manufacturing-processes

[manufacturing-processes]

Metals can be classified in many ways. But one of the common and most used classification is a ferrous metal and non-ferrous metal. Now the question comes: What are ferrous and non-ferrous metals? What is the difference between ferrous and non-ferrous metals?

Well, today we will take a look at the answer.

Before we cover the difference between ferrous and non-ferrous metal let’s take a quick tour about both terminologies.

Ferrous metal

When metal contains iron in a huge portion than it’s considered as ferrous metal. Normally in ferrous metal iron is at least the second or third highest prolific composite. If any metal has less amount of iron than it’s not announced as ferrous metal.

Non-ferrous metal

When metal does not have a significant amount of iron in it’s composite then it’s defined as non-ferrous metal.

Now let’s jump to the difference between ferrous and non-ferrous metal.

The Difference between Ferrous and Non-Ferrous Metals 

As explained earlier in the article the simple answer is that ferrous metals contain iron while non-ferrous metals do not.

Ferrous metals came into existence around 1200BC when iron production became more common in the Iron Age. 

Commonly used ferrous metals include:

Alloy steels

Carbon steel

Cast iron

Stainless steel

Wrought iron

Mild steel

These metals possess tensile strength and durability but are also vulnerable to rust though there are two exceptions: wrought iron and stainless steel. Most ferrous metals are also magnetic making them useful in motor and electrical appliances. 

Ferrous metal has more hardness compare to non-ferrous metal.

Be careful when it comes to stainless steels some people will mistake it for a non-ferrous metal because of its corrosion resistance. But it actually is a ferrous metal.

Applications of Ferrous metal

Carbon steel – in manufacturing of cutting tools

Stainless steel – used to prevent the rust

Cast iron – used in cooking appliances and engines of vehicles

Mild steel – used in building, construction and general engineering purposes

Wrought iron – in manufacturing of gates and fences

Common non-ferrous metals include:

Aluminum

Copper

Lead

Zinc

Tin

Brass

Precious metals like gold and silver.

The main advantage of these over ferrous metals is malleability. No iron content also means they have a higher resistance to corrosion. Unlike ferrous, metals these non-ferrous metals are non-magnetic. This is important for electronic and wiring applications.

Applications of Non-ferrous metal

Aluminum – used in food packaging, power lines, appliances and vehicles

Lead – used in paints, fuels, pipes, and batteries

Copper – used in wiring applications due to the ability of heat and electricity conductor

Silver – used in mirrors, jewelry making, cutlery, etc.

Brass – manufacturing of jigs and fixtures. Also used in screws and bolt manufacturing.

Gold – used in jewelry. 

References:

https://www.asm-recycling.co.uk/ferrous-and-non-ferrous-metals/

https://www.quora.com/What-is-the-difference-between-ferrous-and-non-ferrous-metal

https://www.metalsupermarkets.com/what-is-a-ferrous-metal/

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Many projects need a metal that has holes in it whether it is for traction, ventilation, to let air or liquids pass through or even just for decorative purposes. For these projects, the most useful material to use is often Expanded Metal, Perforated Sheet, or Wire Mesh.

But do you know the difference between these metal types? If not, this article will help you.

Basically, the main three differences in Expanded Metal, Perforated Sheet and Wire Mesh are due to:

·        Their manufacturing process

·        Their characteristics

·        Their end-uses

Let’s start 🙂.

Expanded Metal

Expanded Metal is made by creating multiple slits in a metal coil then stretching the sheet and cutting it to length. This expands the slits resulting in a repeating diamond-like shape throughout the sheet.

This process allows a single sheet to be expanded to a greater length while not wasting any material Also the pattern actually can add structural strength to the finished sheet.

Expanded Metal is typically used for steps, flooring in factories and construction rigging, fences and various other security applications.

Perforated sheet

A perforated sheet is made using a process that punches holes through a metal sheet in a repeating pattern. Typically, the perimeter of the sheet is not perforated helping to maintain structural stability.

A benefit of perforated sheet is the customization available as there are numerous combinations of patterns, hole sizes and hole shapes available. However, unlike Expanded Metal, the holes created mean there is material wasted.

Perforated Sheet is used in a wide variety of applications, including screens, light fixtures, vents, audio speaker covers, patio furniture and more.

Wire Mesh

Wire Mesh is quite different from Expanded and Perforated Sheet. Essentially it is made of rows of parallel and perpendicular metal wire positioned with a specific spacing.

There are two ways in which the Wire Mesh can be connected:

Welded or Woven.

With Welded Wire Mesh, the rows of the parallel wires are laid over the top of the perpendicular rows and a machine is used to weld each connection between the rows. You can see the small weld over every connection of welded wire Mesh.

Woven Wire Mesh is structured similarly to cloth. One direction of the parallel wires is woven over and under the perpendicular rows which produces a stable sheet.

