Fundamental Manufacturing Processes

VIDEO SERIES

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Visualize Manufacturing Processes in Action The Fundamental Manufacturing Processes (FMP) video series contains over 40 video programs illustrating more than 20 hours of hands-on manufacturing processes. > Solid, in-depth examples and applications of technologies and processes that drive manufacturing > Real-world company examples with clear explanations and demonstrations > Free downloadable outline and study guide with review questions for each video

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The FMP video series is an outstanding supplement to your classroom and corporate training program. Even nontechnical audiences will gain an understanding of core manufacturing technologies, processes, and vocabulary to aid in their support of manufacturing operations.

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TABLE OF CONTENTS METALCUTTING Turning & the Lathe..................................2 Milling & Machining Centers ....................2 Holemaking ..............................................2 Threading .................................................3 Grinding ...................................................3 Workholding .............................................3 Cutting Tool Materials ..............................4 Cutting Tool Geometries ...........................4 Computer Numerical Control ....................4 Gears & Gear Manufacturing....................5 Electrical Discharge Machining................5 Thermal & Abrasive Waterjet Cutting Processes ...................................5 Metalcutting Fluids ..................................6 Deburring Processes.................................6

RAPID TECHNOLOGY Rapid Prototyping...................................11 NEAR-NET SHAPE FORMING Casting ..................................................12 Die Casting ............................................12 Forging ...................................................12 Powder Metallurgy ..................................13 Extrusion Processes................................13 HEAT TREATING Heat Treating..........................................13 FINISHING & COATING Plating & Surface Coatings ....................14 Painting & Powder Coating ....................14

METALFORMING Sheet Metal Coil Processing .....................6 Sheet Metal Shearing & Bending..............7 Sheet Metal Stamping Presses .................7 Sheet Metal Stamping Dies ......................7 Punch Presses ..........................................8 Roll Forming .............................................8 Tube Bending ...........................................8 Hydroforming............................................9 PLASTICS & COMPOSITES Plastic Injection Molding ..........................9 Plastic Injection Molds .............................9 Plastic Blow Molding ..............................10 Plastic Thermoforming ...........................10 Plastics Finishing...................................10 Plastics Machining & Assembly .............11 Composite Materials & Manufacturing...11

JOINING & ASSEMBLY Welding ..................................................14 Brazing & Soldering ...............................15 Fastening & Assembly ............................15 Industrial Robotics .................................15 QUALITY & MEASUREMENT Mechanical & Non-Destructive Testing........................16 Measurement & Gaging..........................16

METALCUTTING Turning & the Lathe Turning on the lathe is one of the most common metalcutting operations. Explore the basic components of an engine lathe, workholding arrangements, tooling arrangements, and turning process variables. FEATURES: critical lathe dimensions, stockholding methods, both external and internal turning processes, CNC lathes, tool-holding methods, and operating parameters.

(30 minutes) Product ID: DV09PUB1 ................................... $280/Members: $252 Milling & Machining Centers Discover what makes milling with machining centers an important high-volume process for shaping materials. Learn about the milling process and the use of tool changing, work changing, and workholding arrangements on machining centers. FEATURES: basics of knee mill and machining centers, milling cutters, operations, accessories, process variables, and operational performance. (29 minutes) Product ID: DV09PUB2 ................................... $280/Members: $252 Holemaking Explains the elements of a drill and what types are used in various applications. Includes operating parameters and good drilling practices to help operators understand what is happening during holemaking operations. FEATURES: basic twist drill description, importance of coolants, drill maintenance and sharpening, manual and numerically controlled holemaking equipment, and secondary drilling and finishing operations.

(28 minutes) Product ID: DV09PUB3 ................................... $280/Members: $252

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Threading Illustrates the dimensions that make up all threads, including the major diameter, the minor diameter, the thread pitch, and the thread pitch diameter. Learn about the various processes that produce external threads and internal threads. FEATURES: various forms of tooling, thread-producing machinery, tapping process, and tapping machines.

