Chapter 12

Manufacturing Processes, ME33x2

Lab Engineer Rehan Zahid
NUST School of Mechanical and Manufacturing Engineering
( Fundamentals of Modern Manufacturing; Materials, Processes and Systems, by M. P. Groover)

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Introduction Raw Materials Preparation and Melting Shaping Process in Glassworking Heat Treatment and Finishing Product Design Consideration

 Glass falls in the category of ceramics and has noncrystalline structure Starting material is silica (SiO2) Steps involved in glass working Starting material is heated to transform it from a hard solid into a viscous liquid Viscous liquid is shaped into the desired geometry Heat treatment and solidification Examples of Glass products : light bulbs, beverage bottles, window glass, giant telescope lenses
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 Primary source of silica is quartz Sand must be washed and classified Washing removes impurities (clay) and undesirable coloring of the glass Classifying means grouping the grains according to size (0.1 to 0.6 mm)

 Recycled glass is also added to facilitate melting Batch of starting materials to be melted is known as charge Procedure of loading charge into the melting furnace is called charging the furnace Glass melting is carried out at temperatures 1500C to 1600C Molten glass is a viscous liquid

Spinning

Similar to centrifugal casting of metals Applications: Funnel-shaped components such as the back sections of cathode ray tubes for televisions and computer monitors Process: Stack of molten glass is dropped into a conical mold steel Mold is rotated so that centrifugal force causes the glass spread itself on the mold surface
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Spinning

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Pressing

Used for mass producing glass pieces such as dishes, bake ware, headlight lenses etc. Large quantities of most pressed products justify a high level of automation

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Blowing

Blowing is performed on highly automated equipment Applications: Jars, beverage bottles, incandescent light bulb enclosures etc. Types of blowing sequences Press-and-blow Consists of pressing and blowing operation Split mold is used in the blowing operation for easy part removal
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Blowing

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Press and blow

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Blow and blow

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Casting

Not much used in glassworking Molten glass is poured into a mold Relatively massive objects (astronomical lenses and mirrors) are made by casting To avoid internal stresses and cracking very slow cooling is carried out Finishing is done by lapping and polishing Problems: Molten glass is relatively viscous at normal working temperatures Does not flow through small orifices or into small sections

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Shaping of Flat and Tubular Glass

Used for making plate glass and producing tube stock using continuous processes Long sections of flat window glass or glass tubing are made and later cut into appropriate sizes and lengths

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Rolling of Flat Plate

Starting glass in a plastic condition is squeezed through opposing rolls Separation between rolls determines the thickness of the sheet Rolled glass sheet must later be ground and polished for parallelism and smoothness

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Float Process

Produces smooth surfaces that need no subsequent finishing Glass flows directly from its melting furnace onto the surface of a molten tin bath Highly fluid glass spreads evenly across the molten tin surface, achieving a uniform thickness and smoothness Cooler region of the bath hardens glass Glass is cut to size

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Float Process

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Heat Treatment

Glasses are heat treated using annealing and tempering Annealing involves Heating of glass to an elevated temperature (500C) Maintaining the temperature for some period of time to eliminate stresses Cooling

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Tempering

Tempering increases the toughness of glass Tempering involves Heating the glass to a temperature above its annealing temperature Quenching of the surfaces with air jets Glass formed by tempering is known as Tempered Glass Properties of Tempered Glass Resistant to scratching Resistant to breaking Withstand large compressive stresses

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Tempering

Applications of Tempered Glass Tall buildings Glass doors

Can we use tempered glass in automobile windshields?

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Tempering

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Finishing

Finishing operations include Grinding Polishing Cutting Glass produced by drawing and rolling contains defects and scratch marks due to usage of hard tooling on soft glass which can be removed by polishing Pressing and blowing operation produced by split dies left seam marks which can be removed by polishing Continuous sections produced during plate and tube production are cut into smaller pieces by glass-cutting wheel or cutting diamond

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Finishing

Decorative and surface processes include Sandblasting Chemical etching Coating

How glass can be converted into mirrors?

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 Glasses are used when transparency, light transmittance, magnification etc is required Glasses should not be used in applications that involve impact loading because of brittleness Certain glasses have very low thermal coefficients and can tolerate thermal shock (Any example???) Outside and inside corners should be rounded

Why corners are generally rounded or chamfered???

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