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Content

Manufacturing Engineering


Manufacturing Processes



FUNDAMENTAL MANUFACTURING PROCESSES: ELECTRICAL DISCHARGE MACHINING

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 X 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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FUNDAMENTAL MANUFACTURING PROCESSES: THERMAL AND ABRASIVE WATERJET CUTTING PROCESSES

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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FUNDAMENTAL MANUFACTURING PROCESSES: GRINDING

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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FUNDAMENTAL MANUFACTURING PROCESSES: SHEET METAL STAMPING DIES AND PROCESSES

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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FUNDAMENTAL MANUFACTURING PROCESSES: SHEET METAL STAMPING PRESSES

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 - electro-mechanical, pneumatic, hydraulic, electronic, and others - 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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FUNDAMENTALS OF MANUFACTURING PROCESSES: WORKHOLDING

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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FUNDAMENTAL MANUFACTURING PROCESSES: HOLEMAKING

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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FUNDAMENTAL MANUFACTURING PROCESSES: THREADING

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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FUNDAMENTAL MANUFACTURING PROCESSES: MILLING & MACHINING CENTERS

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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FUNDAMENTAL MANUFACTURING PROCESSES: TURNING & THE LATHE

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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MANUFACTURING INSIGHTS: RAPID CASTINGS - RAPID PROTOTYPES FOR METAL CASTING PROCESSES

This program, scripted by renowned industry specialist Todd Grimm, highlights how rapid casting and its various techniques have become an indispensable part of modern manufacturers' ability to shorten design and production lead times. Case studies look into the evolution of rapid casting technology and evaluate its flexibility for producing complex, finely detailed castings that eliminate the need for hard tooling, which reduces production costs and time to market.

~ In the Investment Casting segment, Express Pattern and Barron Industries are highlighted to see how rapid prototyping accelerates investment casting prototypes, processes and production.
~ In the Sand Casting segment we enter Ford Motor Company's Beech Daly Technical Center to witness the automated, direct production of sand casting copes, drags and cores.
~ In the Plaster Mold Casting segment, tour Armstrong Mold's and Design Prototyping Technologies' operations to understand the role rapid prototyping has in the plaster mold casting process.


DVD / 2009 / () / 35 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: MECHANICAL & NON-DESTRUCTIVE TESTING

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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FUNDAMENTAL MANUFACTURING PROCESSES: PLASTIC THERMOFORMING

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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FUNDAMENTAL MANUFACTURING PROCESSES: PLATING & SURFACE COATINGS

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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FUNDAMENTAL MANUFACTURING PROCESSES: ROLL FORMING

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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BENCHMARKING MANUFACTURING PROCESSES

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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FUNDAMENTAL MANUFACTURING PROCESSES: METALCUTTING FLUIDS

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 / () / 22 minutes

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TMEH TROUBLESHOOTING MANUFACTURING PROCESSES

Detailed troubleshooting information from TMEH Volumes 1-4 is contained on this indexed and searchable CD-ROM.

Twelve chapters cover cutting tool materials, milling, grinding, machining plastics, bending and straightening, blanking and punching, compression molding, quality control, welding and much more.


CD-ROM / 2005 / () /

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CHARACTERISTICS OF A GOOD PROCESS, THE

To handle large numbers of ideas cost-effectively, a manufacturer must evaluate and implement them in an efficient manner. While every manager must design a process specifically for the needs of his or her unit, every effective approach follows the same basic principles. This video addresses the eight characteristics of an effective idea process.

DVD / 2004 / () / 50 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: EXTRUSION PROCESSES

Extrusion is the deformation of either metal or plastic forced under pressure through a die to create a shape. This unique program is an introduction to plastic extrusion and metal extrusion processes, featuring segments on hot metal extrusion, warm and cold metal extrusion processes, plastic profile extrusion, and blown film extrusion. See actual shop floor footage coupled with descriptive animations to help you learn step-by-step how materials are transformed into extrusions. Discover the use of plastic and metal extrusion in a variety of different industries including automotive, aerospace, building and construction, furniture, and electronics. This basic introductory program is ideal tool for the classroom or for anyone who needs a refresher course on the basics of extrusion processes.