(29 minutes) Product ID: DV09PUB5 ................................... $280/Members: $252 Grinding See the grinding process and how it is used to shape and finish metal and other materials. The applications of these methods are featured along with illustrations of the most common abrasives and superabrasives. FEATURES: cylindrical, internal, centerless, and surface grinding processes; types of abrasives and bonding methods; grinding wheel maintenance; the specifics of surface finishing; and grinding safety.

(33 minutes) Product ID: DV09PUB4 ................................... $280/Members: $252 Workholding Examine the principles and concepts inherent to all workholding, such as the “six degrees of freedom.� Explore the various workholding options for milling and machining centers and lathes.

FEATURES: workholding requirements; methods for high- and low-volume parts; machining center workholding; and the use of chucks, collets, and other lathe workholding devices.

(27 minutes) Product ID: DV09PUB6 ................................... $280/Members: $252

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Cutting Tool Materials Explore the wide variety of cutting tools and tool materials, from high-speed steel and carbide to superhard materials. This program shows you how to select the proper tool material for turning and milling operations. The various tool coatings and cutting tool failure modes are also discussed. FEATURES: high-speed steels; carbide properties, types, grades and coatings; ceramics and cermets; superhard cutting materials like cubic boron nitride and polycrystalline diamond; and failure modes, such as cratering, deformation and notching.

(25 minutes) Product ID: DV03PUB12 ................................. $280/Members: $252 Cutting Tool Geometries Learn the various angles and geometries that make up milling and turning cutting tools. Also covered are chip-breaker designs in turning and how to identify which is appropriate for your machining operation. FEATURES: single-point turning tools and toolholders, multi-point milling cutters, mechanics of chip generation with respect to tool geometry, and face milling cutter geometry.

(27 minutes) Product ID: DV03PUB13 ................................. $280/Members: $252 Computer Numerical Control Features segments on CNC principles and CNC programming. The rectangular coordinate system and its use in generating precision tool paths are explained, including: program zero, coordinate points, coordinate polarity, the absolute mode, the incremental mode, quadrants, and the various axes of motion. FEATURES: CNC technology, program creation for parts, and machine programming concepts.

(24 minutes) Product ID: DV03PUB9 ................................... $280/Members: $252

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Gears & Gear Manufacturing Defines several gear and gear-tooth terms and dimensions, such as: base circle, pitch circle, pitch point, line of action, pressure angle, outside circle, root circle, addendum, dedendum, and tooth thickness. Also emphasizes the gear machining methods used, including: hobbing, shaping, broaching, and milling. FEATURES: terminology, gear form types, and finishing techniques.

(22 minutes) Product ID: DV03PUB29 ................................. $280/Members: $252 Electrical Discharge Machining Explains ram and wire-cut EDM processes as well as their basic machine subsystems. Highlights the many benefits as well as the limitations of EDM. FEATURES: the components of an EDM system, EDM erosion process, EDM hole drilling, computer numerically controlled EDM applications, and safety precautions.

(23 minutes) Product ID: DV03PUB14 ................................. $280/Members: $252 Thermal & Abrasive Waterjet Cutting Processes Provides a comprehensive introduction to the three most commonly used thermal cutting processes: oxy-fuel, plasma, and laser, and examines the best applications for waterjet cutting. See the advantages and disadvantages of each process and learn how to choose the most effective method based on the type of material and cut intricacy. FEATURES: basis for specific process selection, the oxy-fuel gas process, plasma- and laser-cutting applications, and abrasive waterjet cutting.

(23 minutes) Product ID: DV03PUB17 ................................. $280/Members: $252

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Metalcutting Fluids Learn what fluids actually do during the metalcutting process and how to properly apply and care for them. Newer technologies like minimum quantity lubrication and dry machining are also explained.

FEATURES: various types of cutting fluids, different application methods, how to select the right fluids for your processes, methods for maintaining fluids, and safety requirements.

