Content

Title
Pages
Introduction 3

Topic
1.Metal working processes 4

Hot working 4

Cold working 4

Extruding 6

Welding 7

Brazing/Soldering 8

2.Treatment method 9

Hardening 9

Tempering 10

Anealling 11

Normalizing 12

Case hardening 13

3.Composite process 14

Wet lay-up 14

Prepreg lay up 15

Filamnet winding 15

Press molding 16

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 Resin transfer molding(RTM) 17

Resin infusion 18

Chopper gun sprayed materials 19

KOBELCO 20

Conclusion 23

Bibliography 23

2
Introduction

The manufacturing process is divided into three,first is metalworking process, metalworking, rolling is a

metal forming process in which metal stock is passed through a pair of rolls. Rolling is classified

according to the temperature of the metal rolled. If the temperature of the metal is above its

recrystallization temperature, then the process is termed as hot rolling. If the temperature of the metal is

below its recrystallization temperature, the process is termed as cold rolling. Second is treatment

method,Heat Treatment is the controlled heating and cooling of metals to alter their physical and

mechanical properties without changing the product shape. Heat treatment is sometimes done

inadvertently due to manufacturing processes that either heat or cool the metal such as welding or

forming,And lastly is composite process, A comprehensive overview of composite manufacturing

processes. For each method, we discusses the process, raw materials and molds, crosslinking, component

characteristics, and applications.

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1.Metal working processes

 Hot working

Hot working refers to processes where metals are plastically deformed above their
recrystallization temperature. Being above the recrystallization temperature allows the material to
recrystallize during deformation. This is important because recrystallization keeps the materials
from strain hardening, which ultimately keeps the yield strength and hardness low and ductility
high.This contrasts with cold working.

 Cold working

A material is considered to be cold worked if its grains are in a distorted condition after plastic
deformation is completed. All the properties of a metal that are dependent on the lattice structure are
affected by plastic deformation or cold working. The following properties are affected by cold work
significantly:

 Tensile Strength

 Hardness

 Yield Strength

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  Ductility

Tensile strength, yield strength and hardness are increased, while ductility is decreased.
Although both strength and hardness increase, the rate of change is not the same.
Hardness generally increases most rapidly in the first 10 percent reduction (cold work),
whereas the tensile strength increases more or less linearly. The yield strength increases
more rapidly than the tensile strength, so that, as the amount of plastic deformation is
increased, the gap between the yield and tensile strengths decreases. This is important in
certain forming operations where appreciable deformation is required. In drawing, for
example, the load must be above the yield point to obtain appreciable deformation but
below the tensile strength to avoid failure. If the gap is narrow, very close control of the
load is required.

Effect of cold working on tensile and yield strength of copper.

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  Extruding

Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or
drawn through a die of the desired cross-section. The two main advantages of this process over other
manufacturing processes are its ability to create very complex cross-sections and work materials that are
brittle, because the material only encounters compressive and shear stresses. It also forms finished parts
with an excellent surface finish. Extrusion may be continuous (theoretically producing indefinitely long
material) or semi-continuous (producing many pieces). The extrusion process can be done with the
material hot or cold.Commonly extruded materials include metals, polymers, ceramics, concrete and
foodstuffs.Hollow cavities within extruded material cannot be produced using a simple flat extrusion die,
because there would be no way to support the center barrier of the die. Instead, the die assumes the shape
of a block with depth, beginning first with a shape profile that supports the center section. The die shape
then internally morphs along its length into the final shape, with the suspended center pieces supported
from the back of the die.

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  Welding

process for joining separate pieces of metal in a continuous metallic bond. Cold-pressure welding is
accomplished by the application of high pressure at room temperature; forge welding (forging) is done by
means of hammering, with the addition of heat. In most processes in common use, the metal at the points
to be joined is melted; additional molten metal is added as a filler, and the bond is allowed to cool. In the
Thomson process, resistance to an electric current, passed through the sections to be joined, causes them
to melt. Other notable methods include the thermite process, oxyacetylene, electric arc, oxyhydrogen, and
the atomic hydrogen flame. In this last-named method, molecules of hydrogen gas passing through an
electric arc are broken up into atoms of hydrogen by absorbing energy; when outside the arc, the atoms
reunite into molecules, yielding in the process enough heat to weld the material. Another process, the
argon-arc method, is widely used with metals such as stainless steel, aluminum, magnesium, and titanium,
which require an inert atmosphere for successful welding. The use of argon prevents slag from forming in
the weld and greatly increases the speed of the welding.