DVD / 2004 / () / 21 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: INDUSTRIAL ROBOTICS

Industrial robots are automated, flexible components used for a wide range of applications within manufacturing systems. This program covers the array of robot configurations and features segments on: - Key manufacturing applications using robots - Rectangular arm robots - SCARA robots - Articulated/jointed arm robots - End effector hand, or gripping devices - End effector tools - On-line & off-line robot programming - Advantages and disadvantages of industrial robots The common contact and non-contacts sensors used to assist industrial robots are also highlighted.

DVD / 2004 / () / 25 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: PLASTIC INJECTION MOLDS

The injection mold is an extremely important element of any plastic injection molding operation. Molds determine the shape of the part, vent trapped air or gases during injection, act as heat exchangers to solidify the molten plastic, and eject the cooled parts. Using shop-floor footage and detailed animations, this program highlights the primary injection mold components and features segments on injection mold types, the use of computer simulation to develop molds, mold prototyping techniques, and mold maintenance & repair.

DVD / 2004 / () / 28 minutes

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ADAPTATION OF THE HIGH PERFORMANCE MILLING PROCESS

This program was presented by Markus Groppe of the Institute of Production Engineering and Machine Tools, University of Hannover at the High Speed Machining Technical Conference in Itasca, IL on April 8- 9, 2003. It focuses on: Optimizing the tool geometry, Determining the spindle frequency, Adaptation of the single components, and Adjusting the process parameters.

DVD / 2003 / () / 44 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: BRAZING & SOLDERING

This program explores the techniques and materials ued to produce brazed and soldered components for the automotive, aerospace, appliance and electronics industries. Ideal as a training tool for shop floor personnel or the classroom , you will learn the fundamental similarities and differnecs between the two joining processes, understand basic terminology such as capillary action, and become familiar with common applications through extensive shop floor footage. This program explains both brazing and soldering, beginning with the primary joint types used, joint preparation techniques, common base and filler materials that can be joined, manual and automated joining methods.

DVD / 2003 / () / 25 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: CASTING

This casting program includes information on pattern and core production methods, and covers an array of casting processes, arranging them into three major categories: Expendable Mold/Reusable Pattern processes, Expendable Mold/Expendable Pattern processes, Permanent Mold/No Pattern processes. The Expendable Mold/Reusable Pattern processes section includes an examination of the most common casting process - Sand-Mold Casting, and its variations. The Expendable Mold/Expendable Pattern processes section has demonstrations of Investment Casting and Evaporative-Foam Casting. The Permanent Mold/No Pattern processes section examines the more precise casting techniques, such as Permanent-Mold Casting, Die Casting, and Centrifugal Casting.

DVD / 2003 / () / 26 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: COMPUTER NUMERICAL CONTROL

This program explains the basics of Computer Numerical Control, or CNC by featuring segments on: Computer Numerical Control Principles and Computer Numerical Control Programming. The CNC Principles section highlights the rectangular coordinate system and its use in generating precision tool paths. Integral elements of the rectangular coordinate system are presented, including: program zero, coordinate points, coordinate polarity, the absolute mode, the incremental mode, quadrants, and the various axes of motion. The CNC Programming section features the step-by-step examination of CNC part program commands and their various letter addresses and numeric values. Also presented are discussions of point-to-point positioning, contouring, interpolation, compensations, special programming features, manual programming, computer-aided part design, and computer-aided manufacturing.

