. Reinforcement is cut to shape and placed in the mold, together with any inserts or fittings. The mold is closed and a low viscosity thermosetting resin (usually polyester) is injected under low pressure (roughly 2MPa) through a mixing head in which hardener is blended with the resin. Shape Circular prismatic True Non-circular prismatic True Flat sheet True Dished sheet True Solid 3-D True Hollow 3-D True Physical attributes Mass range 0.8 - 50 kg Range of section thickness 2 - 6 mm Tolerance 0.25 - 1 mm Roughness * 0.25 - 1.6 µm Surface roughness (A=v. smooth) A Economic attributes Relative tooling cost high Relative equipment cost medium Labor intensity high Economic batch size (units) 1000 - 1e6 Typical uses RTM is used to make large composite structures such as manhole covers, compress soil casings, car doors and side panels, propeller blades, boat building, hulls, canoe paddles, water tanks, bath tubs, roof sections, airplane escape doors.

Pronalaženje informacija pomoću CES-a

Find whatLook in table Processes

RTM

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Organizacija podataka: postupci spajanja

Gas weldingMaterialJoint geometrySize RangeSection thicknessRelative cost ...Documentation

Gas weldingMaterialJoint geometrySize RangeSection thicknessRelative cost ...Documentation

Gas weldingMaterialJoint geometrySize RangeSection thicknessRelative cost ...Documentation

Gas weldingMaterialJoint geometrySize RangeSection thicknessRelative cost ...Documentation

Plinsko zavarivanjeMaterijalGeometrija spojaRaspon veličinaVeličina presjekaRelativan trošak ...Dokumentacija

Plinsko zavarivanjeMaterijalGeometrija spojaRaspon veličinaVeličina presjekaRelativan trošak ...Dokumentacija

Atributi

Lijepljenje

Zavarivanje

Spajanje

Lemljenje

Plinsko zavarivanje

Elektrolučno

E - mlazom ...

Vrsta ČlanGrupaBaza

Površinskaobrada

Spajanje

OblikovanjePostupci

Preklopno

Sučeono

T-spoj

Geometrijaspoja

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Zapis postupka spajanja*

Gas Tungsten Arc (TIG)Tungsten inert-gas (TIG) welding, the third of the Big Three (the others are MMA and MIG) is the cleanest and most precise, but also the most expensive. In one regard it is very like MIG welding: an arc is struck between a non-consumable tungsten electrode and the work piece, shielded by inert gas (argon, helium, carbondioxide) to protect the molten metal from contamination. But, inthis case, the tungsten electrode is not consumed because of itsextremely high melting temperature. Filler material is supplied separately as wire or rod. TIG welding works well with thin sheet and can be used manually, but is easily automated.

Physical AttributesComponent size non-restrictedWatertight/airtight TrueDemountable FalseSection thickness 0.7 - 8 mm

Economic AttributesRelative tooling cost lowRelative equipment cost mediumLabor intensity low

Typical usesTIG welding is used ……….

*Dobiven pomoću CES EduPack Level 1 DB

+ links to materials

Joint geometryLap TrueButt TrueSleeve TrueScarf TrueTee True

Materials Ferrous metals

Ključni uvjeti pri izboru postupka spajanjaDocumentation

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Organizacija podataka: Površinska obrada

GrupaBaza

Površinskaobrada

Spajanje

Obliko-vanje

“ProcessUniverse”

Vrsta

Toplinska o.

Bojanje/tisak

Prevlačenje

Poliranje

Teksturiranje ...

Član

Elektropla-tiranje

Anodizacija

Prahom

Metalizacija...

