SME: Basic Manufacturing Processes

SME (the Society of Manufacturing Engineers) has a great playlist of Youtube videos that outlines many basic manufacturing processes, and they are all right here for you. Most of the videos are from two to five minutes in length, and get the main points of those processes across to students in an easy to understand format. There are 44 videos in all. Thanks SME!

The best way to search for or find  a particular video is to use Ctrl + F in the browser window and then type in the process you are looking for. It will then jump to the video you are searching for!

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What else do we need to teach CIM?

Question:

What else do we need to really teach CIM? Are there any “extras” that you recommend?

Answer:

We get this question weekly. So here’s what we are going to do. Give you a preview to a Google doc that is live so we can update it on the fly. You will see it right below this paragraph. Be sure to scroll left and right and up and down to see all of the content! Links are live too!

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What’s the difference between Ferrous and Nonferrous Metals?

Question:

What’s the difference between Ferrous and Nonferrous Metals?

Answer:

Special thanks to John Hawthorne for some answers to this question. Be sure to see this information in its entirety HERE. There is a youtube video at the end that helps explain it too.

Ferrous Metal Examples
  • Cast iron (iron molded in a cast to achieve a particular shape. Used for everything from brake rotors to skillets)
  • Sheet iron (used in appliances like washing machines, dryers, dishwashers)
  • Wrought iron (used most visibly in fencing and gates)
  • Carbon steel (also called structure steel because it is frequently used in the construction industry)
  • Other alloy steels of various combinations (like stainless steel, used most commonly in surgical instruments and kitchen cutlery; and carbon steel, which is used to make drill bits and other tool parts)
  • Iron-based superalloys (often used to make aircraft bearing and sliding machine parts because if their heat- and erosion-resistance capabilities)

Ferrous Metal Qualities/Uses Given their strong properties, many of these metals are employed in projects that require durability and strength. That’s why they’re used in cars and other forms of transportation, construction, shipping, piping, railroad tracks, and many tools. Additionally, they tend to be highly magnetic, so that is why a stainless-steel pair of scissors or refrigerator door can attract a magnet so easily. However, because of high carbon content, ferrous metals will rust easily when exposed to moisture. The only exceptions are stainless steel (because of its high chromium content) and wrought iron.

     

    Nonferrous Metal Examples
  •  Precious metals (gold, silver, platinum—obviously used for jewelry)
  • Copper (frequently used for pots because of its ability to conduct heat)
  • Lead (used in pipes and roofing)
  • Tin (used in cans and becomes pewter flatware and other household items when made an alloy)
  • Zinc (when an alloy, it’s often used in car building and construction)
  • Aluminum (extremely common in everything from utensils to airplane parts to beer kegs)
  • Brass (used for ornamentation as well as electrical fittings)

       

  Nonferrous Metal Qualities/Uses  The lack of iron in nonferrous metals makes them ideal for uses that require repeated exposure to water and the elements of nature, so gutters, pipes, roofing parts, parts of ships, and even street and highway signs are often made of these metals. They are also highly malleable, which makes shaping them into a finished product much easier and faster. Because of their lack of magneticity, these metals are well-suited to electronic uses like in wiring. Finally, since nonferrous metals are very light but extremely strong, they tend to be used in industries where great strength and extreme light weight is necessary, such as with airplanes and canning machines.

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CIM Material Processes

 

HWMT BrochureYour students really need to know how things are made in industry, so below are some resources to help you get started with the learning process. My students became an “expert” in one particular field, picked a topic, and made a brochure about a specific manufacturing process. Part of their research was to find a great video that explains the process. The links to all of the videos, as well as some of their brochures as well.

Download the 2017 HIM Brochure Topics .

Download the Process Brochure Template as a zipped publisher file.

Download the 2013 HIM Brochure Rubric.

All videos linked below are in order as they appear on the Brochure Topics Handout referenced above.

Prototyping

Fused Deposition Modeling (FDM): is an additive manufacturing technology commonly used for modeling, prototyping, and production applications. It is one of the techniques used for 3D printing.
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Brochure Goes Here!

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 Selective Laser Sintering (SLS):  is an additive manufacturing (AM) technique that uses a laser as the power source to sinter powdered material (typically metal), aiming the laser automatically at points in space defined by a 3D model, binding the material together to create a solid structure.
Brochure coming soon…

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 Stereolithography (SL):  is a form of 3-D printing technology used for creating models, prototypes, patterns, and production parts in a layer by layer fashion using photopolymerization, a process by which light causes chains of molecules to link together, forming polymers.
Brochure coming soon…

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 Laminated Object Manufacturing (LOM): is a rapid prototyping system. In it, layers of adhesive-coated paper, plastic, or metal laminates are successively glued together and cut to shape with a knife or laser cutter.
Brochure coming soon…

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rapid prototyping system. In it, layers of adhesive-coated paper, plastic, or metal laminates are successively glued together and cut to shape with a knife or laser cutter.
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 Separating

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CNC Milling is  the most common form of computer numerical control (CNC) machining, performs the functions of both drilling and turning machines. CNC mills are categorized according to their number of axis and are traditionally programmed using a set of codes that represent specific functions.
 Brochure coming soon…
 

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 CNC Turning refers to the automated machining process of shaping material, such as metal, wood or plastic, using a computer numeric control (CNC) machine. Turning is usually done when making round parts.
  Brochure coming soon…
 

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Waterjet Cutting:  is a form capable of cutting a wide variety of materials using a very high-pressure jet of water, or a mixture of water and an abrasive substance.
 Brochure coming soon…

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Laser Cutting  is a technology that uses a laser to cut materials, and is typically used for industrial manufacturing applications, but is also starting to be used by schools, small businesses, and hobbyists. Laser cutting works by directing the output of a high-power laser most commonly through optics.
Brochure coming soon…

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 Casting

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Drop Forging  is the process of heating metal and hammering it in to a special die (cast die) to produce a final product. Manufacturers use the drop forging process to produce hardware products which need to be strong and durable.
Brochure coming soon…

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Die Casting  is a metal casting process that is characterized by forcing molten metal under high pressure into a mould cavity. The mould cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mould during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
Brochure coming soon…

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Investment Casting is an industrial process based on lost-wax casting, one of the oldest known metal-forming techniques.[1] The term “lost-wax casting” can also refer to modern investment casting processes.Investment casting has been used in various forms for the last 5,000 years. In its earliest forms, beeswax was used to form patterns necessary for the casting process. Today, more advanced waxes, refractory materials and specialist alloys are typically used for making patterns. Investment casting is valued for its ability to produce components with accuracy, repeatability, versatility and integrity in a variety of metals and high-performance alloys.
Brochure coming soon…

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Jim Hanson

Chris Hurd

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