DVD / 2003 / () / 24 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: CUTTING TOOL GEOMETRIES

Part of the Fundamental Manufacturing Processes (FMP) DVD series. Efficient metalcutting requires using the right shaped tool for the task. These cutting tools are all described by their angles or geometries. This program examines the multitude of single point turning tools and toolholders, and their geometries. Insert style chipbreaker shapes and chip formation complete the turning segment. For the milling and multi-point cutting tool geometries section, the angles and pitches are presented, describing how they affect the milling process.

DVD / 2003 / () / 27 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: CUTTING TOOL MATERIALS

Because of the wide variety of machining applications, there is a need for diverse cutting tool materials. The development of tool materials establishes the content flow of this program, beginning with high speed steel tools. Carbide, including its property variables, types, grades and coatings follows high speed steel and makes up the largest portion of this program. Afterwards, ceramic, cermet, and superhard materials like cubic boron nitride and polycrystalline diamond are each featured. Tool failure modes such as cratering, deformation and notching are also examined. You'll learn about the criteria needed to help select the proper tool material for both turning and milling operations.

DVD / 2003 / () / 25 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: DEBURRING PROCESSES

This program includes information on an array of deburring processes, arranging them into three major categories: Mechanical Deburring processes, Thermal Deburring, Electro-Chemical Deburring. The Mechanical Deburring processes section includes segments on: Manual Deburring, Mechanized Cutting, Power Brushing, Bonded Abrasive Finishing, Abrasive Blasting, Abrasive-Flow Deburring, and the various Mass Finishing processes. These Mass Finishing processes include: Vibratory Finishing, Barrel/Rotary Tumbling, Centrifugal Disk Finishing, Centrifugal Barrel Finishing, and Spindle Finishing. Included in the Thermal Deburring and Electro-Chemical Deburring sections are lengthy demonstrations of the processes using both shop-floor footage and animations.

DVD / 2003 / () / 27 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: DIE CASTING

Die casting is a high precision, rapid parts-production process involving the high pressure injection of molten metal into a die having a cavity of the desired part shape. To better understand the versatility of die casting, this program explores the common die cast metals and their various properties, as well as die casting machines and die cast tooling. Using shop floor footage and animated sequences the machine section covers in detail the hot-chamber and the cold-chamber machine types. Also discussed is the importance of lubrication in die casting, the use of accumulators and pressure intensifiers, and machine controls and automation. The tooling section examines the various die production materials and techniques. In addition, terms such as cover die, ejector die, fixed cores, core pulls, venting, die cooling, and draft angles are clearly defined.

DVD / 2003 / () / 23 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: FASTENING AND ASSEMBLY

This program focuses on the primary fasteners and assembly processes used, and includes sections on: mechanical fastening, adhesive bonding, and automated assembly. The mechanical fastening segment features in detail the various types and uses of integral fasteners, threaded fasteners, non-threaded fasteners, and stapling. The adhesive bonding section covers 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 machine types including: the dial, or rotary index machine, the in-line indexing assembly machine, and the carousel assembly machine.

DVD / 2003 / () / 20 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: FORGING

This program begins by outlining forging's function in refining the metallurgical microstructure of wrought mills forms, and it's use in generating parts to near-net shape from these forms. Featured are segments on the various types of forging processes, including: open-die forging, impression-die forging, seamless ring rolling, hot-die forging, and isothermal forging. This program concludes with a segment on forging automation.

DVD / 2003 / () / 23 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: GEARS AND GEAR MANUFACTURING

This program examines basic gear types, functions and manufacturing processes. The program begins with an introduction to the primary gear terms and definitions. The various gear forms and how they relate to axis positions is also explained. The manufacturing of gears is organized into segments on machining methods and finishing processes. The machining methods segment features a detailed examination of the primary processes used, including: hobbing, shaping, broaching and milling. The finishing segment explains the benefits of finishing operations and highlights shaving, honing, and the various grinding processes.