Atributi

Zapisi o postupcima

AnodizeMaterialWhy treatment?Coating thicknessSurface hardnessRelative cost ...Documentation

AnodizeMaterialWhy treatment?Coating thicknessSurface hardnessRelative cost ...Documentation

AnodizeMaterialWhy treatment?Coating thicknessSurface hardnessRelative cost ...Documentation

AnodizeMaterialWhy treatment?Coating thicknessSurface hardnessRelative cost ...Documentation

AnodizacijaMaterijalFunkcija postupkaDebljina prevlakeTvrdoća prevlakeRelativan trošak ...Dokumentacija

AnodizacijaMaterijalFunkcija postupkaDebljina prevlakeTvrdoća prevlakeRelativan trošak ...Dokumentacija

Toplinska izolacija Električna izolacija Boja Tekstura Dekoracija …

Povećana tvrdoća Otpornost na trošenje Otpornost na umor Otpornost na koroziju Otpornost na oksidaciju

Funkcijapostupka

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Zapis o postupku površinske obrade*

Induction and flame hardeningTake a medium or high carbon steel -- cheap, easily formed and machined -- and flash its surface temperature up into the austenitic phase-region, from which it is rapidly cooled from a gas or liquid jet, giving a martensitic surface layer. The result is a tough body with a hard, wear and fatigue resistant, surface skin. Both processes allow the surface of carbon steels to be hardened with minimum distortion or oxidation. In induction hardening, a high frequency (up to 50kHz) electromagnetic field induces eddy-currents in the surface of the work-piece, locally heating it; the depth of hardening depends on thefrequency. In flame hardening, heat is applied instead by high-temperature gas burners, followed, as before, by rapid cooling.

Economic AttributesRelative tooling cost lowRelative equipment cost mediumLabor intensity low

*Dobiven pomoću CES EduPack Level 2 DB

+ links to materials

Ključni uvjeti pri izboru postupka površinske obrade

Physical AttributesCurved surface coverage Very goodCoating thickness 300 - 3e+003 µmProcessing temperature 727 - 794 KSurface hardness 420 - 720 Vickers

Typical usesInduction hardening is used …..

Function of treatmentFatigue resistanceFriction controlWear resistanceHardness

Documentation

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Sažetak

• Struktura stabla omogućava lako pretraživanje podataka o postupcima

• Izbor se vrši prvo preko primarnih zahtjeva:

• Oblikovanje: materijal, oblik i veličina serije

• Spajanje: materijal(i) i geometrija spoja

• Površinska obrada: materijal i funkcija postupka

• Zatim se dodaju sekundarni zahtjevi prema potrebi.

Dokumentacija u CES-u, i na http://matdata.net

• Procesi mogu biti razgranato organizirani i sadržavati zapise za strukturirane podatke i dodatne informacije

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Vježbe: Pregledavanje postupaka

7.1 Nađite grananjem, the Level 2 zapis za postupak oblikovanja Resin transfer molding (RTM) pod “Shaping: Composite forming”. Koji se proizvodi mogu tipično ovako izraditi?

7.2 Nađite na Level 2 zapis za postupak spajanja Abrasive jet machining and cutting pod“Shaping: Machining: non-conventional machining”. Može li se ovim postupkom rezati staklo?

7.3 Nađite na Level 2 zapis za postupak spajanja Friction-stir welding (hrv. Pomično zavarivanje trenjem) pod “Joining: Mechanical welding”.Kakvo je to spajanje?

7.4 Nađite na Level 2 zapis za postupak površinske obrade Metal flame spraying pod “Surface treatment: Surface coating”.Koje su glavne primjene?

Browse Search

Joining

Shaping

Surface treatment

ProcessUniverse

+++

ProcessUniverseProcessUniverse

Edu Level 2Edu Level 2

Select

Table:

Subset:

Browse Search

Joining

Shaping

Surface treatment

ProcessUniverse

+++

ProcessUniverseProcessUniverse

Edu Level 2Edu Level 2

Select

Table:

Subset:

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Vježbe: Traženje postupaka

7.5 Nađite, pretraživanjem, zapis za postupak brze izrade modela poznatim pod trgovačkim nazivom name SLS. Kod kojih se skupina materijala može primijeniti?

7.7 Nađite, pretraživanjem, zapis za Vitreous enameling. Koja površinska svojstva možemo postići ovim postupkom ?

7.6 Nađite, pretraživanjem, zapis za Flexible adhesives. Koji se polimeri koriste kao fleksibilni adhezivi?

Find what:Look in table:

SLSProcessUniverse

Search Browse Select

Find what:Look in table:

SLSProcessUniverse

Find what:Look in table:

SLSProcessUniverse

Search Browse SelectSearch Browse Select