From ancient times THREE different classes of materials have been handled by
human beings.
1. Materials like Clay with important quality of plasticity that allowed the
shaping at ambient temperature.
2. Materials like Wood and Stone were re-shaped by removal of the mass.
3. Metals were workable in both the manners, shaped by heating and beating
(forging) and removal of the mass.
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One may include Weaving as a different class of ‘material formation process’.
Though, weaving is often categorised as a method of ‘material composition’
rather then a ‘forming-shaping’ process.
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Needle Craft tools |
Many Techniques of Materials handling in use today are essentially the same
as those employed in ancient times. Several of the material handling
techniques have originated from day to day living such as cooking, farming,
home building, storage management and rituals.
Over the ages the techniques of materials handling have been refined in terms
of the tools used, and rationalized in terms of procedures. Many processes are
now highly mechanised saving time and energy, and some even are fully
automatized, using programmed automats and robotics that allows faster,
accurate and safer production.
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Ancient stone tools |
Some important techniques of associated with material handling are briefly
discussed in following FOUR groups.
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1 Techniques for material handling by reshaping the form such as plastic
moulding, casting, extruding, pressing, shaping, embossing, reforming,
deforming, removal of material, stretching, compressing and forging.
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2 Techniques for material handling by application of foreign materials
or material deposition such as alloying, embellishing, cladding,
layering, fixing, etc.
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3D Printing Material Deposition |
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3 Techniques of for materials handling by composition, such as
assembling, entwining, joining, tying, bracing, weaving, embroidery,
stitching, etc.
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Industrial multi tasking Robots |
4 Techniques of for materials handling by ‘composite’ forming through
the Matrix and Filler concept, such as layering, particle composites, etc.
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Composite forming- corrugated boards |
Cutting is the oldest of all techniques of material finishing. First cutting tools
were made of sharp edged flint stone chips. These helped in cutting meats
for food and for cleaning the hides. Later cutting stone chips were tied to
wood or bone handles for better tool holding and leverage greater force.
Cutting Axes were reasonable for medium strength materials like wood, but,
for harder materials like stones, cutting and beating actions were separated
into hammer and chisel. Hammering was also used for grinding food,
breaking and crushing nuts and compressing leather. Cutting was used for fast
division of materials and quicker removal of parts of materials (skinning,
shaving, debarking, chopping, mining). Cutting was the crude but primary
technique of material processing.
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Hammer - Material deformation |
Carving is a controlled cutting technique requiring use of a chisel and only
occasional pounding by a hammer. Carving is associated with fine but soft
grain materials like ivory, horn, bones and wood. Carving is also done to
pliable metals like copper, silver-based alloys, and also hard but fracture-able
materials like stones.
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Wood turning Lathe |
Engraving like the carving is a material removal process, but more delicate
and shallower. It was done with sharper and narrower points and with only
hand pressure or very light pounding of the hammer. Engraving is today done
by fine rotary tools similar to the dentist’s pneumatic drill. A computer
controlled, diamond bit engraving is now also done to ultra thin materials. In
Intaglio, or Gravure, printing, the image to be printed is etched or incised into
the surface of the printing plate or cylinder. Gramophone records and
Computer disks have engraved and embossed grooves. Engraving is now,
carried out by laser process rather then sharp points.
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Chasing is engraving, but in small length linear-strokes or in continuous linear
patterns. The material is either depressed or displaced by a fine tool as dots.
Historically wet ceramic pieces and plastered-surfaces (writing tablets-
Cuneiform) were rendered by chasing. Braille writing on a thick paper sheet
is a form of chasing. Engraving and chasing techniques are frequently used to
provide a matt finish, onto normally very glossy stainless steel surfaces.
Chasing techniques are also used for relieving as well as introducing stresses
at the surface section, for facilitating greater moisture or heat transfer, and
to improve the ductility of the material.