(23 minutes) Product ID: DV05PUB41 ................................. $280/Members: $252 Deburring Processes Explores mechanical deburring, thermal deburring, and electrochemical deburring. Learn about the various mass-finishing processes such as vibratory finishing, barrel/rotary tumble, centrifugal disk finishing, centrifugal barrel finishing, and spindle finishing. FEATURES: deburring processes and applications; types of systems and equipment; and mechanical, thermal, and electro-chemical processes.

(27 minutes) Product ID: DV03PUB27 ................................. $280/Members: $252 METALFORMING Sheet Metal Coil Processing Illustrates the essentials of coil slitting, coil blanking, and coil processing lines. Coil slitting details the slitting process and the elements of loop-type slitting lines and pull-through slitting lines.

Coil blanking highlights the use of stationary cut-to-length shearing lines, flying shear lines, and blanking presses. FEATURES: coil stock production and handling, slitting line systems, blanking and shearing processes, and basic components of a coil processing line.

(25 minutes) Product ID: DV03PUB30 ................................. $280/Members: $252

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Sheet Metal Shearing & Bending See how a part is sheared and the variety of shearing machines available, along with examples of press brake dies, bending operations, and coil slitting. Additionally, learn about the necessity for gaging in both shearing and bending operations. FEATURES: the principles of shearing and bending, demonstration of the theory of shearing and bending, machinery operation, and the functions of die tooling.

(21 minutes) Product ID: DV03PUB18 ................................. $280/Members: $252 Sheet Metal Stamping Presses This video outlines the differences between mechanical and hydraulic presses, their components, and the advantages and disadvantages of each. Also, learn about press drive configurations, high-speed presses, and feeding methods for sheet metal blanks and coiled stock. FEATURES: the mechanical aspect of stamping, press drive systems, press selection, and control and feed systems.

(29 minutes) Product ID: DV11PUB8 ................................... $280/Members: $252 Sheet Metal Stamping Dies This video explores basic die operations such as shearing, drawing, and bending, as well as single-station dies, multiple-station dies, and tandem press lines. Segments on die lubrication and stamping analysis are also included. FEATURES: components of the stamping, process, basic stamping terms, progressive and transfer die technology, die lubrication, and circle grid analysis.

(24 minutes) Product ID: DV11PUB9 ................................... $280/Members: $252

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Punch Presses Examine the versatility of the turret punch press and its tooling accessories such as the plasma cutting torch, laser cutting attachment, and automated material loading and unloading equipment. Operations such as nibbling are also covered along with a look at special punch press tooling, such as multi-tools and special rotary adapters. FEATURES: CNC turret punch operation, types of punch presses, accessories, and material handling systems.

(20 minutes) Product ID: DV03PUB19 ................................. $280/Members: $252 Roll Forming Provides viewers with an immediate understanding of basic roll forming concepts. Shop floor footage and high-quality animations detail roll form tooling design and the forming of coil stock.

FEATURES: basic concepts and technical terms; dimensional tolerances; straightness, camber, curve, bow, and twist; tooling design and manufacturing; machine types; and lubricants.

(26 minutes) Product ID: DV06PUB5 ................................... $280/Members: $252 Tube Bending Examine the various materials and methods used for bending and forming tubes, and the most common tube bending methods: rotary-draw bending, compression bending, ram bending, press bending, and roll bending. Also, explore the basic forms that can be applied to the end of a tube, with the primary types being: reduction, expansion, flaring, and beading. FEATURES: types of tubing, bending dynamics, tube bending methods, tooling, and machinery.

(22 minutes) Product ID: DV03PUB31 ................................. $280/Members: $252

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Hydroforming Gain a basic understanding of the materials and tools of the three primary types of tubular hydroforming techniques: low pressure, high pressure, and pressure sequence. The sheet metal hydroforming process, as well as in-process hydro-piercing and the importance of lubricants, are also presented. FEATURES: elements of a hydroforming system, sheet metal hydroforming and tubular hydroforming methods, requirements for each hydroforming type, and metals used in hydroforming.

