ISAT211 Lab 5 – Manufacturing Processes 3 points 1. Purpose To get familiar with traditional manufacturing processes 2. Lab tasks a. Watch the casting process video and summarize major steps. Use your own word and explain what need to be done in each step. https://www.youtube.com/watch?v=2CIcvB72dmk Summary: - Use sand that is banded together with oil. - Make sand mold in a metal box called a flask o The flask is a box that is divided into two equal sections w/ locating pins. (Top – Cope || Bottom – Drag) - Starting with the drag flip it upside down. “Inverted Drag” - Add the first half of the pattern face down in the top left of the flask without touching the edges of the flask. The pattern is spilt into two haves for cost efficient and manufacturing efficient development of the part, otherwise the pattern would have to break apart the sand mold to be removed. - Sprinkle parting powder inside the box. To help remove the part from the sand. - Wear gloves or a barrier cream to protect hands from sand. - Start crumbling the sand into the box only partially filling the box. - Press sand into the box and around the mold. - Use a ramming tool to beat the sand down at an appropriate speed and strength without compromising the mold. - Keep filling the box with more sand, pressing the sound down followed by the use of the ramming tool until the box is completely filled. - Use a strickling bar to remove excess sand off the top of the box and level off the sand. - Flip the Drag right side up so you can see the first half of the pattern. - Take the second half of the pattern and perfectly lay it on top of first half of the pattern. - Place the Cope on top and secure it into place with the locating pins. - Sprinkle the parting powder just as before but this time using a slight larger amount of powder. - Place a tapered wooded pin “Sprue Pin” and place it in the top right corner of the Cope without touching the pattern or the flask. - Repeating the process of packing down small layers of sand using the ramming tool to appropriately tightly pack the sand together. Do this until the flask is completely filled with sand. - Take the strickling bar and remove the excess sand off of the top. - Gently tap the Sprue Pin with the strickling bar to loose it and then carefully remove the sprue pin from the sand mold by twisting it. - Then use a trowel to scraped of the rest of the excess sand. - Add vent holes by pressing a piece of wire straight down through the sand mold allowing air and smoke to escape - Separate the Cope frog the drag, flipping the cope upside down. - With both part of the pattern exposed, gently remove them by pulling on the pins on the both halves of the pattern. - Cut a “gate” trench impression on the drag sand mold between the imprint of the sprue pin and the pattern. - Put on goggle and blow on the impressions of the pattern in the sand to remove any excess sand. - Take the two halves of the core pattern and place them together. Fill them both with sand while packing the sand down periodically as its being filled. - Once filled scrape off the excess sand on both sides and pull apart the two halves. Remove the sand mold and place it into the original pattern where the hole is supposed to be located in the Drape. - Place the Cope Back on top and use the locating pin the secure them together. - Put on a heat resistant apron, gloves, and visor to protect from the melted metal. - Use the tong to grab the cup of metal and carefully pour it into the hole at the top of the flask. - Let the metal cool for 10 to 15 minutes. - Push the sand out of the casting. b. Watch the video and answer the following questions. https://www.youtube.com/watch?v=TecC9_nwpUw&t=9s Compare the following aspects and explain the differences between a manual Bridgeport machine and Tormach CNC. 1. Moving the workpiece 2. Move the tools 3. Cutting the workpiece - The main differences hand positioning dials versus computerized measuring and cutting machine. The Bridgeport machine moves by hand spinning the dials in the front and the side to perfectly position a piece of metal. Can cut a piece of metal by moving the dial in a smooth motion back and forth. Whereas the Tormach CNC using a computerized system and motors to move the desired piece of metal in order to create perfect cuts. c. Watch the injection molding process video and use your own word to summarize and explain the major steps of the process. https://www.youtube.com/watch?v=RMjtmsr3CqA Summary: - The used a machine to shape celluloid. Essentially the process of injection molding is done by melting plastic down to a liquid state and carefully injecting it into a mold where it will cool off and form into a solid. - An injection machine has three main part of execution, the injection unit, the mold, and the clamp. - A hopper is used to feed plastic pellets into the injection unit where a screw inside the barrel of the injection unit pushes the pellets forward and the pellets are simultaneously melted. Once enough molten plastic reached the front of the barrel of the screw the screw plunges forward pushing the molten plastic into the mold in the cavity image and once cooled in a matter of second the desired plastic shape is dropped out of the mold. Deliverables: Save your work as a pdf file and submit the file on Canvas.