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 Brazing/Soldering

Brazing joins two pieces of base metal when a melted metallic filler flows across the joint and
cools to form a solid bond. Similar to soldering, brazing creates an extremely strong joint, usually
stronger than the base metal pieces themselves, without melting or deforming the components.
Two different metals, or base metals such as silver and bronze, are perfect for brazing. Use this
method to make a bond that is invisible, resilient in a wide range of temperatures, and can
withstand jolting and twisting motion.
The process of brazing is the same as soldering, although metals and temperatures differ. You can
braze pipes, rods, flat metals, or any other shape as long as the pieces fit neatly against each other
without large gaps. Brazing handles more unusual configurations with linear joints, whereas most
welding makes spot welds on simpler shapes.

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2.Treatment method

 Hardening

Hardening involves heating a steel to its normalising temperature and cooling (Quenching )
rapidly in a suitable fluid e.g oil, water or air.
Steel is basically an alloy iron and carbon some steels alloys have have various other elements in
solution.   When steel is heated above the upper critical temperature (about 760 oC), the iron
crystal structure will change to face centered cubic (FCC), and the carbon atoms will migrate into
the central position formerly occupied by an iron atom.   This form of red-hot steel is called
austentite (γ iron).   If this steel form cools slowly, the iron atoms move back into the cube
forcing the carbon atoms back out, resulting in soft steel called pearlite.   If the sample was
formerly hard, this softening process is called annealing.

If the steel is cooled quickly (quench) by immersing it in oil or water, the carbon atoms are
trapped, and the result is a very hard, brittle steel.   This steel crystal structure is now a body
centered tetragonal(BCT) form called martensite.

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  Tempering

After the hardening treatment is applied, steel is often harder than needed and is too brittle for most
practical uses. Also, severe internal stresses are set up during the rapid cooling from the hardening
temperature. To relieve the internal stresses and reduce brittleness, you should temper the steel after it is
hardened. Tempering consists of heating the steel to a specific temperature (below its hardening
temperature), holding it at that temperature for the required length of time, and then cooling it, usually
instill air. The resultant strength, hardness, and ductility depend on the temperature to which the steel is
heated during the tempering process.

The purpose of tempering is to reduce the brittleness imparted by hardening and to produce definite
physical properties within the steel. Tempering always follows, never precedes, the hardening operation.
Besides reducing brittleness, tempering softens the steel. That is unavoidable, and the amount of hardness
that is lost depends on the temperature that the steel is heated to during the tempering process. That is true
of all steels except high-speed steel. Tempering increases the hardness of high-speed steel.

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  Annealing

Full annealing is the process of slowly raising the temperature about 50 ºC (90 ºF) above the Austenitic
temperature line A3 or line ACM in the case of Hypoeutectoid steels (steels with < 0.77% Carbon) and 50
ºC (90 ºF) into the Austenite-Cementite region in the case of Hypereutectoid steels (steels with > 0.77%
Carbon).

It is held at this temperature for sufficient time for all the material to transform into Austenite or
Austenite-Cementite as the case may be. It is then slowly cooled at the rate of about 20 ºC/hr (36 ºF/hr) in
a furnace to about 50 ºC (90 ºF) into the Ferrite-Cementite range. At this point, it can be cooled in room
temperature air with natural convection.

The grain structure has coarse Pearlite with ferrite or Cementite (depending on whether hypo or hyper
eutectoid). The steel becomes soft and ductile

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  Normalizing

Normalizing is the process of raising the temperature to over 60 º C (108 ºF), above line A 3 or line ACM
fully into the Austenite range. It is held at this temperature to fully convert the structure into Austenite,
and then removed form the furnace and cooled at room temperature under natural convection. This results
in a grain structure of fine Pearlite with excess of Ferrite or Cementite. The resulting material is soft; the
degree of softness depends on the actual ambient conditions of cooling. This process is considerably
cheaper than full annealing since there is not the added cost of controlled furnace cooling.

