Post on 06-Feb-2018
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
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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