Welded Wire Mesh is typically used in agricultural and industrial applications, while Woven Wire Mesh can be used for screening machinery, architectural framework, and more.

References:

https://en.wikipedia.org/wiki/Expanded_metal

https://en.wikipedia.org/wiki/Perforated_metal

https://www.metalsupermarkets.com/difference-between-perforated-metal-expanded-metal-and-wire-mesh/

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The mechanical property of metal is highly depended on its chemical composition. In the industry, we are dealing with a wide range of materials in a verity of applications. In some cases, we need to alter the present chemical composition of metal to fulfill the specific requirements.

Here the heat treatment process comes in the game. Industry using different types of heat treatment processes like annealing, normalizing, hardening, quenching, etc. Although all have their own advantages.

But hardening is most commonly using the heat treatment process in industries.

Hardening heat treatment process

Metal is always defected due to wear and tear. So metal pass through the heat treatment process to make them suitable for their applications.

Basically, hardening is the combined process of heating and cooling, which includes heating, soaking and cooling the metal.

“According to American society of martial testing in hardening heat treatment process steel is heated at 20 degree C above the transformation range (temperature range in which austenite forms when a ferrous metal is heated and disappears when the metal is cooled), soaking at this temperature for an appropriate time to get the desired temperature inside the component and finally cooling to room temperature by quenching in oil, brine solution or water.”

Heating is applied 20 ºC above the upper critical temperature of steel for hypo-eutectoid steel and 20 ºC below the hyper-eutectoid steel. ( hypo-eutectoid steel has carbon content less than 0.8% C and hyper-eutectoid steel has carbon content higher than 0.8% C).

Hypo-eutectoid steel contains ferrite and pearlite while hyper-eutectoid steel contains pearlite and cementite. For more information about term ferrite, cementite, pearlite, and austenite you can read this quora answer.

Hardness produced by hardening process is depended on the percentage of carbon in steel.

It is identified by a figure that carbon content less than 0.15% does not react to the hardening process. After increasing carbon content up to 0.2% of steel greatly react to the hardening process.

The rate of cooling is another important factor which affects the hardness of the material. It is controlled by the quenching medium.  Some of the commonly used quenching medium is a solution of salt or caustic soda, high flash point oil or clean water, dry air, furnace cooling, etc.

Part which needs to apply for harness should be imported in such a position that does not defect any places. Places where bubbles are generates need to proper sealed.

Sharp corner and asymmetrical shapes require extra attention comparer to uniform and symmetrical parts.

Purpose of hardening heat treatment process

To improve the hardness of steel to resist wear

To enable steel to cut other metal

To generate the desired microstructure

To improve mechanical, magnetic, physical and electric properties.

Types of Hardening heat treatment process

Hardening processes are mainly divided into five sub-categories.

Grain boundary strengthening

Work hardening

Solid solution strengthening

Precipitation hardening

Martensitic transformation

If you want to more about types of hardening processes you can check out this link

Applications hardening heat treatment process

Machine cutting tools like drill, taps, lathe tools

Construction materials

Bearings

Armor plating and Anti-fatigue 

Knife blades

References:

https://www.dictionary.com/browse/transformation-range

https://sciencing.com/info-8737494-types-metal-hardening-processes.html

https://www.quora.com/What-is-the-difference-between-hypoeutectoid-steel-and-hypereutectoid-steel

https://en.wikipedia.org/wiki/Hardening_(metallurgy)

[manufacturing-processes]

So you are willing to know about computer-aided design, you are in the right place. Sit back and get ready! 

Here we are covering all about CAD, which you need to know!

let's start...

Computer-aided design

Computer-aided design is defined as the use of computers for the creation, modification, optimization, and analysis of different types of design and design process. Basically, CAD uses graphical symbols like point, line, plane, curve and various shape to describe any type of component in graphical manner.

CAD software increases the productivity of designer and engineer, improve quality of design, enhance understanding of complex product by 3D view and store data for manufacturing. The output of CAD software is in digital form. CAD is often referred to as CADD (computer design and drafting). Designing of the geometric model is also referred to as computer-aided geometric design (CAGD).

Nowadays CAD is used in almost every industry.

Designing task of electric system is done with the help of CAD which is known as electric design automation (EDM).

In the mechanical field, it’s known as mechanical design automation (MDA). Detail drawing and engineering drawing related work is known as computer-aided drafting (CAD).

Mechanical CAD software uses vector-based graphics or raster graphics for visualization of an object. Such software also includes a bill of material (BOM), dimensions and tolerances, auto layout, interference checking and many more. Designers can also do engineering calculations in CAD software with the use of functions and formulas. We can also say that CAD merges the role of draftsman, designers, and engineers. In short CAD revolutionary change the engineering industry.