(23 minutes) Product ID: DV03PUB28 ................................. $280/Members: $252 PLASTICS & COMPOSITES Plastic Injection Molding Follow plastic material from its raw material state through the melting process and onto its injection into the mold. Scripted by plastics industry expert, Irvin I. Rubin, the program covers injection and clamping systems, various components of the injection machine, definition of terms, and common mold types. FEATURES: the properties inherent in plastic, types of plastic materials, overview of the injection machine, and mold types.

(25 minutes) Product ID: DV03PUB22 ................................. $280/Members: $252 Plastic Injection Molds Illustrates the primary injection mold components, injection mold types, use of computer simulation to develop molds, mold prototyping techniques, and mold maintenance and repair.

FEATURES: mold components, various mold types, aspects of mold maintenance, and storage.

(28 minutes) Product ID: DV04PUB13 ................................. $280/Members: $252

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Plastic Blow Molding Details various blow molding production methods, including intermittent and continuous extrusion blow molding, injection blow molding, single- and two-stage bi-axial stretch blow molding, and coextrusion blow molding. FEATURES: parison and preform production, reciprocal-screw-style and accumulator-style blow molding machines, and head and die assembly.

(20 minutes) Product ID: DV03PUB21 ................................. $280/Members: $252 Plastic Thermoforming Discover methods used to produce low- and high-volume products for the packaging, food, medical, automotive, and appliance industries. Learn about materials used in thermoforming, the types of clamping and heating systems, mold types and arrangement, thermoforming forces, and various in-cycle and post-thermoforming trimming methods. FEATURES: drape, cavity, pressure, plugassist, and twin-sheet thermoforming.

(22 minutes) Product ID: DV06PUB3 ................................... $280/Members: $252 Plastics Finishing Explore plastics finishing processes such as degating, deflashing, painting, plating, vacuum metallizing, pad printing, hot stamping, silk screening, and fill-and-wipe. See how contaminants infiltrate the molding process and how parts are cleaned for these secondary decorative operations. FEATURES: runnerless molds, post-molding operations, and basic methods of “applied� decoration.

(23 minutes) Product ID: DV02PUB1 ................................... $280/Members: $252

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Plastics Machining & Assembly Highlights the use of sawing, milling, routing, turning, waterjet cutting, laser cutting, drilling, and secondary holemaking operations while covering the many fastening and joining methods.

FEATURES: methods of machining plastics, cutting tool materials and geometries, and various assembly and joining methods.

(27 minutes) Product ID: DV02PUB3 ................................... $280/Members: $252 Composite Materials & Manufacturing Illustrates the methods to produce composite parts such as: manual layup, automated layup, spray up, filament winding, pultrusion, and resin transfer molding. Covers the most widely used composite materials — fiber-reinforced thermosetting polymers with the primary types of matrix and reinforcement materials — as well as the various forms in which they are available. FEATURES: physical nature of composites, function of the various types of reinforcements, fabrication, and assembly methods.

(28 minutes) Product ID: DV02PUB2 ................................... $280/Members: $252 RAPID TECHNOLOGY Rapid Prototyping An introduction to several technologies and systems used to produce rapid prototyped models, parts, and tooling. Provides a fundamental understanding of stereolithography, selective laser sintering, fused deposition modeling, ultrasonic consolidation, the PrometalÂŽ System, various ink- and multi-jet systems, and room temperature vulcanized tooling. FEATURES: basic concepts of rapid prototyping, layer-by-layer modeling, and pattern-based prototyping.

(24 minutes) Product ID: DV03PUB106 ............................... $280/Members: $252 800.733.4763 | sme.org/fmp

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NEAR-NET SHAPE FORMING Casting Explore more than a dozen casting processes and learn how part size, part configuration, part quantity, required tolerances, and metal specified determine the best casting process to choose.