The main difference between full annealing and normalizing is that fully annealed parts are uniform in
softness (and machinablilty) throughout the entire part; since the entire part is exposed to the controlled
furnace cooling. In the case of the normalized part, depending on the part geometry, the cooling is non-
uniform resulting in non-uniform material properties across the part. This may not be desirable if further
machining is desired, since it makes the machining job somewhat unpredictable. In such a case it is better
to do full annealing

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  Case hardening

Case hardening produces a hard, wear-resistant sur- face or case over a strong, tough core. The principal
forms of casehardening are carburizing, cyaniding, and nitriding.  Only  ferrous  metals  are  case-
hardened. Case hardening is ideal for parts that require a wear-resistant surface and must be tough enough
inter- nally  to  withstand  heavy  loading.  The  steels  best  suited for case hardening are the low-carbon
and low-alloy series. When high-carbon steels are case-hardened, the hardness penetrates the core and
causes brittleness. In case hardening, you change the surface of the metal chemically by introducing a
high carbide or nitride content.  The  core  remains  chemically  unaffected.  When heat-treated,  the
high-carbon  surface  responds  to  hard- ening,  and  the  core  toughens.

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 3.Composite processes
 Wet lay-up

The fibre is positioned in or on the mould by hand. If the mould is a complex shape small pieces of mat
are cut to fit and then more layers applied to achieve the required thickness. The liquid resin is poured
over the fibre and rolled to ensure complete wetting of the fibre and removal of air bubbles. In general the
resin cures at room temperature with the use of an accelerator and a catalyst. If a hot cure is used then
there is no need to use an accelerator. Post curing of cold cured laminates is recommended (2 hours @
80°C or 16 hours @ 40°C depending on resin manufacturers instructions).

Prior to application of the fibre and resin, the mould is prepared with either polyvinyl alcohol or non-
silicon wax to aid release of the component. Release of the component is achieved by either tapping
wedges between mould and component or by the use of compressed air to gently force the pieces apart.

Chopped Strand Mat is the most commonly used fibre although woven roving is used when a stronger and
stiffer laminate is required. A gel coat is applied to the mould surface to produce a resin rich smooth
surface for appearance and protection purposes. For improved surface finish and corrosion resistance a
surface veil is used which is applied with an embedded fabric for reinforcement or mixed with resin for
smooth surface.

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  Prepreq lay-up

 Filament winding

Filament winding is a fabrication technique for creating composite material structures. The process
involves winding filaments under varying amounts of tension over a male mould or mandrel. The mandrel
rotates while a carriage moves horizontally, laying down fibers in the desired pattern. The most common
filaments are carbon or glass fiber and are coated with synthetic resin as they are wound. Once the
mandrel is completely covered to the desired thickness, the mandrel is placed in an oven to solidify (set)
the resin. Once the resin has cured, the mandrel is removed, leaving the hollow final product.

Filament winding is well suited to automation, where the tension on the filaments can be carefully
controlled. Filaments that are applied with high tension results in a final product with higher rigidity and
strength; lower tension results in more flexibility. The orientation of the filaments can also be carefully
controlled so that successive layers are plied or oriented differently from the previous layer. The angle at
which the fiber is laid down will determine the properties of the final product. A high angle "hoop" will
provide crush strength, while a lower angle pattern (known as a closed or helical) will provide greater
tensile strength

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 Press molding

Compression molding is a method of molding in which the molding material, generally

preheated, is first placed in an open, heated mold cavity. The mold is closed with a top force or
plug member, pressure is applied to force the material into contact with all mold areas, while heat
and pressure are maintained until the molding material has cured. The process employs
thermosetting resins in a partially cured stage, either in the form of granules, putty-like masses, or
preforms. Compression molding is a high-volume, high-pressure method suitable for molding
complex, high-strength fiberglass reinforcements. Advanced composite thermoplastics can also
be compression molded with unidirectional tapes, woven fabrics, randomly oriented fiber mat or
chopped strand. The advantage of compression molding is its ability to mold large, fairly intricate
parts. Also, it is one of the lowest cost molding methods compared with other methods such as
transfer molding and injection molding; moreover it wastes relatively little material, giving it an
advantage when working with expensive compounds. However, compression molding often
provides poor product consistency and difficulty in controlling flashing, and it is not suitable for
some types of parts.

