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Design Procedure
1Art of constructing
2The art of directing great sourceof power in nature for use andconvenience of man
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Aesthetics
Apart from proper designing the productshould look good in order to impress thebuyer
Aesthetics is the set of principlesconcerning beauty of product duringdesigning
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Factors affecting Aesthetics
Shapes
Symmetry
Continuity Proportion
Style
Surface finish Colour
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Ergonomics
Ergon- work
Nomoi- natural laws
It is a scientific study between man andworking environment (tools, materialsused)
Its purpose is to find out the ways of
designing machine operations so that theyshould match the capabilities andlimitations of the man working on machine
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Aspects covered under Ergonomics
Communication between operator andmachine
Working environment
Human anatomy and posture duringoperation
Energy expenditure by hand or foot
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Manufacturing processes
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Primary shaping or forming process
Manufacturing a solid body from moltenGaseous state or from amorphous material
Forming tool contains a hollow space withallowance for contraction
Cohesion is normally created
Eg casting, powder metallurgy, plastictechnology
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Deforming process
Deforming process makes the use ofsuitable stresses like compression ,tension, shear or combined stresses to
cause plastic deformation of the materialsto produce required shapes withoutchanging its mass or material composition
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Deforming process
No material is removed but it is deformedand displaced
Eg forging , extrusion, rolling, sheet metalworking, rotary swanging,etc
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Machining
In this process material is removed fromthe unwanted region of the input materialby providing the suitable relative motions
between work piece and tool
Eg
Turning, grinding, shaping and planing,drilling,
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Joining processes
In this two or more metal pieces arecombined to form sub assembly or finalproduct by fusing , pressing, riveting,
Eg
Welding, brazing, soldering
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Brazing
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soldering
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Surface finishing process
These processes are utilized to achievethe intended surface finish on the metalsurface of a job
Dimension of the part hardly changes
Eg
Plastic coating, metallic coating, organicfinishes, anodizing,
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Material properties modificationprocesses
Material properties of material arechanged in order to achieve the desirablecharacteristics in metals without changing
the shape
Eg
Heat and surface treatment, anneling,stress reliving
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Welding
Welding is the procedure of joining similarmetals by application of heat with orwithout application of pressure and
addition of filler material
Weldability is defined as capacity of beingwelded into inseparable joints having
specified properties such as definite weldstrength, proper structure , etc
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Types of welding
welding
Plastic/pressurewelding
Fusion /Non pressurewelding
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Plastic/pressure welding
The piece of metal to be joined are heatedto a plastic state and then forced togetherby external pressure
Types of Plastic/pressure
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Types ofPlastic/pressurewelding
Plastic/pressurewelding
forge resistance thermit gas
Types of Fusion /Non pressure
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Types of Fusion /Non pressurewelding
Fusion /Non pressurewelding
Gas Arc Thermit
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Cold welding
Joints are produced without application ofheat but by applying pressure whichresults in intersurfase molecular fusion of
parts to be joined
Mainly used for non ferrous metal sheets
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Resistance welding
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ARC WELDING
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TAGS/TIG/GTAW
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TAGS/TIG/GTAW
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MAGS/MIG/GMAW
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SPOT WELDING
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SPOT WELDING
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SEAM WELDING
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SEAM WELDING
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BENDING
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BENDING
Sheet metal work strained around a straightaxis.
Metal on the inside of neutral axis iscompressed.
Metal on the outside of neutral axis is stretched . Metal is plastically deformed so that bend is
permanent. There is no change in thickness .
Deformed shape tends to change a little afterforce acting on it is taken out . This is known asSPRING BACK effect.
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TYPES OF BENDING
V-BENDING :Sheet metal is bent between V-
shape die & punch
Acute & obtuse angles can bemade with V dies
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Edge bending
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