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Manufacturing Processes


Electrical discharge machining, or EDM, shapes metal by creating sparks that melt tiny portions of the workpiece, and is an exceptionally diverse process that generates no cutting forces. EDM is especially useful in the production of fragile parts that cannot take the stress of conventional machining.

This program examines the EDM process and the two primary forms of electrical discharge machining - ram EDM and wire EDM.

The EDM process segment details the components of an EDM system, the EDM erosion process, and cycle time. The ram EDM, or sinker EDM, segment outlines the process and presents the various process subsystems, including the power supply, dielectric fluid system, the electrode and its manufacture, and the servo system.

The wire EDM segment features the various wire EDM process subsystems, including the power supply, dielectric fluid system, the wire feeding system, and the wire positioning system. EDM holemaking is also explored.

DVD / 2013 / () / 29 minutes

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Thermal cutting processes use heat for cutting. The abrasive waterjet process uses no heat, but cuts by abrasive erosion. All these processes provide precision non-contact cuts in a wide variety of materials, and cut in single pass, rather than multiple passes.

To better understand the various cutting processes, this program, examines, explains, and compares oxy-fuel cutting, plasma cutting, laser cutting applications, and abrasive waterjet cutting.

The oxy-fuel cutting segment explores the cutting variables, torch tip types, depth of cut variables, and oxy-fuel cutting machine tools.

The plasma cutting segment defines plasma, and talks about plasma gas types, plasma arc system elements, kerf width, cutting jet shielding, and more.

The laser cutting segment features the advantages and limitations of laser cutting while examining the process, laser types and features, machine types and components, laser holemaking, and more.

The abrasive waterjet cutting segment outlines the process and system components, the pressures needed, kerf and workpiece surface conditions, production application variables, and waterjet safety.

DVD / 2013 / () / 28 minutes

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This program focuses on grinding and how it is used to shape and finish high precision workpieces made from metals and nonmetals. It features segments on precision grinding methods, abrasives and grinding wheels, balancing, and dressing grinding wheels, grinding safety, and workpiece surface finish.

The abrasives and grinding wheels segment explores grinding wheel abrasives, such as aluminum oxide, ceramic, silicon carbide, cubic boron nitride and diamond, as well as abrasive grains, abrasive bonds, pore structure, and dressing procedures.

The grinding safety segment emphasizes employee safety while outlining the proper handling and care of wheels, visual inspection, and ring testing to determine wheel integrity.

The grinding process segment examines the grinding process parameters and the resulting force, friction, and heat relationships.

The precision grinding methods segment covers cylindrical grinding, internal diameter (ID grinding), centerless grinding, surface grinding processes and machine types, and nomenclature.

The workpiece surface finish segment covers the process variables that contribute to the properly ground workpiece surface finish, such as feed rate, machine rigidity, and workpiece materials.

DVD / 2011 / () / 25 minutes

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Stamping dies are the tools that shape and cut sheet metal parts. They are commonly developed using computer-aided design (CAD) software and analytical programs to create and prove-out highly accurate, unambiguous designs. These designs are then translated into stamping dies by skilled craftsmen, known as diemakers. Once these stamping dies are mounted into presses, sheet metal is fed to them to produce parts.

This program will help you better understand how stamping dies operate. You will explore sheet metal deformation and formability, segments on dies and die functions, die lubrication, and stamping analysis.

The dies and die functions segment looks at cutting die operations and forming die operations. The cutting die operations include shearing, blanking, punching, and trimming. The forming die operations include drawing, bending, flanging, and hemming. Single- and multiple-station dies are also examined, and include compound dies, combination dies, progressive dies, and transfer dies.

The die lubrication segment details the various types of lubricants used in stamping operations, as well as the common application methods, such as manual application, drip, roller, spraying, and flooding.

The stamping analysis segment focuses on the use of computer software programs to create stamping designs that can be manufactured with certainty, while minimizing the lengthy process of die making. The use of circle grid analysis (CGA) to fine tune these die designs is also highlighted.

DVD / 2011 / () / 25 minutes

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Stamping presses transform sheet metal into functional products by applying the force of a moving ram to tooling located within the press. Stamping's primary advantage is the ability to transform two-dimensional sheet metal stock into three-dimensional finished components at a relatively high rate of speed with minimum operator intervention.