CAD software uses point, curves, line and sketch to represent 2D geometry, and for 3D geometry uses curves, features, surfaces and solids.

CAD is an important bit of industries like automotive, aerospace, architecture and many more. CAD is also used in digital content creation (Digital content creation (DCC) includes computer animation, special effects in movies, advertising, etc.)

Use Of CAD

Before the development of CAD software, any type of prototype was done manually. Its very time consuming and costly due to trial and error strategy.  But the use of CAD in industry eliminates the necessity of prototype by advance simulation, motion study, and analysis in realistic conditions. Since it digitize the design and development process, CAD spread its legs in almost all types of industries.

CAD software is widely used in engineering-oriented industries. However, both industry-oriented and general-purpose design applications are heavily dependent on CAD.

Here we listed the major industries where CAD is essential. 

Aerospace

Architecture

Civil Engineering

Automotive

Interior design

Fashion and jewelry

Digital content creation

Types of CAD

Computer-aided design uses computers to create design and development. CAD was first introduced in the 1960s. With time CAD grows smartly and now we have various types of CAD in industries.

2D CAD

2.5 D CAD

3D CAD

3D Wireframe and Surface Modeling

Solid Modeling

Freeform modeling

Advantages of CAD

In the present time, the world is fairly dependent on CAD, they are used in different industries. That’s question arrives Why world is addicted to CAD?

Here we take a quick tour of the advantages of CAD

Easy Replication of Products

Eliminate the requirement of Prototypes

Decrease in error percentage

Decrease in effort

Saves time

Easy to edit

Improved accuracy

Easy to share

Software of CAD

Based on market analysis CAD software are divided as commercial software (payware) and Freeware software (open source).

Here we have made a list of both types of software.

Commercial software

·        AgiliCity Modelur

·        Autodesk AutoCAD

·        Bricsys BricsCAD

·        Dassault Systemes CATIA

·        Dassault Systemes SolidWorks

·        Kubotek KeyCreator

·        PTC PTC Creo (formerly known as Pro/ENGINEER)

·        Siemens Solid Edge

·        Trimble SketchUp

·        Alibre Design

·        AllyCAD

·        Autodesk Inventor

·        AxSTREAM

·        Bentley Systems - MicroStation

·        Cobalt

·        IRONCAD

·        MEDUSA

·        Onshape

·        ProgeCAD

·        Promine

·        PunchCAD

·        Remo 3D

·        Rhinoceros 3D

·        RoutCad

·        Siemens NX

·        SketchUp

·        SpaceClaim

·        T-FLEX CAD

·        TurboCAD

·        VariCAD

Freeware software

·        123D

·        BRL-CAD

·        BricsCAD Shape

·        FreeCAD

·        LibreCAD

·        QCad

·        OpenSCAD

·        SolveSpace

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Additive Manufacturing Process Chain

Every manufacturing process passes through a certain sequence of tasks. 3D printing machines emphasize the simplicity of this job sequence. These machines are divided by their cost, simple to use and ability to be placed in an office or home environment.  The larger 3D printers are suitable for industrial purposes. It can produce a wide variety of object but it also needs an experienced operator and also careful installation of the machine.

Here we go through the different stages of the additive manufacturing process. The objective is to allow you to understand the difference between the 3D printer, their working method and it helps you to identify the best fit 3d printer for your project.

Before we jump into 3D printing manufacturing process chain, let’s take a quick overview of term ‘additive manufacturing’.

Additive manufacturing is the advanced technology that produces 3D objects by adding layer upon layer of metal rather than a traditional machining process where material is removed. For more information about additive manufacturing, you can check out this link Additive manufacturing

Here we are going to discuss the 8 steps in the additive manufacturing process.

·        Conceptualization and CAD

·        Conversion to STL/AMF

·        Transfer and manipulation of STL/AMF file to 3D printer

·        Machine setup

·        Build

·        Part removal and Cleanup

·        Post-processing of part

·        Application

Above mentioned sequence is generally applied to all additive manufacturing technologies but there will be some variations according to part and its applied additive technology.

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Conceptualization and CAD

 The product development process begins with the idea, how the product will glance and function. The concept of the product can be done in many forms, like text, representation of sketches and 3d models.

If additive manufacturing is used, then the product description must be in digital form. 3D printer uses this digital product for final product generation.

Conceptualization and product development is a crucial task, it can cover sub-stages depending on the type of product.

3D CAD model is essential for additive manufacturing, without the 3D model it is not possible to make final output. In additive manufacturing, solid objects are presented on the computer. Initially, this method is used in CNC machining. So we can say that additive manufacturing and CAD/ CAM is interconnected.

The generic process must begin with 3D CAD information. 3D source data can be created by various ways like by design expert via a user interface, using 3D CAD software, by reverse engineering like 3D scanning or a combination of the above method.

