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