This program provides a broad understanding of stamping presses, and includes segments on: mechanical presses, hydraulic presses, press controls, and press feeding.

The mechanical presses segment outlines the advantages/disadvantages and the similarities/differences between the two most common types of presses, the gap-frame press and the straightside press. Defined and detailed are the various press components, including the crown, columns, gibs, bed , bolster, flywheel, gears, clutch, crankshaft, pitman, connection, slide/ram, counterbalance, and brake. Drive arrangements, such as direct drive, single gear reduction, double gear reduction, and eccentric geared presses are also illustrated.

The hydraulic presses segment explains the major differences between hydraulic presses and mechanical presses and highlights the advantages of hydraulic systems and press selection factors.

The press controls segment features the range of controls X electro-mechanical, pneumatic, hydraulic, electronic, and others X used to safely control press operations. Computer numerical control (CNC) systems, programmable logic controllers (PLC), and self-checking/diagnostic features are also detailed.

The press feeding segment covers coil stock and blank feeding methods, as well as coil line components. These components include payoff reels, cradles, stock straightening/leveling, slide feeds, roll feeds, gripper feeds, and scrap processing.

DVD / 2011 / () / 24 minutes

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Workholding includes any device used to grip and present a workpiece to a cutting tool on a machine tool.

To provide an understanding of workholding as a fundamental issue in the machining process, this program examines:

~ the principles of workholding
~ basic to advanced workholding approaches for milling and machining centers
~ chucks, collets, mandrels and other lathe workholding devices

DVD / 2011 / () / 27 minutes

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Holemaking is the most common machining operation, consuming half of all cutting tools used in chip making operations. To better understand holemaking and its various applications, this program examines:

~ The basic components of the twist drill
~ Holemaking operations and process variables
~ Machines and drill types commonly used to perform holemaking
~ Operations that finish and add special features to holes

This program concludes with a review to summarize and reinforce the presented material.

DVD / 2010 / () / 28 minutes

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The screw form as used in manufacturing has two primary functions--to transmit power and motion, as with a lead screw on a machine tool, and as threaded fasteners such as nuts, screws, and bolts.

This program examines the many dimensions that make up all threads, such as:
~ the major diameter
~ the minor diameter
~ the thread pitch
~ the thread pitch diameter.

You will learn about the various processes that produce external threads, such as manual threading, thread turning, thread chasing, thread milling, and thread rolling. Internal threads, the tapping process, and tapping machines are also extensively explored.

DVD / 2010 / () / 29 minutes

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Milling is a highly versatile machining process that uses rotating, multi-edge cutters to generate flat and contoured surfaces. Because of its effectiveness, cutting tool choices, and compatibility with automation, milling with machining centers is perhaps the most important high-volume manufacturing process for shaping materials.

This program provides a broad understanding of the milling process, including segments on:

~ The basic components of the knee mill and machining centers
~ Milling cutters, operations, accessories, and process variables
~ Toolchanging, workchanging & workholding arrangements on machining centers

This program concludes with a review to summarize and reinforce the presented material.

DVD / 2009 / () / 29 minutes

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Turning on the lathe is one of the most common metalcutting operations. Lathes are particularly suited to machining relatively long, cylindrical workpieces, yet can create a variety of parts ranging from small watch components to massive propeller shafts.

This program provides a broad understanding of the turning process, including segments on:
~ The basic elements that comprise the lathe
~ Lathe operations and process variables
~ Manual through computer numerical control (CNC) lathe types
~ Tooling and workholding arrangements on production lathes

This program concludes with a review to summarize and reinforce the presented material.

DVD / 2009 / () / 30 minutes

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Both mechanical and non-destructive tests are used to gage the quality of materials and parts throughout the manufacturing process.

Mechanical tests are used to gather specific performance or property values of materials for part design purposes and quality control. These tests include:
~ Hardness
~ Tensile
~ Compression
~ Impact
~ Fracture-Toughness
~ Fatigue
~ Creep

Non-destructive tests examine an object or material in a manner that does not impair it's future usefulness. The most common non-destructive tests include:
~ Visual Inspection
~ Liquid Penetrant Testing
~ Magnetic Particle Inspection
~ Eddy-Current Testing
~ Ultrasonic Testing
~ Radiographic Testing

DVD / 2007 / () / 26 minutes

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Featuring: Honda of America Manufacturing, Inc.

