Machining is a manufacturing process that involves shaping or creating a part by removing material, typically metal, from a larger workpiece through cutting. This method is known as subtractive manufacturing, as it removes material to achieve the desired shape, unlike additive manufacturing, such as 3D printing, which adds material. Machining is crucial in producing many…
Solidification of metal is a complex process where molten metals and alloys turn into solid forms. It includes dendrite formation, compositional segregation, zone formation in the final casting structure, and the creation of microporosity due to shrinkage. What is Solidification Solidification refers to the process of a substance changing from a liquid to a solid…
Metalworking is the art of shaping metals into various tools, equipment parts, and structures. It involves forming, cutting, and joining metal pieces using techniques like welding, casting, and molding. In the industrial age, metalworking has developed into a sophisticated science. The industrial revolution has led to exponential growth in the scale of modern metalworking processes,…
Spot welding, also known as resistance spot welding, is a type of resistance welding. It is mainly used to join two or more metal sheets by applying pressure and heat from an electric current to the weld area. Spot welding is extensively used in the automotive industry to create strong and aesthetically pleasing welds. RSW…
What are common engineering materials and why are they important? Throughout history, the significant accomplishments of each era have consistently revolved around the development of new materials, playing a pivotal role in the advancement, prosperity, safety, and overall well-being of humanity. Since the dawn of civilization, it has consistently been the introduction of innovative materials…
Have you ever wondered why are cars so heavy? it seems like each year that goes by cars seem to get bigger and heavier! The average weight of a recently purchased vehicle in the United States reached 4,329 pounds in 2022. This figure exceeds the 1980 average by over 1,000 pounds and reflects an increase…
The automotive body structure is one the main and most important components of a modern automobile. This system serves as the cohesive link for all other subsystems. It accommodates the drivetrain and primarily providing support and protection for passengers and cargo. A robust body structure is imperative to withstand loads, and pressure, and effectively unify…
How are car parts joined? In the automotive industry, there are a few common ways of joining different parts together. The three most common methods which are practiced by automotive manufacturers are fusion welding, adhesive bonding, and mechanical fasteners. While assembling the Body-In-While (BIW), the most common joining process used would be fusion welding such…
Design for assembly (DFA) is a method that involves designing products while considering how easy they will be to assemble. Simplifying the number of parts in a product reduces assembly time, thus lowering assembly costs. Characteristics of Manual Assembly In manual assembly, operations are carried out manually, often using simple tools like screwdrivers or pliers….
What is the history of casting? Casting is the oldest manufacturing process, the first casting of metals can actually be traced all the way back to around 4000 BC: copper castings in Mesopotamia. Around 3500 BC, Bronze casting was developed by the ancient Sumerians in western Asia. Around 1200 BC bronze casting started to appear in Greece,…