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Embossing is a technique of form deformation or mass reshaping of a sheet
like material. It introduces a texture through pounding, beating or by
pressing of the surface. The pressure may be applied from one face or both
faces of a sheet, locally as spots, or continuously under a plate or roller,
creating repeat patterns or random designs. Pounding or beating compacts,
the surface-sections of the material, and thereby increases its density and
integrity. Embossing techniques are used to reduce the gloss by matting the
surface. Embossing is done to increase the thickness bulk of very thin surface
materials and make them apparently stiffer. Synthetic fabrics and fibres are
emboss-deformed and permanently set (perma-set and texturizing) through
heat or chemical treatments.
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Repousse is a method of raising a design in relief from the reverse side. There
are three essential types of tools used: -for tracing, -for bossing, -for chasing.
Ornaments in relief are also produced by mechanical means. A thin, pliable
sheet of metal is pressed into moulds, between set of dies, or over the stamps.
Embossed utensils of copper and brass, statuettes of gods formed of thin silver
and gold plates are very much part of every Indian house. Today Aluminium
craft pieces are similarly embossed and black anodized.
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The design is first drawn on the surface of the metal and the motifs outlined with
a tracer, which transfers the essential parts of the drawing to the back of the
plate. The plate is then embedded face down in an asphalt block and the
portions to be raised are hammered down into the soft asphalt. Next the plate is
removed and re embedded with the face on top. The hammering is continued,
this time forcing the background of the design into the asphalt. By a series of
hammering and re embedding, followed finally by chasing, the metal sheet
attains the finished appearance.
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Traditional Indian Brass and copper utensils have hammered finish on the outside.
The same is often copied on aluminium utensils but reducing the strength due to
‘cold working’ of the metal. Leather and paper surfaces are rolled embossed to
create textured patterns. Timber veneered surfaces are pressed for texture
creation. Rendering of a wet plaster face by variety of pressing and chasing tools
is very common. Chasing is very common with copper and brass pots (e.g.
Peshwai Lotas and glasses).
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Matting is mainly used for creating textured surfaces. Matting is a mechanical
technique compared to etching where a chemically active substance is used.
Mating and etching can also be done by chemical metal removal processes
(such as by reversing the metal deposition by changing the cathode charge)
in the final stage of plating. Parallel, crossed, irregular, concentric, circular and
other geometric configurations are carved or embossed on the surface. In
matting process very fine lines or dots are created. Matted areas contrast with
other glossy areas.
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Matting of Surface |
Etching is usually done by an active or reactive chemical substance that will
either erode away part of the surface or change its colour quality. Acid and
alkali treatments also provide etched surfaces. Etching is also an artwork
technique of Hydrofluoric acid over Glass surfaces.
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Concrete surface levelling |
Surface levelling is a major field of material handling. Surfaces are levelled by
chipping away very thin sections off the surface. The material must have
layered formation (e.g. Kotah -Ladi stones, bamboo, cane) or fracturable or
brittle constitution (e.g. stones). Surfaces are ground and polished for a
levelling. Surface levelling is done as plastering with materials like clay, lime,
gypsum, etc.
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Shaving is done to remove material’s components such as outward hair or
fibres, layers, etc. Leather surfaces are shaved to remove the surface hair and
also for thinning. Leathers are also surface split to separate leather suitable
for uppers and soles. The palm leaves are shaved to remove the stems and
make them smoother for writing. Tree-barks are removed by axes and
choppers to retard insect attack and increase moisture removal. Timbers are
re-cut or planned with finer tools to achieve a smoother surface. Timbers are
split very finely to create veneers. Wood planning is also a shaving technique.
Carpets and rugs require close shearing by scissors to shave of protruding
fibres.
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Grinding removes material from the surface to roughen a normally glossy
surface like glass, or polish a rough surface like stone. Grinding requires
material of higher hardness than the surface material, and is done by rubbing
down with a graded series of coarse to fine abrasives, such as Carborundum,
sandstone, emery, pumice, sand, glass and diamond powders. Where a
material constitution permits, very fine grinding may polish the surface.