Every manufacturing process has its own quality characteristics. These are the types of things that typically go wrong with those processes. The activities to take care of these problems must be more of a proactive or preventative approach than a reactive approach. Honda of America Manufacturing is always trying to find ways to do things better and more efficiently with the bottom line of trying to improve quality.

DVD / 2007 / (Grades 9-12, College, Adult) / Approx. 7 minutes

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Featuring: Aquion

Aquion, an international water treatment product company, is headquartered just outside of Chicago, Illinois. Their production process is a great example of cellular manufacturing and how it can benefit the company and customers. The floor of the manufacturing plant is organized to have a good flow of product movement, and customers are benefitted through quick turnaround of their orders; customized parts can even be provided within 2-3 days. The company has also been ISO certified for four years.

DVD / 2006 / (Grades 9-12, College, Adult) / Approx. 7 minutes

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Plastic thermoforming is the process of producing parts by heating and shaping plastic sheet and film. Using shop floor footage and detailed animations, this program highlights both cut sheet and roll fed thermoforming operations, and features segments on clamping systems, heating systems, thermoforming mold types, forming forces, and trimming processes.

The basic thermoforming methods are also examined, including:
~ Drape thermoforming,
~ Cavity thermoforming,
~ Pressure thermoforming,

Plug assist thermoforming, and Twin sheet thermoforming

DVD / 2006 / () / 22 minutes

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Plating and surface coating processes are used throughout manufacturing to provide protection, durability and decoration to parts. Using shop floor footage and detailed animations, this program explains and highlights the use of :
~ Electroplating
~ Electroless Plating
~ Phosphate Conversion Coatings
~ Chromate Conversion Coatings
~ Oxide Conversion Coatings
~ Anodizing
~ Batch Galvanizing
~ Continuous Galvanizing
~ Porcelain Enameling

DVD / 2006 / () / 28 minutes

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Roll forming is a high-volume production process used to produce an unlimited variety of formable cross-sections.

This program was written and reviewed by industry experts, and provides viewers with an immediate understanding of basic roll forming concepts and technical terms.

Through the use of shop floor footage and detailed animations, this program highlights:
~ Roll forming dimensional tolerances
~ Straightness, camber, curve, bow & twist
~ Roll form tooling design & manufacturing
~ Roll forming machine types
~ Lubricants used in roll forming

DVD / 2006 / () / 26 minutes

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Featuring: Washburn Guitars

This program takes a look at the steps Washburn Guitars takes to create their high quality, customized guitars that reflect their tradition of craftsmanship and innovation. The process integrates Computer Aided Design (CAD), Computer Numeric Control Machines, and highly trained workers. This has improved product quality and reduced the number of labor-intensive tasks.

DVD / 2006 / (Grades 9-12, College, Adult) / Approx. 7 minutes

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This two DVD set show how to structure a best-practices search and how to transform benchmarking data into an improvement action plan. Tips for forming, training, and managing a benchmarking team, plus expert advice to help avoid common benchmarking project pitfalls are explained.

DVD 1 Introspection, the focus is on assessing training needs, ethics, etiquette, protocols, and guidelines for conducting internal analysis and selecting benchmarking partners.

DVD 2 Reaching Outward, covers the mechanics of benchmarking, including how to know when you've done enough research, preparing a site visit agenda, and why benchmarking is often less costly than implementing other improvement strategies.

2 DVDs / 2005 / () / 92 minutes

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Since Metalcutting Fluids are an integral part of many machining operations, they need to be applied correctly to make parts productively. When understood and used correctly, cutting fluids also optimize the production process to yield quality parts safely and at lower cost.

This program explains how cutting fluids serve several functions during a machining operation, such as, controlling heat generation by reducing friction between the tool and material, removing chips from the work area, prolonging tool life, maintaining surface integrity of the part, and preventing corrosion.

You will gain practical knowledge on:
~ Various types of fluids
~ Different application methods
~ How to select the right fluids for your processes
~ Methods for maintaining fluids
~ General understanding of safety requirements This program gives an in-depth examination of what fluids actually do during the metalcutting process and the correct care for these fluids. Newer technologies like Minimum Quantity Lubrication and Dry Machining are also illustrated.

DVD / 2005 / () / 23 minutes

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Forging; Extrusion; Powder and sheet metal forming; Wire drawing

DVD / / () / 16 minutes

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