Watch how different molds and patterns are created and how molten metal is transferred from the pouring basin to the mold cavity. FEATURES: principles of casting, various casting methods, mold and pattern construction, and typical alloys cast and their finished characteristics.

(26 minutes) Product ID: DV03PUB6.................................... $280/Members: $252 Die Casting Covers the most common die-cast metals and their various properties, as well as die casting machines and die casting tooling.

The two principal types of die casting machines — the hotchamber machine and the cold-chamber machine — are covered in detail. Learn what types of metals are typically used in each type of machine and see how molten metal is injected into the die.

FEATURES: die casting metallurgy, die casting machinery, hot and cold chamber casting, and die construction.

(23 minutes) Product ID: DV03PUB23.................................. $280/Members: $252 Forging Focus is on the two primary types of forging: open-die and impression-die forging. Learn various properties of forgeable metals and factors that affect their forgeability. Other related forging processes, including ring rolling, hot-die forging, and isothermal forging, are also detailed. FEATURES: definitions and principles behind the technology, open and closed die methods, hot die technology, and use of computers.

(23 minutes) Product ID DV03PUB7..................................... $280/Members: $252

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Powder Metallurgy The methods used to produce metal powders as well as an in-depth discussion of the common part production processes — mechanical pressing and sintering, metal injection molding, and hot and cold isostatic pressing — are illustrated in this program.

FEATURES: mechanical pressing and sintering, metal injection molding, hot and cold isostatic pressing, types of powder metal particles, mechanical pressing, and injection molding processes.

(23 minutes) Product ID: DV03PUB20 ................................. $280/Members: $252 Extrusion Processes An introduction to plastic extrusion and metal extrusion processes with segments on hot metal extrusion, warm and cold metal extrusion processes, plastic profile extrusion, and blown film extrusion. FEATURES: demonstrations of the extrusion process; hot, warm, and cold extrusion processes; industrial applications; direct, indirect, combination, and impact extrusion; and plastic extrusion processes.

(21 minutes) Product ID: DV04PUB12 ................................. $280/Members: $252 HEAT TREATING Heat Treating Explains and defines heat treating and how it produces stronger, harder, tougher, and sometimes softer metals and alloys. Explore the relationship between temperature, alloy composition, and the metallurgical changes that occur during heating and cooling.

Learn about austenitizing and quenching speeds, mediums, and temperature control, as well as the tempering process.

(30 minutes) Product ID: DV03PUB24 ................................. $280/Members: $252

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FINISHING & COATING Plating & Surface Coatings Gain an in-depth understanding of the numerous plating and surface coating methods and technologies used to modify and finish parts including electroplating, electroless plating, chemical conversion coatings, anodizing, galvanizing, and porcelain enameling. FEATURES: plating and surface coating terminology, application methods, and methods for high production.

(28 minutes) Product ID: DV06PUB4 ................................... $280/Members: $252 Painting & Powder Coating Learn about the two types of resin polymer structures: enamels and lacquers. Extensive shop floor footage shows numerous paint applications, including conventional air spraying, airless spraying, air-assisted airless spraying, high volume low-pressure spraying, and electrocoating. Process subsystems used to coat parts are also explained. FEATURES: paint and powder formulations, solvent borne and waterborne coatings, application methods, and drying and curing methods.

(23 minutes) Product ID: DV03PUB26.................................. $280/Members: $252 JOINING & ASSEMBLY Welding An illustrative primer on welding processes, learn about arc welding, resistance welding, laser beam welding, and electron beam welding. This program also examines both the friction and ultrasonic welding processes. FEATURES: joint design and preparation, a guide to process selection, fusion and solid-state welding methods, and the operative aspects of the processes and their applications.

(29 minutes) Product ID: DV03PUB1 ................................... $280/Members: $252

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Brazing & Soldering Gain an understanding of the fundamental similarities and differences between the two joining processes, learn basic terminology, and become familiar with common applications.

