In metalworking, casting involves pouring a liquid metal into a
mold, which contains a hollow cavity of the desired shape, and then is allowed to
solidify. The solidified part is also known as a casting, which is ejected or broken
out of the mold to complete the process. Casting is most often used for making complex
shapes that would be difficult or uneconomical to make by other methods.
Sand casting is one of the most popular and simplest types of casting that
has been used for centuries. Sand casting allows for smaller batches to be made
compared to permanent mold casting and at a very reasonable cost. Not only does
this method allow manufacturers to create products at a low cost, but there are
other benefits to sand casting, such as very small size operations. From castings
that fit in the palm of your hand to train beds (one casting can create the entire
bed for one rail car), it can all be done with sand casting. Sand casting also allows
most metals to be cast depending on the type of sand used for the molds.
Investment casting (known as lost-wax casting in art) is a process that has
been practised for thousands of years, with the lost-wax process being one of the
oldest known metal forming techniques. From 5000 years ago, when beeswax formed
the pattern, to today's high technology waxes, refractory materials and specialist
alloys, the castings ensure high-quality components are produced with the key benefits
of accuracy, repeatability, versatility and integrity.
The die casting process forces molten metal under high pressure into mold cavities
(which are machined into dies). Most die castings are made from nonferrous metals,
specifically zinc, copper, and aluminium based alloys, but ferrous metal die castings
are possible. The die casting method is especially suited for applications where
many small to medium sized parts are needed with good detail, a fine surface quality
and dimensional consistency.
Stamping includes a variety of sheet-metal forming manufacturing processes,
such as punching using a machine press or stamping press, blanking, embossing, bending,
flanging, and coining. This could be a single stage operation where every stroke
of the press produce the desired form on the sheet metal part, or could occur through
a series of stages. The process is usually carried out on sheet metal.
Forging is one of the oldest known metalworking processes. Forging was done
historically by a smith using hammer and anvil, and though the use of water power
in the production and working of iron dates to the 12th century, the hammer and
anvil are not obsolete. The smithy has evolved over centuries to the forge shop
with engineered processes, production equipment, tooling, raw materials and products
to meet the demands of modern industry. In modern times, industrial forging is done
either with presses or with hammers powered by compressed air, electricity, hydraulics
or steam. These hammers are large, having reciprocating weights in the thousands
of pounds.
Extrusion is a process used to create objects of a fixed cross-sectional
profile. A material is pushed or drawn through a die of the desired cross-section.
The two main advantages of this process over other manufacturing processes is its
ability to create very complex cross-sections and work materials that are brittle,
because the material only encounters compressive and shear stresses. It also forms
finished parts with an excellent surface finish
Spinning Spin forming or spinning, is a metalworking process by which a disc
or tube of metal is rotated at high speed and formed into an axially symmetric part.
The spinning process is fairly simple. A mandrel, also known as a form, is mounted
in the drive section of a lathe. A pre-sized metal disk is then clamped against
the mandrel by a pressure pad, which is attached to the tailstock. The mandrel and
workpiece are then rotated together at high speeds. A localized force is then applied
to the workpiece to cause it to flow over the mandrel. Simple workpieces are just
removed from the mandrel, but more complex shapes may require a multi-piece mandrel.
Machining is a part of the manufacture of almost all metal products The three
principal machining processes we employ are:
» Turning operations are operations that rotate the workpiece as the
primary method of moving metal against the cutting tool. Lathes are the principal
machine tool used in turning.
» Milling operations are operations in which the cutting tool rotates
to bring cutting edges to bear against the workpiece. Milling machines are the principal
machine tool used in milling.
» Drilling operations are operations in which holes are produced or
refined by bringing a rotating cutter with cutting edges at the lower extremity
into contact with the workpiece. Drilling operations are done primarily in drill
presses but sometimes on lathes or mills.
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In metalworking, casting involves pouring a liquid metal into a mold, which contains a hollow cavity of the desired shape, and then is allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods.
Sand casting is one of the most popular and simplest types of casting that has been used for centuries. Sand casting allows for smaller batches to be made compared to permanent mold casting and at a very reasonable cost. Not only does this method allow manufacturers to create products at a low cost, but there are other benefits to sand casting, such as very small size operations. From castings that fit in the palm of your hand to train beds (one casting can create the entire bed for one rail car), it can all be done with sand casting. Sand casting also allows most metals to be cast depending on the type of sand used for the molds.
Investment casting (known as lost-wax casting in art) is a process that has been practised for thousands of years, with the lost-wax process being one of the oldest known metal forming techniques. From 5000 years ago, when beeswax formed the pattern, to today's high technology waxes, refractory materials and specialist alloys, the castings ensure high-quality components are produced with the key benefits of accuracy, repeatability, versatility and integrity.
The die casting process forces molten metal under high pressure into mold cavities (which are machined into dies). Most die castings are made from nonferrous metals, specifically zinc, copper, and aluminium based alloys, but ferrous metal die castings are possible. The die casting method is especially suited for applications where many small to medium sized parts are needed with good detail, a fine surface quality and dimensional consistency.
Stamping includes a variety of sheet-metal forming manufacturing processes, such as punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produce the desired form on the sheet metal part, or could occur through a series of stages. The process is usually carried out on sheet metal.
Forging is one of the oldest known metalworking processes. Forging was done historically by a smith using hammer and anvil, and though the use of water power in the production and working of iron dates to the 12th century, the hammer and anvil are not obsolete. The smithy has evolved over centuries to the forge shop with engineered processes, production equipment, tooling, raw materials and products to meet the demands of modern industry. In modern times, industrial forging is done either with presses or with hammers powered by compressed air, electricity, hydraulics or steam. These hammers are large, having reciprocating weights in the thousands of pounds.
Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The two main advantages of this process over other manufacturing processes is its ability to create very complex cross-sections and work materials that are brittle, because the material only encounters compressive and shear stresses. It also forms finished parts with an excellent surface finish
Spinning Spin forming or spinning, is a metalworking process by which a disc or tube of metal is rotated at high speed and formed into an axially symmetric part. The spinning process is fairly simple. A mandrel, also known as a form, is mounted in the drive section of a lathe. A pre-sized metal disk is then clamped against the mandrel by a pressure pad, which is attached to the tailstock. The mandrel and workpiece are then rotated together at high speeds. A localized force is then applied to the workpiece to cause it to flow over the mandrel. Simple workpieces are just removed from the mandrel, but more complex shapes may require a multi-piece mandrel.
Machining is a part of the manufacture of almost all metal products The three principal machining processes we employ are:
» Turning operations are operations that rotate the workpiece as the primary method of moving metal against the cutting tool. Lathes are the principal machine tool used in turning.
» Milling operations are operations in which the cutting tool rotates to bring cutting edges to bear against the workpiece. Milling machines are the principal machine tool used in milling.
» Drilling operations are operations in which holes are produced or refined by bringing a rotating cutter with cutting edges at the lower extremity into contact with the workpiece. Drilling operations are done primarily in drill presses but sometimes on lathes or mills.