Lost Foam Casting

Today’s video shows the complete lost foam casting process. One of the advantages to this process as compared to other casting processes is there is no need for draft to be designed into the part. This makes the cast part a near net shape which is mass and material optimised as well as reducing the need for machining operations to …

Sheet Metal Stamping Fundamentals: Dies And Processes

This video from the Society of Manufacturing Engineers takes us through the fundamentals of dies and processes used in the sheet metal stamping operations. The video looks at single and multiple station stamping operations. Single Station Stamping Processes Compound Dies – used for only shearing operations such as cutting and hole punching. Combination Dies – combines shearing operations with forming or shaping operations in a …

Manual Metal Spinning

Here is an interesting video of a manual metal spinning operation. It shows a nose cone for a wind vane being made. This form is somewhat simple and much more complex shapes can be manufactured with metal spinning. Whilst automated or CNC metal spinning operations are available these days it is good to see how these processes are done by …

Has Ford Developed The Most Flexible Sheet Metal Forming Process?

Just when you thought that sheet metal forming technology couldn’t progress much further Ford Motor Company has managed to almost re-invent the wheel. The machine shown in their video below is called ‘Ford Freeform Fabrication Technology’ (F3T) and is a cross between a sheet metal press tool and a 3D printer. The machine uses a pair of opposed delta robots where the upper robot …

Aluminium Extrusion Die And Process Explained

This video provides a breakdown of the components in an aluminium extrusion die. Machine and die components shown for the extrusion process are; the container the inner tool the outer tool the tool carrier the press disc; and the main ram. The video goes on to show aluminium extrusion process used to make a round tube including how the inner and outer extrusion …

3D CNC Tube Bending

I was absolutely mesmerised by this process when I first saw it. The machine shown in this video is a Nissin 3D CNC Tube Bender. You can see the machine bend tube in any direction to form complex 3D forms. It is even possible to bend continuously variable curvatures. Imagine the design optimisation that is possible with such a flexible …

The Fundamentals Of Friction Stir Welding

Manufacturing Technologies Inc have produced this video explaining the fundamentals of friction stir welding. A colleague of mine in the Aerospace industry directed me to this process as one that has allowed significant optimization in the aircraft manufacturing industry. As he explained to me the technology has been implemented in select areas aircraft manufacturing in lieu of painstaking process of …