ENMF417 Manufacturing and Production Processes

Assignment 4 Solution

Q1. Describe some of non-traditional machining processes (at least 3) and discuss pros and cons
of each method.

Please explain the processes

a. Ultrasonic – Pro. Cheap, easy to cut Con. hard to maintain depth

b. Chemical machining – Pro. Can process thin metal or layered composites, Con. Undercut,
environmentally unfriendly
c. EDM – Pro. Accurate, hard to machine materials, Con. Limited for conductive material
d. Laser – Pro. fast, efficient, Con. Expensive – requires optics
e. Electron beam – pro. Accurate, con. Needs vacuum, small size

Q2. How can you tell whether a part is made of a thermoplastic or a thermoset?

Open-end answers. There are several nondestructive and destructive tests that can be
performed. For example, tension tests will demonstrate the difference: a pronounced
plasticity is indicative of a thermoplastic. Exposure to high temperatures is another test: the
presence of a glass-transition temperature is indicative of a thermoplastic. The shape of the
part is often a clue; for example, thin films must be made of thermoplastics because they are
blown from extruded tubing.

Q3. (a) Make a simplified sketch of screw injection molding, complete with a simple die. (b)
indicate the relative temperatures at the exit of the barrel and in the die for a thermoplastic and for
a thermosetting plastic. (c) Identify the essential die elements.

a) Screw, Clamp, Hopper, Heaters, Molds

b) Thermoplastics: Screw section – higher than the melting temp
Die section – less than the melting temp
Thermoset: Barrel temp < Die temp

c) sprue, runners, gates, ejectors, core and cavity

Q4. Describe and compare following Rapid Prototype processes: stereolithography, fused
deposition modeling, selective laser sintering, and 3D printing.

Stereolithography – uses a UV laser, cures photo sensitive exoxy resin, then solidifies at
the UV oven
ENMF417 Manufacturing and Production Processes
FDM – polymers are melted and squeezed

SLS – uses powders and melted by a CO2 laser

3D Printing – uses inkjet cartridges (instead of ink uses powders and binders)

Q5. Explain the PM process (draw the flow chart) and state the advantages & disadvantages of
the PM process.

Pros and Cons of PM

Adv.
Near net shape, no waste, controlled porosity dimension control better than casting

Disadv.
High cost of tooling and powder, powder harder to handle, geometric and size limitation, density
variations