BOLT manufacturing process.pdf

Bolt Manufacture: Process Selectionver. 1 ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009 1 How would you make a bolt? ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009 2 Questions you might ask in response: • • • • • • • Make it out of what (material)? ( ) Make how many (volume)? (quality, y, tolerance)? ) Make it how well (q Make how fast (rate or time)? Make it how cheaply (cost)? Make it how large (size, dimensions)? Make it for what (function)? ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009 3 Possible Manufacturing g Methods for Metal Bolts • • • • • • Casting C ti Powder processing Rolling / Heading Machining Welding head to threads R id prototyping Rapid t t i ME 6222: Manufacturing Processes and Systems Prof. Colton © GIT 2009 4 .S. J. J.Casting • • • • • • • • Sand Shell Expendable mold Plaster Ceramic Investment Slush Pressure • • • • • • Die Centrifugal Squeeze Semi-solid g crystal y Single Directional solidification ME 6222: Manufacturing Processes and Systems Prof. Colton © GIT 2009 5 .S. S.Sand Casting Risers Sprue Gate Parting Line Drag Casting Cope ME 6222: Manufacturing Processes and Systems Prof. Colton © GIT 2009 6 . J. Powder Processing • Cold compaction p and sintering g – Pressing – Rolling g – Extrusion – Injection molding – Isostatic pressing • Hot Isostatic Pressing ME 6222: Manufacturing Processes and Systems Prof.S. J. Colton © GIT 2009 7 . Powder Pressing g and Sintering g Punch Die Part Punch Dual action press ME 6222: Manufacturing Processes and Systems Prof. Colton © GIT 2009 8 .S. J. J.Cold Isostatic Pressing ME 6222: Manufacturing Processes and Systems Prof. Colton © GIT 2009 9 .S. Hot Isostatic Pressing ME 6222: Manufacturing Processes and Systems Prof. Colton © GIT 2009 10 .S. J. Rolling / Heading • Roll the threads • Upset forge g the head ME 6222: Manufacturing Processes and Systems Prof. Colton © GIT 2009 11 .S. J. Colton © GIT 2009 12 .Thread Rolling g Machine ME 6222: Manufacturing Processes and Systems Prof.S. J. Colton © GIT 2009 13 .Thread Rolling g Die ME 6222: Manufacturing Processes and Systems Prof. J.S. S. Colton © GIT 2009 14 .Heading Process Punch Blank Kickout pin Die ME 6222: Manufacturing Processes and Systems Prof. J. Colton © GIT 2009 15 .S. J.Forge g for Heading g ME 6222: Manufacturing Processes and Systems Prof. Machining Cut threads on a lathe from hexagonal stock ME 6222: Manufacturing Processes and Systems Prof. J. Colton © GIT 2009 16 .S. Colton © GIT 2009 17 . J.Weld Head to Threads • Threads : – rolled ll d – machined • Head: – cut from barstock • Welding: – arc – oxyacetylene y y ME 6222: Manufacturing Processes and Systems Prof.S. Rapid Prototyping . J. Colton © GIT 2009 18 .S.Powder Processing Direct fabrication from a CAD file • Selective Laser Sintering (SLS) • 3-D 3DP Printing i ti • Light Engineered Net Shaping (LENS) ME 6222: Manufacturing Processes and Systems Prof. J.Layered y Manufacturing g Mirror Layered Object Laser Vat Platform ME 6222: Manufacturing Processes and Systems Prof.S. Colton © GIT 2009 19 . Colton © GIT 2009 20 . J.Selective Laser Sintering g (3D Systems) ME 6222: Manufacturing Processes and Systems Prof.S. 3D Printing Process (Soligen) ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton © GIT 2009 21 . Colton © GIT 2009 22 .S.3D Printing Head (Soligen) ME 6222: Manufacturing Processes and Systems Prof. J. S. J. Colton © GIT 2009 23 .Light Engineered Net Shaping (1) (S di N (Sandia National ti lL Lab) b) ME 6222: Manufacturing Processes and Systems Prof. Light Engineered Net Shaping (2) (Sandia National Lab) Laser Powder delivery tube ME 6222: Manufacturing Processes and Systems Prof. Colton © GIT 2009 24 . J.S. J. Colton © GIT 2009 25 .Light Engineered Net Shaping Parts (Sandia National Lab) ME 6222: Manufacturing Processes and Systems Prof.S. Colton © GIT 2009 26 .Organize Processes • Casting • Powder – Compaction – Rapid Prototyping • Deformation D f ti • Machining ME 6222: Manufacturing Processes and Systems Prof. J.S. and cutting through grains Deformation Machining ac g ME 6222: Manufacturing Processes and Systems Prof. Colton © GIT 2009 27 . incomplete fusion) Good strength strength. due to cold working and grain deformation Reduced educed due to s sharp ap corners. due to grain structure Can be C b b brittle ittl due d to t sintering process (voids. J.S.Material Properties Limits Process Casting P d Powder Effect on thread strength Brittle. Therefore. Colton © GIT 2009 28 .Problems due to grain structure • Cast objects j have g grains that grow together. J. Th f fracture f t can occur along grain boundaries more easily. • Cast objects are not cold worked worked.S. il ME 6222: Manufacturing Processes and Systems Prof. Si t i P Sintering Problems bl Voids Incomplete fusion vs. ME 6222: Manufacturing Processes and Systems Prof. Colton © GIT 2009 29 . J.S. machining) Rolled Machined ME 6222: Manufacturing Processes and Systems Prof. J. Colton © GIT 2009 30 .S. Cutting (rolling vs.Grain Deformation vs vs. Mass Production Process Casting Powder D f Deformation i Machining g Mass Production Yes Yes for compaction.S. Colton © GIT 2009 31 . J. No for Rapid Prototyping Y Yes Yes ME 6222: Manufacturing Processes and Systems Prof. J. especially rapid prototyping L Low Low ME 6222: Manufacturing Processes and Systems Prof.Cost Process Casting Powder D f Deformation ti Machining g Cost Low Can be high.S. Colton © GIT 2009 32 . Flexibility Process Casting Powder Deformation Machining Flexibility Low High for Rapid Prototyping Low High ME 6222: Manufacturing Processes and Systems Prof.S. J. Colton © GIT 2009 33 . S. Colton © GIT 2009 34 . J.Tolerance Process Casting Powder D f Deformation i Machining g Tolerance Low Good G d Good High g ME 6222: Manufacturing Processes and Systems Prof. Which process to pick? • Normal sized bolts. d d good d strength: t th Rolling and heading • Small bolts. J. Colton © GIT 2009 35 . mass produced. mass produced: Machining on screw machine • Large bolts. small numbers: M hi i Machining ME 6222: Manufacturing Processes and Systems Prof.S. Summary • Choice depends on what you are trying to accomplish.S. • Choosing Ch i i is not t a simple i l t task. k • Lots of thought and calculations are needed. J. Colton © GIT 2009 36 . ME 6222: Manufacturing Processes and Systems Prof. S. Colton © GIT 2009 37 .ME 6222: Manufacturing Processes and Systems Prof. J.