manufacturing

transcript

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

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MEIE-4262

Manufacturing Processes

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Chapter-1

Introduction

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Manufacturing Processes - Definition

• A method of converting raw material into a finished products by

using machines, tools and labour

• Finished products may be used as such or for manufacturing

other, more complex products, such as aircraft, household

appliances or automobiles

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Evolution of Manufacturing

• Began about 5000 to 4000 B.C with the production of various

articles of wood, ceramic, stone and metal

• Derived from Latin word manu factus – meaning “made by hand”

• The word manufacture first appeared in 1567

• The word manufacturing appeared in 1683

• Production is also used interchangeably .

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What is Manufacturing?Range of Materials & Processes in a Tractor

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FIGURE 1.1 Model 8430 tractor, with detailed illustration of

its diesel engine, showing the variety of materials and

processes incorporated. Source: Courtesy of John Deere

Company.

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History of Manufacturing

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History of Manufacturing (cont.)

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History of Manufacturing (conc.)

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Manufacturing Importance

FIGURE 1.2 Importance of manufacturing to national economies. The trends

shown are from 1982 until 2006. Source: After J.A. Schey with data from the

World Development Report, World Bank, various years.

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Classification of Manufacturing

Processes

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Manufacturing Process

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Classification of Manufacturing Processes

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Manufacturing Processes

• Two basic types:

1. Processing operations - transform a work material from one state of

completion to a more advanced state

• Operations that change the geometry, properties, or

appearance of the starting material

2. Assembly operations - join two or more components to create a new

entity

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Processing Operations

• Shaping operations

• Solidification processes

• Particulate processing

• Deformation processes

• Material removal processes

• Property-enhancing operations (heat treatments)

• Surface processing operations

• Cleaning and surface treatments

• Coating and thin-film deposition

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Shaping Processes – Four Categories

• Solidification processes - starting material is a heated liquid or

semifluid

• Particulate processing - starting material consists of powders

• Deformation processes - starting material is a ductile solid

(commonly metal)

• Material removal processes - starting material is a ductile or

brittle solid

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Solidification Processes

• Starting material is heated sufficiently to transform it into a liquid or

highly plastic state

• Examples: metal casting, plastic molding

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Particulate Processing

• Starting materials are powders of metals or ceramics

• Usually involves pressing and sintering, in which powders are first

compressed and then heated to bond the individual particles

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Deformation Processes

• Starting workpart is shaped by application of forces that exceed

the yield strength of the material

• Examples: (a) forging, (b) extrusion

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Material Removal Processes

• Excess material removed from the starting piece so what remains is

the desired geometry

• Examples: machining such as turning, drilling, and milling; also

grinding and nontraditional processes

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Property-Enhancing Processes

• Performed to improve mechanical or physical properties of work

material

• Part shape is not altered, except unintentionally

• Examples:

• Heat treatment of metals and glasses

• Sintering of powdered metals and ceramics

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Surface Processing Operations

• Cleaning - chemical and mechanical processes to remove dirt, oil,

and other contaminants from the surface

• Surface treatments - mechanical working such as sand blasting,

and physical processes like diffusion

• Coating and thin film deposition - coating exterior surface of the

workpart

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Assembly Operations

• Joining processes

• Welding

• Brazing and soldering

• Adhesive bonding

• Mechanical assembly

• Threaded fasteners (e.g., bolts and nuts, screws)

• Rivets

• Interference fits (e.g., press fitting, shrink fits)

• Other

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Development Process

FIGURE 1.3 (a) Chart showing various steps

involved in designing and manufacturing a

product. Depending on the complexity of the

product and the type of materials used, the

time span between the original concept and

the marketing of a product may range from a

few months to many years. (b) Chart showing

general product flow, from market analysis to

selling the product, and depicting concurrent

engineering. Source: After S. Pugh.

Product Design and Concurrent

Engineering

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Shapes &

Manufacturing

Process

TABLE 1.2 Shapes and some common

methods of production.

Design for

Manufacture,

Assembly,

Service, …

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Design for Assembly

FIGURE 1.4 Redesign of parts to facilitate automated assembly. Source: Reprinted from G. Boothroyd and P.

Dewhurst, Product Design for Assembly, 1989, by courtesy of Marcel Dekker, Inc.

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All-Aluminum

Automobile

FIGURE 1.5 (a) The Audi A8 automobile, an example of advanced materials construction; (b) The aluminum

body structure, showing various components made by extrusion, sheet forming, and casting processes.

Source: Courtesy of ALCOA, Inc.

Design for Environment; Sustainable

Manufacturing; Product Life Cycle

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Material Selection

• Types of materials

• Material substitution

• Material properties

• Cost and availability

• Service life and recycling

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Methods of Manufacture

FIGURE 1.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or

upsetting, (c) extrusion, (d) machining, (e) joining two pieces.

Selection of Manufacturing Process

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Scales in

Manufacturing

FIGURE 1.7 Illustration of the range of

common sizes of parts and the

capabilities of manufacturing processes in

producing these parts.

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Machining a Mold Cavity

FIGURE 1.8 Machining a mold cavity for making sunglasses. (a) Computer model of the sunglasses as

designed and viewed on the monitor. (b) Machining the die cavity using a computer numerical control milling

machine. (c) Final product produced from the mold. Source: Courtesy Mastercam / CNC Software, Inc.

Computer Integrated Manufacturing

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Flexible Manufacturing

FIGURE 1.9 General view of a flexible manufacturing system, showing several machines (machining centers)

and an automated guided vehicle (AGV) moving along the aisle. Source: Courtesy of Cincinnati Milacron, Inc.

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Lean Production and Agile Manufacturing;

Quality Assurance and TQM

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Global Labor Rates

Manufacturing Cost

manufacturing

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