DVD / 2003 / () / 22 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: HEAT TREATING

This program highlights heat treating's versatility in altering the metallurgical properties of metals and alloys. This versatility is broken down into three groups of processes: through-hardening processes, surface hardening processes, and softening processes. The through-hardening segment utilizes animations, phase diagrams and photomicrographs to explain the hardening process and define its many variables. Quenching speed, mediums, and temperature control are examined, as well as the tempering of heat treated materials. The surface hardening section offers examples of the processes that produce surface, or case hardened parts. Included are explanations of: flame hardening, induction hardening, carburizing, nitriding, and carbonitriding. The softening processes examined in this heat treating program include: annealing, normalizing and stress relieving.

DVD / 2003 / () / 30 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: MEASUREMENT & GAGING

This measurement & gaging program begins with an introduction to the core concepts regarding measurement. These concepts include: precision, resolution, accuracy, repeatability and reproducibility. Standards are then addressed, featuring sections on gage blocks and surface plates. This program then focuses on the array of measurement & gaging tools, arranging them into three categories: non-graduated measurement & gaging tools, graduated measurement & gaging tools, and advanced measurement & gaging tools. The non-graduated measurement & gaging tools section features tools and gages that are used to transfer measurements to or from graduated measurement tools, or as pass/fail comparisons to standards. The graduated measurement & gaging tools section highlights the use of tools, such as vernier calipers, micrometers, and tools using dial indicators and electronic digital readouts. The advanced measurement & gaging tools section focuses on optical measurement projectors, vision systems and coordinate measurement machines.

DVD / 2003 / () / 28 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: PAINTING AND POWDER COATINGS

This program begins with an introduction to the basic elements of all paint formulations: pigments, additives, solvents and resins. The two types of resin polymer structures, enamels and lacquers, are explained with an emphasis on the crosslinking aspect of enamels. The liquid paint section examines both solventborne and waterborne high solids paints, and their type of liquid fluidization, including either: solution fluidization, dispersion fluidization, or emulsion fluidization. The process of applying liquid paints is broken down into three fundamental sequences: part pretreatment and cleaning, paint application, and paint curing. The paint application processes detailed include: conventional air spraying, airless spraying, air-assisted airless spraying, high volume, low pressure spraying, electrostatic spraying, and electrocoating. The powder coating section fully examines the various process sub-systems, including: pretreatment methods to prepare the part surface for coating, the various application systems to apply the powder, spray booths and powder recovery systems, powder curing, to move parts through the process.

DVD / 2003 / () / 23 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: PLASTIC BLOW MOLDING

Plastic blow molding processes are the most popular methods used to produce hollow products out of thermoplastic materials. Blow molding is performed using a wide variety of production methods, including: intermittent and continuous extrusion blow molding, injection blow molding, single and two stage bi-axial stretch blow molding, and co-extrusion blow molding. Through the use of shop floor footage and animations this program provides a detailed discussion of each of these processes, presenting a clear understanding of the similarities and differences between each of them. In addition, information on parison and preform production, the reciprocal screw style blow molding machine, the accumulator style blow molding machine, and the head and die assembly is provided.

DVD / 2003 / () / 20 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: PLASTIC INJECTION MOLDING

Injection molding is the most common method of producing parts out of plastic material. Using shop floor footage and animated sequences this program focuses on the injection molding machine and the injection mold to illustrate the injection molding process. The injection machine section covers in detail both the injection system and the clamping system. In step by step progression, plastic material is followed from its raw material state through the melting process and onto it's injection into the mold. Throughout the sequence, various components of the injection machine are explained. The mold section continues this examination, allowing clear definition of mold terms as the molten material is formed, cooled, and ejected as the final part. Also featured in the mold segment are the common mold types, including the two-plate cold runner mold, three-plate cold runner mold, the hot runner mold, and the insulated runner mold. This tape concludes with a section on injection machine controls.

