Introduction to manufacturing-week1.ppt
- 1. Introduction to Manufacturing Process
- 2. 2 What is Manufacturing? Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and appearance of a starting material to make parts or products for a given application
- 3. Material-Process-Geometry Relationships 3 IE 337: Materials & Manufacturing Processes Function Process Material Geometry Role of Prod Engr Role of Mfg Engr
- 5. 5 Purpose of Manufacturing Manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations
- 6. Manufacturing “The Process of Converting Raw Materials Into Products”
- 7. Manufacturing a Product: General Considerations Material Selection Processing Methods Final Shape and Appearance Dimensional and Surface Finish Economics of Tooling Design Requirements Safety and Environmental Concerns
- 8. Choosing Methods of Production Use a Selection Chart
- 9. Manufacturing Processes for Metals Casting: expendable mold and permanent mold. Forming and Shaping: rolling, forging, extrusion, drawing, sheet forming, powder metallurgy, molding Machining: turning, boring, drilling, milling, planing, shaping, broaching, grinding, ultrasonic machining, chemical machining, electrical discharge machining (EDM), electrochemical machining, high-energy beam machining Joining: welding, brazing, soldering, diffusion bonding, adhesive bonding, mechanical joining Finishing: honing, lapping, polishing, burnishing, deburring, surface treating, coating, plating
- 10. Casting Processes Introduction of molten metal into a mold cavity; upon solidification, metal conforms to the shape of the cavity. Die Casting Sand Casting
- 11. Forming and Shaping Processes Bulk deformation processes that induce shape changes by plastic deformation under forces applied by tools and dies. Forging Extrusion
- 12. Machining Processes Material removal from a work piece: cutting, grinding, nontraditional machining processes. Milling Lathe Machine
- 13. NC Machine Tool and Controller
- 14. NC Punch Press Machine
- 15. Manufacturing Processes for Plastics Plastics are shipped to manufacturing plants as pellets or powders and are melted just before the shaping process. Polymers melt at relatively low temperatures and are easy to handle. Plastics can be molded and formed, as well as machined and joined, into many shapes with relative ease.
- 16. Injection Molding of Plastics
- 17. Selective Laser Sintering System Courtesy of the University of Texas
- 18. Unit 2 Manufacturing Operations Sections: 1. Manufacturing Industries and Products 2. Manufacturing Operations 3. Production Facilities 4. Product/Production Relationships 5. Lean Production 6. Manufacturing Metrics Manufacturing Lead Time Rate of Production Production Capacity Work in Progress Design Times Utilisation/Availability
- 19. Classification of Industries 1. Primary industries – cultivate and exploit natural resources Examples: agriculture, mining 2. Secondary industries – convert output of primary industries into products Examples: manufacturing, power generation, construction 3. Tertiary industries – service sector Examples: banking, education, government, legal services, retail trade, transportation
- 20. Manufacturing Industry Transformation Operations Machine Processing Assembly Adding value* Other Operations Material handling Inspection and testing Coordination and control Transformation Process Raw Material Part or Product Power Tools Machin es Labour Scrap or Waste
- 21. Production Facilities and Layout Facilities organised in the most efficient way to serve the particular mission of the plant and depends on: Types of products manufactured Production quantity Product variety
- 22. Production Quantity (Q) Number of units of a given part or product produced annually by the plant Three quantity ranges: 1. Low production – 1 to 100 units 2. Medium production – 100 to 10,000 units 3. High production – 10,000 to millions of units
- 23. Product Variety (P) Number of different product or part designs or types ‘Hard’ product variety – products differ greatly Few common components in an assembly ‘Soft’ product variety – small differences between products Many common components in an assembly
- 24. Low Production Quantity (Qlow) Job shop – makes low quantities of specialized and customized products Products are typically complex (e.g., specialized machinery, prototypes, space capsules) Equipment is general purpose Plant layouts: Fixed position Process layout
- 26. Process Layout
- 27. Medium Production Quantities (Qmed) 1. Batch production – A batch of a given product is produced, and then the facility is changed over to produce another product Changeover takes time – setup time Typical layout – process layout Hard product variety 2. Cellular manufacturing – A mixture of products is made without significant changeover time between products Typical layout – cellular layout Soft product variety
- 28. Cellular Layout
- 29. High Production (Qhigh) 1. Quantity production – Equipment is dedicated to the manufacture of one product Standard machines tooled for high production (e.g., stamping presses, molding machines) Typical layout – process layout 2. Flow line production – Multiple workstations arranged in sequence Product requires multiple processing or assembly steps Product layout is most common
- 30. Product Layout
- 32. Production quantity and variety Production quantity: low (<100), medium (102-104), high (>104) Production variety: low, medium, high soft, hard
- 33. Selecting manufacturing processes Manufacturing process decisions Deformation processes Casting processes Sheet metalworking Polymer processing Machining Finishing Assembly Material compatibilities / Process capabilities Material costs, Tooling costs, Processing costs
- 34. Types of manufacturing processes Extrusion Forging Rolling Bar drawing Wiredrawing Deformation Centrifugal Die casting Investment Permanent mold Sand casting Casting Bending Blanking Drawing Punching Shearing Spinning Sheet Metal Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding Polymer Processes Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM Machining Anodizing Honing Painting Plating Polishing Finishing Automated Bonding Brazing Manual Riveting Soldering Welding Assembly Manufacturing Processes How is the input material changed?
