Search Results for process planning

This article describes the thermodynamics and kinetics of gas carburizing reactions, and details the mass transfer mechanism during gas carburizing. It discusses the various considerations involved in carburizing process planning, and reviews successful operation of the gas carburizing process based on the control of three principal variables: temperature, atmosphere composition or carbon potential, and time. The article also describes the selection criteria for alloy, carbon sources, atmosphere types, and carbon monoxide level for endothermic carburizing atmospheres. It provides information on carburizing modeling, case depth prediction, case depth measurement, and case depth evaluation as well as on carburizing equipment, and also covers the factors affecting distortion after carburizing.

This article discusses the advantages and limitations of drop hammer forming and presents the key factors for determining a process plan. It describes the characteristics of hammers and presents information on tool materials. It explains the use of lubricants and preparation of blanks for forming. The article also details the drop hammer forming process of steels, aluminum alloys, magnesium alloys, and titanium alloys.

This article focuses on the technologies and applications of additive manufacturing (AM) in the oil and gas industry. It then presents the challenges of AM and the oil and gas industry. The article provides a detailed description of the critical steps in the AM process chain, including part selection, design optimization, and process planning, control, and inspection. Qualification and certification standardization is discussed, as is a commitment to reduce the carbon footprint of the manufacturing sector through AM. It ends with the future outlook of AM in the oil and gas industry.

Machining or material removal processes are secondary manufacturing operations that are used to achieve precise tolerances or to impart controlled surface finishes to a part. This article summarizes rules for designing parts to improve machined part quality and reduce machining costs in mass and batch production environments. It discusses the factors affecting the total cost of a machining operation, including raw material costs, labor costs, and equipment costs. The article describes three types of machining systems, namely, general-purpose machine tools, production machining systems, and computer numerically controlled (CNC) machining systems. It reviews general design-for-machining rules that are applicable to all parts, regardless of the type of equipment used to produce them. Special considerations for production machining systems and CNC machining systems are discussed. The article describes the structure and typical uses of computer-aided process planning and design-for-manufacturing programs.

This article describes the basic functions that should be included when considering the relationship of computer-aided design (CAD)/computer-aided manufacturing (CAM) and machining. These include design, analysis, drafting, process planning, part programming, program verification, part machining, and inspection. The article provides information on hardware, data base, interfaces, and benefits of integrating machining with the CAD/CAM system of a manufacturing plant. It also provides an overview of direct, computer and, distributed numerical control, which are devoid of a number of problems inherent in conventional numerical control.

Data formats play an integral role in leveraging the flexibility of additive manufacturing and achieving consistent part quality. This article compares and contrasts data formats optimized for design, materials, processes, and inspection methods. It also discusses the types of data associated with the six phases of additive manufacturing, namely design, build, design with build plan, design with machine-specific build plan, post-processed part, and qualified part.

This article surveys common additive manufacturing (AM) data-acquisition methods, covering preprocess materials characterization in the lab, machine calibration in the field, in-process monitoring during a build, and the postprocess part inspections and tests. The focus is to identify acquisition-related metadata for AM data sets to improve data usability and reusability. Also included in the article are exemplar metadata definitions for a data set acquired from light-scattering-based particle size analysis.

As additive manufacturing (AM) gains maturity as a manufacturing technique for production in many industrial sectors, inspection as a tool for quality control gains importance. This article is focused on the field of dimensional metrology, which is typically concerned with the verification of size, location, form, and surface topography of geometric features. This is split into two categories: geometric (size, location, form) and surface measurement (topography). The article also focuses on applicable inspection technologies, and it discusses the context within digital thread manufacturing. A case study on the Digital Inspection Requirements Enhancing Coverage and Traceability (DIRECT) is also presented.

Efforts in improving the efficiency of automated equipment lead to combining automatic joining equipment with a modem computer technique eventually known as artificial intelligence (intelligent automation) that usually includes an off-line planning system and a real-time adaptive control system connected through a computer communications interface. This article focuses on the application of intelligent automation system to arc welding, called WELDEXCELL, and other joining processes. An outline of the interface between off-line planners and real-time control systems is also provided.

The basic quality analysis tools are cause-and-effect diagrams, check sheets, control charts, histograms, Pareto charts, scatter diagrams, and run charts. This article reviews how basic quality analysis tools are built upon to become a more advanced set of quality tools. It describes the advanced quality tools: advanced product quality planning, failure mode and effects analysis, control planning, measurement systems analysis, lean tools, statistical process control, production viability and tryout, and Six Sigma.

Uniform corrosion refers to the attack on an exposed metal surface that results in homogeneous thickness loss that is evaluated by mass loss or measurement of thickness change. This article focuses on the various processes involved in mass loss tests, namely, selection and preparation of suitable test specimens, planning of the experimental technique, posttest sample cleaning, data acquisition, and reporting. It further discusses the test variables addressed during the experimental planning and provides an overview of the other test and evaluation methods of evaluating uniform corrosion.

When planning a corrosion-testing program, it is advisable to select the testing conditions carefully in order to produce ranking parameters with minimal influence from testing conditions while rich in engineering significance. This article provides a discussion on test objectives, metal composition and metallurgical conditions, test specimen preparation, and corrosion damage assessment. It describes a strategy for planning the design of controlled and uncontrolled factorial experiments. The article contains a table that lists the elements of an iterative process for the experimental design. It illustrates the experimental designs applied to corrosion testing.

This article discusses four subsystems of the electrochemical machining (ECM) system: power source, electrolyte cleaning and supply system, tool and tool-feed system, and workpiece and workpiece-holding system. It describes the theory of ECM and provides information on the electrolytes used in ECM. The article reviews the methods associated with workpiece shape prediction. The procedures and integrated approach for the tool design in ECM are discussed. The article also explains the process control, capabilities, and the limitations of ECM. It concludes with information on the applications of ECM.

This article presents a detailed account of the processes involved in vat-photopolymerization-based fabrication of ceramics, namely bioceramics, structural ceramics, piezoelectric ceramics, optical ceramics, and polymer-derived ceramics. Information and methods of material preparation, curing characteristics, green-part fabrication, property identification, process design and planning, and quality control and optimization are introduced. The article also provides information on postprocessing techniques, namely debinding and sintering, as well as on the phenomenon of shrinkage and compensation.

This article describes the general concepts and practices related to manufacturing and design. It discusses the activities of design and manufacturing by placing it in the context of the business system that they support. The article presents an overview of the manufacturing technology field from a design and material selection perspective. It provides an insight to the complex relationship among design, material selection, and manufacturing. The article offers information on modern design for manufacturing practices that are widely used in the industry.

This article describes the methodology for performing a failure modes and effects analysis (FMEA). It explains the methodology with the help of a hot water heater and provides a discussion on the role of FMEA in the design process. The article presents the analysis procedures and shows how proper planning, along with functional, interface, and detailed fault analyses, makes FMEA a process that facilitates the design throughout the product development cycle. It also discusses the use of fault equivalence to reduce the amount of labor required by the analysis. The article shows how fault trees are used to unify the analysis of failure modes caused by design errors, manufacturing and maintenance processes, materials, and so on, and to assess the probability of failure mode occurrence. It concludes with information on some of the approaches to automating the FMEA.