Grinding is a cutting operation in which each grit that comes in contact with
the material cuts out a minute chip, or swarf. Grinding wheels usually consist
of particles of a synthetic abrasive, such as silicon carbide or aluminium oxide,
mixed with a vitrified or resinoid bonding material. Grinding can be coarse or
fine, depending on the size of the grit used in the grinding wheel. Metal and
glass can be ground to a mirror finish and an accuracy of 0.0000025 cm.
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Abrasives are used as grinding wheels, sandpapers, honing stones, polish, cutoff
wheels, tumbling and vibratory mass-finishing media, sandblasting, pulp-stones,
ball mills, and many other tools and products. Stone surfaces are chiselled to split
the material into thinner sections, to remove the weathered crust and also to level
out the surface. Grinding and polishing is done to: Hard materials such as building
stones, marbles, granites, metals, glass; Precious and Semiprecious stones like
gems, diamonds; Animal products like ivory, bones, horns, teeth, leather; Plant
products like timbers, seeds; Ceramics like pottery products, bricks, cement
concrete and other cement products.
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Polishing, Honing, Lapping, Buffing: Polishing uses extremely fine abrasive
substances, such as jewellers rouge, Tripoli, whiting, putty powder and emery
dust to rub or burnish an extremely smooth and brilliant finish on the surface
of a material. The polishing materials are coated on the surface of cloth, felt,
leather, rubber pr polymer wheels or as belts. Metal surfaces are levelled and
finished by honing and lapping. Honing removes less than 0.0125 millimetres
of material from the surface to eliminate micro scratches and machine marks
from ground machine parts. It is done with bonded abrasive sticks or stones
that are mounted in a honing head. Lapping is a process in which a soft cloth
(wool, linen and chamois-leather) impregnated with abrasive pastes (rubbing
compounds), is rubbed against the surface of a workpiece.
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Buffing is a term used for polishing of metals. Buffing is done with polishing
compounds and brushes of various shapes, and abrading materials, like:
(animal hair, synthetic fibres, plant fibres -coir), flex, wool and leather. Barber
polishing the razor on a leather stripe is a buffing process that levels out small
nicks on the blade. Utensils are buffed for a polished surface.
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There are four types of precision grinding machines: Centre-type grinders used
for tiny valve spools to steel mill roles. Centre-less grinders used for bowling balls,
surgical sutures, and tapered roller bearings. Internal grinders are employed for
inside diameters of gears, bearing races, and similar parts. Surface grinders are
used for die tops, bench surfaces.
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Lapping is used to produce a high-quality surface finish or to finish a
workpiece within close size limits. Dimensional tolerances of 0.00005
millimetres can be achieved in the hand or machine lapping of precision parts
such as gauges or gauge blocks.
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Burnishing is controlled burning (or a heat treatment) at the surface section
to remove part of the material and to change the colour or texture properties
of the surface. Burnishing is both a process of surface finish and surface
cleaning. Most of the organic materials can be surface-treated directly with
fire or indirectly with high heat to achieve a burnished or ironed effect.
Textiles, paper, leather, leaves, wood, etc. are some materials that can be
burnished. High temperature burnishing removes the surface fibres and hair,
and chars or burns (sinter) the top part of the surface, creating a burnt colour
+ texture effect. Textiles are Ironed, i.e. decreased or perma-set, i.e. creased
with pressurized heat treatment. Synthetics or composite textiles are
selectively or locally burnished to fuse the fibres or filaments, create textured
effects and also alter the transparency, opacity, etc. Wood surfaces on
burnishing, creates a dehydrated or an old shrivelled or shrunk surface,
similar to an old wood.
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Metal surfaces also burnished not only to harden or anneal the top surface but
to burn the oily residues, dehydrate, and descale the surface. Burnished metal
surfaces often attain peculiar colour and pattern effects.
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