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34 Cards in this Set
- Front
- Back
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SMAW (Shielded Metal Arc Welding/Stick Welding) |
filler metal encased in flux arc between stick and part stick consumed can join dirty parts slag generated |
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MIG (Metal Inert Gas/Wire) |
Gas Shield No flux, no slag Arc between wire and part Fast, useful for automation Filler metal (wire) fed through the gun |
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SAW (Sub Arc Welding) |
Wire filler metal Automated Granular flux shields to pool Excess flux is recovered Slag generated |
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Advantages and Disadvantages to SAW |
ADV: continuous DIS: less flexible for irregular part |
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TIG (Tungsten Inert Gas) |
Gas shield No flux, No slag Filler metal is supplied manually Better for non-ferrous parts, like aluminum Slow, pretty weld, no spatter |
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FCAW (Flux Cored Arc Welding) |
Usually no gas (depends on dirt and weld size) Flux is inside the electrode (wire/stick) Can handle dirty parts better than stick welding Large beads |
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PAW (Plasma Arc Welding) |
Like TIG on steroids Gas shield No flux, no slag HAZ is small Can have filler metal Deep penetration |
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EBW (Electron Beam Welding) |
Needs vacuum No flux, no slag No gas shield No filler metal Good for deep, narrow weld Can weld dissimilar metals Small HAZ |
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LBW (Laser Beam Welding) |
Gas Shield No Filler metal Expensive Automated |
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OFW (Oxy Fuel Welding) |
Oxy/Acetylene gas flame makes heat Manually applied filler metal No gas shield No flux, no slag |
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Solid State |
Friction Welding Twist & Press No gas shield No flux, no shield Expensive equipment |
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Ultrasonic |
Resonant vibration to weld Works well with plastics like polyethylene CNC and NC -part programs can be edited on the computer |
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Machining |
The controlled cutting away of unwanted material |
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Generation tools |
Standard tooling -drill bits -end mills -single point tools Machines -drill press -lathe, mill -shaper, planer -abrasive |
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Forming Tools |
Form Tools -thread dies -broach Machines -lathe, mill -broach |
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Copying tools |
Standard tooling Machine Control -duplicator -pantograph Machines -lathe, mill -planer, shaper |
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Lathe |
Part rotates Tool moves into part |
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Mill |
Spindle moves vertical or horizontal Parts fixed on table Cutting tool rotates, table moves |
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Drill Press |
Vertical Spindle Raise and lower bit Flutes are the cutting edges on a bit |
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Shaper |
Part is fixed Tool moves and indexes |
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Planer |
Tool is fixed, but it indexes Part moves |
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Abrasive Machines (types of grinders) |
Cylindrical Centerless Surface |
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Broach |
Used for internal dimension Fast, plunges once |
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Blanchard (abrasive) |
Hone internal Make smoother |
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Super Finishing |
Like honing, but on external surface |
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Lapping |
Powder and mineral oil Gives mirror-like finish Cutting tool material must be harder and tougher than workpiece UTS is achieved by forcing tool against part |
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Things you want in tool |
high hot hardness toughness stiffness resistance to wear and edge chipping thermal shock resistance low coefficient of friction ideally zero coefficient of thermal expansion high coefficient of thermal conductivity |
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Grinding Wheels |
Abrasive -aluminum oxide (steel) -silicon carbide (harder) -low strength, cast iron, bronze, oil, non metals |
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Cutting Fluids |
Reduces friction Reduces temperature Water based fluids have high thermal capacity |
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Powder Metallurgy |
Metallic and Non-metallic powders Atomization |
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Powder Metallurgy Steps |
1. Blend 2. Fill and Compact 3. Sintering 4. Multiple option -Machining -Welding -Forging -Surface Hardening -Coating |
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Advantages to Powder Metallurgy |
Tailor the material composition High production rates Efficient use of material Good surface finish |
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Disadvantages to Powder Metallurgy |
Expensive die costs Size limitations Design limitations 3:1 (length:width) Pressed Parts are fragile before sintering |
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Application of Powder Metallurgy |
Pump gears Self lubricated bearings Cutting tool inserts Precise small parts |