Modern solid modeling CAD software generates models without any gaps in the model. But if any case is there any gap in the 3D model, this makes very difficult to make the final product by 3D printers. Such types of problems are generally detected once the 3D model is converted to STL format.

Conversion to STL/AMF

Nearly every 3D printers support the STL file format. The terminology STL was derived from STereoLithograhy, which was the first additive manufacturing technology in the 1990s.

STL is a simple method of representing the CAD model in terms of geometry. STL file format removes construction data, modeling history and feature tree of CAD model.  It represents the model surfaces in the series of triangular facets. The triangle size is calculated by the minimum distance between the plane represented by a triangle and the surface it is supposed to represent. In simple language, the minimum triangle offset is smaller than the resolution of the 3D printer machine.

The STL file is automatically generated by CAD software, but there is a little possibility of errors in a complex model. So it is recommended to double-check the file with STL repair tool like Materialise Magics to detect and rectify errors. For complex geometries, it is difficult to inspect the CAD model or STL file. So much software is used for checking before manufacturing the final product.

STL is the unordered collection of triangle vertices and surface normal vectors. STL file does not contain any units, material, color or feature information. This drawback of the STL file leads to the generation of new file format which is ‘AMF’. This format is the international ISO standard format that provides info like color, dimension, unit, material, and feature tree, etc. Although STL is the most used file format at the present time in this industry.

In the STL file, the corresponding triangles must be pointing in the proper direction. The surface normal vector must correctly describe the which side of the triangle is inside and which is outside. The discontinuous and complex geometry may not align properly. This creates gaps in the model. Some 3D printer automatically detects such errors and auto-fill such gaps. Sometimes it possibly adds unwanted material in the autofill process. So in such case software highlight the defected portions.

Transfer and manipulation of STL/AMF file to 3D printer

Once the STL file format is created and checked by STL repair software, it can be sent to the target 3D printer. Basically, it is possible to press the ‘print’ button and the machine will create the final product. But it is necessary to check the number of actions before start printing.

First verify the part which we are going to print is correct. Additive manufacturing software helps to visualize, view and manipulate the part. We can reposition or even change the orientation of the part. This will help when we print multiple parts at the same time in 3D printer to utilize the free space and increase productivity.

Sometimes part needs to make slightly larger or smaller than the original size to compensate for the changes due to shrinkage or coating. In such case scaling of part in additive manufacturing software is necessary.

In some part identification marking is required. It can also be done by embossing characters.

Machine setup  

All 3D printers have some set of parameters that are specific to that process or machine. Some 3D printers are designed for specific materials and provide limited options to very thickness and build parameters. These machines have few setup changes to make from build to build. Other machines can run with a wild range of materials and create part quickly. This machine provides numerous setup options. Incorrect machine setup will lead to faulty products.

After setting up machine software parameters, machines need to physically prepared for build. the operator must check build material is properly loaded in the machine. For printers that use powder as raw material, they must check loaded and leveled correctly.  For build plate as raw material must be leveled with respect to machine axes.

Build

The first few stages of additive manufacturing are semiautomatic tasks, this needs a sufficient amount of human control in the form of interaction, decision making, and inspection. After that process switches to the computer-controlled building phase. Here layer base manufacturing takes place.

All additive manufacturing machines have a similar sequence of layering, material spreading, layer cross-section formation, and height-adjustable platform. Some 3D printer combines some of above mention processes. 3D printer will repeat the process until the completion of the building process.

Part removal and Cleanup

Generally object printed from the 3D printer is ready to use but in some cases, it requires some minimal human intervention. Some objects need a sufficient amount of post-processing before using. Parts must be removed from the build platform. Some complex part needs additional extra material to support the original object such excess material is known as support materials. Support removal is a crucial task, it may damage the object or even reject if they don’t do it carefully. Recently some processes are developing for easy removal of support.

In the metal industry, a wire EDM, milling equipment and band saw are required to remove the object from the support. The part removal and cleanup are highly dependent on the skill of the operator.

Post-processing of part

Post-processing makes part ready for application purposes. Different types of post-processing are carried out on part as per the application of part. Some of post-processing are:

Polishing

Sandpapering

Coting

Chemical and thermal treatment

Infiltration and surface coating

This post-processes are required to maintain the good surface finish and precision.

Application

After completion of post-processing, parts are ready for use. The same part with the same material can be manufactured by different methods. In such a case, it is possible that the behavior may differ. Some additive manufacturing machines create part with little voids inside part, this can lead to failure under mechanical stress. In some 3D printer some material not bond, link or crystallize in an optimum way. The rapid cooling in the 3D printer can defer properties than conventional and CNC machining. So the designer should properly decide the manufacturing process by considering all affecting parameters.