Coverage includes the techniques and materials used to produce brazed and soldered components for the automotive, aerospace, appliance and electronics industries. FEATURES: fluxes and filler metals — both manual and automated methods.

(25 minutes) Product ID: DV03PUB124 ............................... $280/Members: $252 Fastening & Assembly Covering both fasteners and adhesives, this program explains: the various types and uses of integral fasteners, threaded fasteners, non-threaded fasteners, and stapling along with the many types and applications of adhesives used in joining similar and dissimilar materials together. The automated assembly segment examines the ways in which parts are sorted, loaded, and presented for automated assembly. FEATURES: mechanical fastener types and assembly devices, adhesive bonding, manual and automated assembly systems, and automated assembly machines.

(20 minutes) Product ID: DV03PUB8 ................................... $280/Members: $252 Industrial Robotics Review the overall advantages and disadvantages of industrial robots in manufacturing operations, including major applications such as welding, spray painting, machining, assembly, machine loading and unloading, and material handling. FEATURES: overview of robot technology, primary types of industrial robots, programming methods, robot tooling and sensors, key manufacturing applications using robots, and advantages and disadvantages of industrial robots.

(25 minutes) Product ID: DV04PUB11 ................................. $280/Members: $252

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QUALITY & MEASUREMENT Mechanical & Non-Destructive Testing Both mechanical and non-destructive tests are used to gage the quality of materials and parts throughout the manufacturing process. Program introduces the key concepts, terminology, and basic methods of these tests. FEATURES: testing methods and how they are performed and advantages and limitations of the various tests.

(26 minutes) Product ID: DV06PUB6 ................................... $280/Members: $252 Measurement & Gaging Beginning with an introduction to the core concepts of measurement, this program focuses on the wide array of measurement and gaging tools available. Tools are arranged into three categories: nongraduated measurement and gaging tools, graduated measurement and gaging tools, and advanced measurement and gaging tools. FEATURES: concepts of measurement; nongraduated and graduated tools; direct-reading devices; and optical, vision, and coordinate measurement systems.

(28 minutes) Product ID: DV03PUB25 ................................. $280/Members: $252

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INDEX Brazing & Soldering ............................... 15

Painting & Powder Coating .................... 14

Casting .................................................. 12

Plastic Injection Molding .......................... 9

Composite Materials & Manufacturing... 11

Plastic Injection Molds ............................. 9

Computer Numerical Control .................... 4

Plastic Thermoforming ........................... 10

Cutting Tool Geometries ........................... 4

Plastics Finishing................................... 10

Cutting Tool Materials .............................. 4

Plastics Machining & Assembly ............. 11

Deburring Processes................................. 6

Plating & Surface Coatings .................... 14

Die Casting ............................................ 12

Powder Metallurgy .................................. 13

Electrical Discharge Machining................ 5

Punch Presses .......................................... 8

Extrusion Processes................................ 13

Rapid Prototyping................................... 11

Fastening & Assembly ............................ 15

Roll Forming ............................................. 8

Forging ................................................... 12

Sheet Metal Coil Processing ..................... 6

Gears & Gear Manufacturing.................... 5

Sheet Metal Shearing & Bending.............. 7

Grinding ................................................... 3

Sheet Metal Stamping Dies ...................... 7

Heat Treating.......................................... 13

Sheet Metal Stamping Presses ................. 7

Holemaking .............................................. 2

Thermal & Abrasive Waterjet Cutting Processes .................................. 5

Hydroforming............................................ 9 Industrial Robotics ................................. 15 Measurement & Gaging.......................... 16 Mechanical & Non-Destructive Testing... 16 Metalcutting Fluids .................................. 6 Milling & Machining Centers .................... 2

Threading ................................................. 3 Tube Bending ........................................... 8 Turning & the Lathe.................................. 2 Welding .................................................. 14 Workholding ............................................. 3

Plastic Blow Molding .............................. 10

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