DVD / 2003 / () / 25 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: POWDER METALLURGY

Powder metallurgy is a metalworking technology used for producing parts from metal powder. Advantages include part design flexibility and the ability to produce net or near-net shaped parts. This program illustrates the physical and mechanical 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. Through the use of shop floor footage and animations, each of these processes is explained in detail, providing a clear understanding of the similarities and differences between each of them. Secondary operations are also featured.

DVD / 2003 / () / 25 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: PUNCH PRESSES

Punch presses are the primary source for punching round and irregular shaped holes in flat sheet metal stock. This program examines the machine types that perform punching, such as the single-station and turret punch press, as well as the multi-purpose ironworker. The main emphasis of this program is the versatile turret punch press and its tooling. Operations such as nibbling are covered along with a look at special punch press tooling that includes multi-tools, and special rotary adapters that permit the punch and die to be rotated radially. Also explored are the accessories that, when incorporated with the turret punch press, enable it to perform a greater variety of work. These accessories include a plasma cutting torch, a laser cutting attachment, and automated material loading and unloading equipment.

DVD / 2003 / () / 20 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: RAPID PROTOTYPING

This program introduces the various technologies, systems and materials used to produce rapid prototype models, parts and tooling. These rapid prototyping technologies and systems include: Stereolithography, Selective Laser Sintering, Fused Deposition Modeling, Ultrasonic Consolidation, The Pro Metal System, The Thermojet Modeler, The 612 Modeler, The Z810 Modeler, The Eden 330 Modeler, and Room Temperature Vulcanized Tooling.

DVD / 2003 / () / 24 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: SHEET METAL COIL PROCESSING

This program introduces the primary methods of processing sheet metal coils, featuring segments on coil slitting, coil blanking, and coil processing lines. The coil slitting segment features detailed examinations of the two primary types of slitters: the pull-through slitter, and the loop type slitter. The coil blanking segment highlights the use of stationary cut-to-length shearing lines, flying shear lines, and blanking presses. The coil processing lines segment focuses primarily on the equipment and methods of feeding coil stock to stamping presses, and other processing lines.

DVD / 2003 / () / 25 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: SHEET METAL SHEARING AND BENDING

This program examines two of the oldest manufacturing processes: shearing and bending. The shearing segment begins with an animated view of how a part is sheared, and then focuses on the variety of shearing machines that are available. Coil slitting is also featured. The bending section concentrates mainly on the terms defining a bend, and on the primary bending machines - the press brake. Various examples of press brake dies and bending operations are shown, as well as, a segment on folding technology. Additionally, this program outlines the necessity for gaging in both shearing and bending operations.

DVD / 2003 / () / 21 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: TUBE BENDING

This program explores the various materials and methods used for bending and end forming tubes. The bending portion of the program explores in detail the most common bending method Rotary-Draw Bending. Also featured are segments on Compression Bending, Ram Bending, Press Bending and Roll Bending. The end forming section of the program examines the basic forms that can be applied to the end of a tube, with the primary types including: Reduction, Expansion, Flaring, and Beading.

DVD / 2003 / () / 22 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: WELDING

This program includes information on welding joint design, joint edge shape and preparation. This program then focuses on the array of welding processes, arranging them into two major categories:

~ Fusion welding processes
~ Solid-state welding processes

The fusion welding section begins with an examination of the four common groups of fusion processes: arc welding, resistance welding, laser beam welding, and electron beam welding.

The arc welding section features the six most common arc welding processes: shielded metal arc welding, submerged arc welding, gas metal arc welding, flux-cored arc welding, gas tungsten arc welding, and plasma arc welding.

The resistance welding processes section features the three most common methods of resistance welding: spot welding, seam welding, and projection welding.

The solid-state welding processes section examines in detail both the friction welding and ultrasonic welding processes.


