Hose Clamp:
I dont have one in front of me so this is from memory. I believe
there are 3 pieces in a newer style hose clamp(the kind that tighten
with a screw). The band, the tigntening screw, and the housing for
the screw.
The band that wraps around the hose is most likely stamped from
sheet metal. The stamping process will cut the band from the entire
sheet and punch the slots that are used to tighten the clamp, in one
shot. Stamping uses a upper and lower die that are pressed together
by a large hydraulic ram. The dies are specially shaped to make the
specific part being produced. Just like a cookie cutter, the ram
presses the upper die into the lower die with the material being
worked between them.
The screw housing is probably stamped, and then placed onto the
band and then crimped to attach them together. This operation squezes
the metal parts together so they can't come apart easly.
The screw is probably made like most screws. The process starts
with a bar of metal. The end with the screw slot and hex head is
formed by cold forging. This happens by pressing a die into the bar
stock. Think about pushing your finger into play-dough. Then the
threads are formed by rolling the screw over another die with a thread
pattern on them.
Brake Light:
I dont know how a light bulb is made, so I'll assume you are
talking about the pastic assembly the bulb goes into. Again I'm not
looking at one so this is just an educated guess. There are two main
processes. One is called plastiforming. Durring this process a sheet
of plastic is gently heated so that it is still solid but limp and
formable. Then the sheet is eather sucked or blown onto a die that is
the shape of the final part. This is good for making a thin shaped
part, like the outside of the assembly that takes the shape of the car
body (sheet metal) around it.
Other parts of the light assembly, especially thicker structual
shapes that are less complex and solid, are probably die cast. These
areas include where the bolts that hold the assembly to the rest of
the car are mounted and where the bulb is mounted to the assembly.
Die casts parts start out as small balls of plastic. The balls are
loaded into the die casting machine and are plasticized (technically
different than melting but for this basic description more or less the
same). The plasticized plastic is then injected into the closed die
which is the negative of the shape being made. When the plastic cools
and the die is opened and the finished part ejected.
The complete light assembly comprised of both types of parts is
assembled with adhesives. Bolts may also be glued to the assembly. |
