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Manufacturing Methods

Die Casting- 

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

Injection-

Injection moulding (injection molding in the USA) is a manufacturing process for producing parts by injecting material into a mould. Injection moulding can be performed with a host of materials, including metals, (for which the process is called diecasting), glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers. Material for the part is fed into a heated barrel, mixed, and forced into a mould cavity, where it cools and hardens to the configuration of the cavity. 

 

Steel Pressing-

Steel sheet, (a few mm thick), or steel plate, is pressed into cylinders and cones, and steel can be pressed around specific arcs to form bends or angles. 

 

Forging-

Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The blows are delivered with a hammer (often a power hammer) or a die. Forging is often classified according to the temperature at which it is performed: cold forging (a type of cold working), warm forging, or hot forging (a type of hot working). For the latter two, the metal is heated, usually in aforge. Forged parts can range in weight from less than a kilogram to hundreds of metric tons. Forging has been done by smiths for millennia. 

 

Sand Casting-

Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand as the mold material. The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. Over 70% of all metal castings are produced via sand casting process.

Sand casting is relatively cheap and sufficiently refractory even for steel foundry use. In addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is moistened, typically with water, but sometimes with other substances, to develop strength and plasticity of the clay and to make the aggregate suitable for molding. The sand is typically contained in a system of frames or mold boxes known as a flask. The mold cavities and gate system are created by compacting the sand around models, or patterns, or carved directly into the sand.

 

Gravity Casting-

Gravity casting (called Permanent Mold Casting in USA and Canada) is useful when dealing with aluminum and other light alloys. It can serve for parts with undercut by sand-core to meet the feature needs. The metal is introduced into the mold by the force of gravity so the constraint is the wall thickness, the minimum of which is 3.5mm. The mold is usually made of steel and sand (with resin core). The casted material is usually aluminum.BenefitsGravity castingis cost effectiveproduces good quality componentsoffers process controlis best for creating small scale partsdoes not require a large machine to inject the metalneeds much less start up cost than die castinglends itself to more material types

Sourcing:http://www.mgprecision.com/services/gravity-casting.html 

 

Core-

A core is a device used in casting and molding processes to produce internal cavities and reentrant angles. The core is normally a disposable item that is destroyed to get it out of the piece. They are most commonly used in sand casting, but are also used in injection molding.

An intriguing example of the use of cores is in the casting of engine blocks. For example, one of the GM V-8 engines requires 5 dry-sand cores for every casting

 

Investment Casting- (Lost-Wax Casting)-

Investment casting is an industrial process based on and also called lost-wax casting, one of the oldest known metal-forming techniques. 

There are a variety of materials that can be used for the investment casting process, including stainless steel alloys, brass, aluminum, and carbon steel. The material is poured into a ceramic cavity designed to create an exact duplicate of the desired part. Investment casting can reduce the need for secondary machining by providing castings to shape.

Investment casting derives its name from the pattern being invested (surrounded) with a refractory material. The fragile wax patterns must withstand forces encountered during the mold making. Much of the wax used in investment casting can be reclaimed and reused.

 

Lathe-

A lathe /ˈleɪð/ is a machine tool that rotates the workpiece on its axis to perform various operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning, with tools that are applied to the workpiece to create an object with symmetry about an axis of rotation.

 

Extrusion- 

Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed through a die (a certain manufacturing tool) of the desired cross-section. The two main advantages of this process over other manufacturing processes are its ability to create very complex cross-sections, and to work materials that are brittle, because the material only encounters compressive and shear stresses. It also forms parts with an excellent surface finish.

 

(Sourcing: https://en.wikipedia.org/wiki/)

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