Manufacturing Process (Cutting Process)

IDT 203MANUFACTURI-NG PROCESS(CUTTING TECHNOLOGY)GROUP MEMBERS MOHD ZARAHAN BIN ZAKARIAMOHD ROZAIME BIN ABDULLAHMEOR SYUKRI BIN MEOR ARIS

PHOTOCHEMICAL CUTTING

INTRODUCTION Unprotected metal is chemically dissolved in

photochemical machining. Masks are design so that components are cut out and engraved simultaneously. The results are both decorative and functional.

The chemical cutting is used predominantly to mill and machine thin sheet metals, is also known as chemical blanking and photofabrication.

This process is limited to foils and thin sheet metal between 0.1mm and 1mm thick.

TYPICAL APPLICATION The technical aspects of this technology

are utilized in aerospace, automotive and electronics industries.

RELATED PROCESS Laser cutting and engraving are used to

produce similar products. Abrasive blasting CNC machining

QUALITY This process produces an edge finish

free from burrs, and it is accurate to within 10% of the material thickness.

DESIGN OPPORTUNITIES Photochemical machining is used to

score lines, mill holes, remove surface material and profile entire parts.

DESIGN CONSIDERATIONS The intricacy of a pattern is restricted by

the thickness of the material: any configuration can be machined, as long as the smallest details are large than the material thickness.

COMPATIBLE MATERIALS Most metals can be photo etched

including stainless stell, mild steel, aluminium, copper, brass, nickel, tin and silver.

Glass, mirror, porcelain and ceramic are also suitable for photo etching.

COSTS Very low tooling cost. Moderate to high unit cost.

ENVIRONMENT IMPACTS Metal that is removed from the

workpiece is dissolved in the chemical etchant.

The chemical used to etch the metal is one-third ferric chloride.

LASER CUTTING

INTRODUCTION This is a high precision CNC process that

can be used to cut, etch, engrave and a mark a variety of sheet materials including metal, plastic, wood, textiles, glass, ceramic and leather.

The two main types of laser used for this process are CO2 and Nd:YAG.

Both work by focusing thermal energy on a spot 0.1mm to 1mm wide to melt or vaporize the material.

TYPICAL APPLICATION Application are diverse and include

modelmaking, furniture, consumer electronics, fashions, signs and trophies, point of sale, film and televisions sets, and exhibition pieces.

RELATED PROCESS CNC maching, water jet cutting and

punching and blanking can all be used to produce the same effect in certain materials.

QUALITY Certain materials, like thermoplastics,

have a very high surface finish when cut in this way.

DESIGN OPPORTUNITIES These processes do not stress the

workpiece, like blade cutting, so small and intricate details can be produced without reducing strength or distorting the part.

DESIGN CONSIDERATIONS These are vector-based cutting systems:

the laser follow a series of lines from point to point.

COMPATIBLE MATERIALS These processes can be used to cut a

multitude of materials including timber, veneers, paper and card, synthetic marble, flexible magnets, textiles and fleeces, rubber and certain glasses and ceramics.

COSTS There are no tooling costs for this

process. Data is transmitted directly from a CAD file to the laser cutting machine.

ENVIRONMENT IMPACTS Careful planning will ensure minimal

waste, but it is impossible to avoid offcuts that are not suitable for reuse.

Thermoplastic scrap, paper and metal can be recycled, but not directly.

ELECTRICAL DISCHARGE MACHINING

INTRODUCTION High voltage sparks erode the surface of the

workpiece or cut a profile by vaporizing the material, making this a precise method of machining metals. Material is removed from the workpiece and a texture is applied simultaneously.

Electrical discharge machining (EDM) has revolutionized toolmaking and metal prototyping.

There are two versions of the EDM process : die sink EDM and wire EDM.

TYPICAL APPLICATIONEDM equipment is very expensive, so its use is limited to applications that demand the very high levels of precision and the ability to work hardened steels and other metals that are impractical for CNC machining.

RELATED PROCESS CNC machining Laser cutting Water jet cutting

QUALITY The quality of EDM parts is so high they

can be used to manufacture tooling for injection molding without any finishing operations.

The quality of the finish and resulting texture are determined by the cutting speed and voltage.

DESIGN OPPORTUNITIES EDM produce accurate textures, which

are determined by the machine settings, eliminating the need for further finishing operations.

Die sink EDM can be used to produce internal geometries on parts that are not possible with conventional machining.