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 Resin transfer molding(RTM)

Resin transfer molding (RTM) is a low pressure closed molding process for moderate volume
production quantities, filling the gap between the slow, contact molding processes and the faster,
compression molding process, which requires higher tooling costs. Continuous strand mats and
woven reinforcement is laid up dry in the bottom mold half. Preformed glass reinforcements are
often used for complex mold shapes. The mold is closed and clamped, and a low viscosity,
catalyzed resin is pumped in, displacing the air through strategically located vents. Metered
mixing equipment is used to control resin/catalyst ratios that are mixed through a
motionless/static mixer and injected into the mold port

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 Resin infusion

Resin infusion is an environmentally friendly alternative to open molding. Resin infusion

produces consistent, high-quality parts for products like pleasure boats and windmill blades.
Using this process, large and complex structures are produced, and cores and inserts may be
incorporated.
This process impregnates layers of dry reinforcement contained between a rigid, air-tight mold
and a flexible sheet sealed to it around its perimeter. A partial vacuum is applied to the mold
cavity before resin is allowed to infuse into the reinforcement under atmospheric pressure,
impregnating both across and down through the reinforcement layers. The upper sheet is removed
once resin cure is complete, and the component may be removed.

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 Chopper gun sprayed materials

Fibreglass spray lay-up process is very different to the hand lay-up process. The difference comes
from the application of the fibre and resin material to the mould. Spray-up is an open-moulding
composites fabrication process where resin and reinforcements are sprayed onto a reusable
mould. The resin and glass may be applied separately or simultaneously "chopped" in a combined
stream from a chopper gun. Workers roll out the spray-up to compact the laminate. Wood, foam,
or other core material may then be added, and a secondary spray-up layer embeds the core
between the laminates. The part is then cured, cooled, and removed from the mould.

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Kobe Precision Technology Sdn Bhd.

Plot 39, Phase IV,

Bayan Lepas Industrial Estate,
11900 Penang, Malaysia

KPTec is the leading manufacturer of aluminum substrate in the world. We have the
latest and most advanced manufacturing process, equipment and facility. Aluminum
substrate is the base material for HDD media that uses magnetic recording technology
for its storage. Our key customers are the largest hard disk drive suppliers in the
world. KPTec invests heavily in people and technology to produce consistently high
quality product to cast our position as the leading aluminum substrate supplier for the
HDD industry.

Our process

 Blank
 Substrate

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Blanking Process

Our Blanking process has been developed to a highly advanced and matured level to
be a leading edge process of the HDD industry. Blanking is a process whereby the
aluminum coil or sheet is stamped into disk form. The disk then goes for heat
treatment to allow recrystallization of the microstructure to occur before final
inspection and testing. Our blanks are mainly for internal use although a portion is
sold to certain customers.

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Substrate Process

Substrate process is where the aluminum blanks undergo chamfering, annealing,

grinding and cleaning. The blanks are edge-lathed (chamfered) according to
customer's Inner Diameter & Outer Diameter (IDOD) specifications. The chamfered
blanks are then annealed at a certain temperature for a period of time to release the
mechanical stress from blanking process. Finally, the blanks undergo surface grinding
and cleaning. Grinding is the most critical process, as its purpose is to meet certain
edge profiles or curvatures, surface waviness and roughness. Our substrate facility is
capable to process various form factors and sizes.

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Conclusion

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In conclusion Student able to know about manufacturing process,especially heat treatment

method is important to know about flow process,after that student gain about the process

industrial manufacturing,

Beside that student also know about the how to design part effectively with use manufacturing

process,and lastly This knowledge facilitates the students to get a job after graduate will

Bibliography

Serope Kalpakjian,2010,Manufacturing Engineering and Technology,Singapore:Pearson

Education South Asia Pte Ltd

Meyers and Krishan Kumar Chawla,1999, Mechanical Behavior of Materials,United Kingdom:

Cambridge University Press

Vasiliev,2007, Advanced Mechanics of Composite Materials, Department of Mechanics and

Optimization of Processes and Structures, Russian State University of Technology, Moscow,
Russia

Avallone, Eugene A.; & Baumeister III, Theodore (1996). Mark's Standard Handbook for
Mechanical Engineers (8th ed.). New York: McGraw-Hill. ISBN 0-07-004997-1

Web

Composites, Copyright © 1998-2005 by Pichai Rusmee, http://www.mech.utah.edu

Composites - A Basic Introduction, AZoM™.com Pty.Ltd Copyright © 2000-2010,

http://www.azom.com/

Properties for Composite Materials, AZoM™.com Pty.Ltd Copyright © 2000-2010,

http://www.azom.com/

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