- 35. Deformation processes Rolling Extrusion Drawing Forging
- 36. Rolling (of ductile materials) Plastic deformation Rollers in compression thick slab thin sheet
- 39. Extrusion Typical use: ductile metals (Cu, Steel, Al, Mg), Plastics, Rubbers Common products: Al frames of white-boards, doors, windows, …
- 40. hydraulic piston chamber chamber stock die extruded shape hydraulic piston chamber chamber stock die extruded shape hydraulic piston chamber chamber stock die extruded shape Extrusion: Schematic, Dies Exercise: how can we get hollow parts?
- 42. Drawing Commonly used to make wires from round bars stock (bar) F (pulling force) wire die stock (bar) F (pulling force) wire die Similar to extrusion, except: pulling force is applied
- 44. Casting Processes Sand casting Die casting Investment casting
- 46. Die casting Parting line Plunger Sprue Moving die Stationary die Ejector pins Molten metal
- 47. Investment casting Wax pattern is cast Wax removed by melting Molten metal solidifies in cast Ceramic mold is removed Ceramic mold (hardened slurry) 4-part pattern tree
- 48. Sheet Metalworking Bending Blanking Drawing Punching Shearing Spinning
- 49. Sheet metal drawing Blank Drawn part Clamp force Blank holder Die Punch Punch ram
- 50. Polymer Processes Compression molding Transfer Molding Blow molding Injection molding
- 53. Blow molding Extruder air injector parison Part is removed Air blown into parison Mold halves close Molten parison is extruded
- 54. Injection molding Shear-heating Cavity half of mold Core half of mold Ejector pins Moving Feed hopper Sprue Fixed Barrel Pellets Mold closure direction Parting plane/surface
- 55. Machining processes Extrusion Forging Rolling Bar drawing Wiredrawing Deformation Centrifugal Die casting Investment Permanent mold Sand casting Casting Bending Blanking Drawing Punching Shearing Spinning Sheet Metal Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding Polymer Processes Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM Machining Anodizing Honing Painting Plating Polishing Finishing Automated Bonding Brazing Manual Riveting Soldering Welding Assembly Manufacturing Processes
- 56. Machining – removal of material… Sawing –using a toothed blade. Milling – from a flat surface by a rotating cutter tool. Planing – using a translating cutter as workpiece feeds. Shaping - from a translating workpiece using a stationary cutter. Boring - increasing diameter of existing hole by rotating the workpiece. Drilling- using a rotating bit forming a cylindrical hole. Reaming – to refine the diameter of an existing hole. Turning - from a rotating workpiece. Facing - from turning workpiece using a radially fed tool. Grinding - from a surface using an abrasive spinning wheel. Electric discharge machining - by means of a spark.
- 57. Finishing processes Extrusion Forging Rolling Bar drawing Wiredrawing Deformation Centrifugal Die casting Investment Permanent mold Sand casting Casting Bending Blanking Drawing Punching Shearing Spinning Sheet Metal Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding Polymer Processes Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM Machining Anodizing Honing Painting Plating Polishing Finishing Automated Bonding Brazing Manual Riveting Soldering Welding Assembly Manufacturing Processes protection?
- 58. Assembly processes – fastening / joining of 2 or more components Extrusion Forging Rolling Bar drawing Wiredrawing Deformation Centrifugal Die casting Investment Permanent mold Sand casting Casting Bending Blanking Drawing Punching Shearing Spinning Sheet Metal Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding Polymer Processes Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM Machining Anodizing Honing Painting Plating Polishing Finishing Automated Bonding Brazing Manual Riveting Soldering Welding Assembly Manufacturing Processes permanent?