Wire EDM can be used in much the same way as hot wire cutting polymer foam.

DESIGN CONSIDERATIONS These processes can be produce

internal radii as small as 30 microns. These do not need to be any larger than

500 microns in most applications. The thickness of the material that can

be cut by wire EDM ranges from 0.1mm up to 200mm but depends on the capabilities of the equipment.

COMPATIBLE MATERIALS Metals can be shaped by EDM

techniques. Metals including stainless steel, tool

steel, aluminium, titanium, brass and cooper are commonly shaped in this way.

COSTS Low tooling costs for EDM: no tooling

costs for wire EDM: very high equipment costs.

Moderate to high unit costs.

ENVIRONMENTAL IMPACTS This process requires a great deal of

energy to vaporize the metal workpiece. It does eliminate the need for any

further processing. The metal electrodes are also suitable

for recycling.

PUNCHING AND BLANKING

INTRODUCTION Punching refers to cutting an internal

shape. Blanking is cutting an external shape in

a single operation. Circular , square and profiled hole can

be cut from sheet.

TYPICAL APPICATIONS Use in :

Automotive and transportation Consumer electronics and appliances kitchenware

RELATED PROCESSES This process can only used for thin

sheet matrials up to 5mm. Related processes

CNC machining Laser cutting Water jet cutting

QUALITY High quality and precise but adges

require de-burring.

DESIGN OPPORTUNITIES Specialized tooling is required for 3D

parts, which will increase investment cost.

Selective material will reduce weight but may not reduce strength too much.

DESIGN CONSIDERATION The width of material being removed or

left behind. Punch diameter or width should be not

smaller than material thickness.

COMPATIBLE MATERIALS Almost all metals can be processed in

this way. Commonly used to cut carbon

steel,stainless steel and aluminium and copper alloys.

COST Low to moderate tooling cost Low to moderate unit costs

ENVIRONMENTAL IMPACTS Any scrap is collected and separated for

recycling, so there is very little wasted material.

DIE CUTTING

INTRODUCTION Is a rotary operation Most cost effective way to cut complex

net shapes from most non-metallic sheet materials.

TYPICAL APPLICATION Use in :

Packaging Promotional material Stationery and labels

RELATED PROCESSES Laser cutting Punching Water jet cutting

QUALITY High quality edge finish

DESIGN OPPORTUNITIES A multitude of materials can be die cut. Means that an entire packaging system

can be shaped in this way.

DESIGN CONSIDERATIONS The type of material will determine the

thickness that can be cut Nesting parts is essential to reduce

cycle time , scrap material and cost in general

COMPATABLE MATERIALS Many materials can be cut by die

casting , including plastic sheet, plastic film, cardboard, board, foam, rubber, leather, textile, very thin matels, flexible magnets and cork.

COST Low tooling costs Low unit costs

ENVIRONMENTAL IMPACTS Die cutting does produce offcuts Scrap can be minimized by nesting the

scrap together on a sheet and can be recycle.

WATER JET CUTTING

INTRODUCTION A high-pressure jet of water, which is

typically mixed with abrasive, produce the cutting action.

This is a versatile process for cold cutting sheet materials.

TYPICAL APPLICATIONS Use in :

Aerospace components Automotive Scientific apparatus

RELATED PROCESSES Die cutting Laser cutting Punching and blanking

QUALITY Good quality

DESIGN OPPORTUNITIES This process cuts most sheet materials

between 0.5mm and 100mm thick. The hardness of the material will be

determine the maximum thickness.

DESIGN CONSIDERATIONS Reducing cycle time reduce the cost of

water jet process. Sharp corners slow down the process;

the water jet cutter will slow down to avoid drag.

COMPATIBLE MATERIALS Mild steel, steanless steel and tool steel

can all be cut with high accuracy. Titanium, aliminium, copper and brass

are suitable for complex profiles and can be cut rapidly with this process.

COST No tooling cost Moderate unit cost

ENVIRONMENTAL IMPACT Offcuts in most materials can be cycled

of re-used The water is usually tapped from the

mains and is cleaned and recycled for continous use.

GLASS SCORINGINYRODUCTION

-most widely use.- there is the technique for cutting

out the stained glass design

RELATED PROCESSES Laser cutting Water jet cutting

QUALITY Good quality cut edge,but with some

lateral cracking.

COST No tooling cost Low unit cost.