DVD / 2003 / () / 29 minutes

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SIX SIGMA IMPROVEMENT PROGRAM DEPLOYMENT IN A HIGH SPEED PROCESS ENVIRONMENT

Scott Lee Wise, BPI Program Manager, UT Six Sigma Black Belt, CQA, CQE, Dell Computer. Description of Presentation: Mr. Wise completed the first ever Dell BPI Black Belt project and helped create, develop and implement Dell's BPI (Six Sigma) Program with results of over 70 million dollars in annualized savings to date. His professional certifications include ASQ CQA & CQE certification, Competent Toastmasters (CTM) certification, and serves as a Texas Quality Award Auditor. Mr. Wise speaks about Six Sigma improvement program deployment in a high-speed process environment.

DVD / 2003 / () / 38 minutes

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USING QUALITY METHODOLOGY THROUGHOUT THE COMMERCIALIZATION PROCESS

Chris J. Johnson, Worldwide Commercialization Manager, Eastman Kodak. Description of Presentation: Mr. Johnson discusses the impact of Six Sigma on Eastman Kodak's operations. His presentation focuses on how the Six Sigma process was used in the development of a new film so that the image quality was enhanced in a way that was demanded by the customer.

DVD / 2003 / () / 28 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: COMPOSITE MATERIALS AND MANUFACTURING

This DVD program explains the basics of composite materials and manufacturing by featuring segments on: composite matrix and reinforcement materials, composite manufacturing processes, and composite fabrication and joining methods. The first segment features the primary types of matrix and reinforcement materials, as well as the various forms in which they are available. The composite manufacturing processes segment highlights the numerous methods of producing composite parts, including: manual lay-up, automated lay-up using tape laying machines and fiber placement machines, vacuum bag molding, spray-up, filament winding, pultrusion, and resin transfer molding. The various ways in which composite parts are cured is also presented. The composite fabrication and joining segment features the use of cutting, machining and drilling to fabricate composite parts, as well as, adhesive bonding and mechanical fastening methods for joining composite components.

DVD / 2002 / () / 28 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: HYDROFORMING

This program examines the basic materials, tools, and techniques of tubular hydroforming and sheet metal hydroforming. The tubular hydroforming segment features detailed animations and production applications of the three primary types of tubular hydroforming techniques: Low-Pressure Hydroforming, High-Pressure Hydroforming, and Pressure Sequence Hydroforming. The use of in-process hydro-piercing and the importance of lubricants is also presented. The sheet metal hydroforming section includes animations and shop-floor footage of: Rubber Diaphragm Forming, and Active Hydro-Mechanical Drawing operations. The various secondary operations performed on hydroformed parts, such as: additional holemaking, part trimming, and joining operations conclude the program.

DVD / 2002 / () / 23 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: PLASTICS FINISHING

This program includes information on the array of plastics finishing processes, arranging them into four categories degating, deflashing, cleaning, and decorating.

The degating section includes segments on manual degating and the various automated tooling devices.

The deflashing section covers the cutting and trimming, media blasting, and cryogenic deflashing processes.

The cleaning segment features the ways in which contaminants infiltrate the molding process and how parts are cleaned for secondary decorative operations.

The decoration section features lengthy process examinations of painting, plating, vacuum metallizing, pad printing, hot stamping, silk screening, and fill-and-wipe.


DVD / 2002 / () / 23 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: PLASTICS MACHINING AND ASSEMBLY

This program focuses on the primary machining and assembly processes used for plastics.

The plastics machining segment highlights the use of sawing, milling, routing, turning, waterjet cutting, laser cutting, drilling and the secondary holemaking operations, such as tapping and reaming. The importance of coolant used while machining plastics is also explored in detail.

The plastics assembly section covers the many fastening and joining methods used to produce plastic parts. Included are segments on snap-fit fasteners, the use of hinges, mechanical fasteners, adhesive and solvent bonding applications, and the various plastic welding processes, including: spin welding, hot-gas welding, ultrasonic welding, vibration welding, heat staking and ultrasonic staking.


DVD / 2002 / () / 27 minutes

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