Advanced Manufacturing ME 10405/10505 Professor Jim Waterman For Today – Objectives of the Course...

Advanced ManufacturingME 10405/10505Professor Jim Waterman

For Today– Objectives of the Course– Who am I?– My approach to the course– Outline for the semester– What is Manufacturing – intro to the course

Advanced ManufacturingME 10405/10505Professor Jim Waterman

For Today Objectives of the Course Who am I? My approach to the course Outline for the semester

What is Manufacturing – intro to the course

Advanced ManufacturingME 10405/10505

1. Course Objectives– Provide an overview of modern manufacturing

processes – Enable students to select and design processes to

make things– Provide insights as to what is state of the art now,

and what is coming

Advanced ManufacturingME 10405/10505

1. My Approach– Bring some relevance to the subject• What is happening in industry today

– Bring you into the discussion• I want your questions, and your knowledge• We'll learn together

– Get you ready to design for manufacture, or design the processes of the future

Advanced ManufacturingME 10405/10505Course Outline – First Half

Intro and Overview of ManufacturingEngineering Materials

Properties of Engineering MaterialsDimensions Tolerancing and Surfaces

Metal Casting GlassworkingShaping processes for PlasticsShaping processes for Rubber/Polymer CompositesPowder MetallurgyCeramicsMetal Forming

Metal working (roll/forge/extrude)Sheet MetalMetal Machining(including tool life)

PrinciplesMachine ToolsCutting tools tech

Mid TermOct 15

Advanced ManufacturingME 10405/10505Course Outline – Second Half

Grinding/abrasive processesNon-traditional Processes

Mechanical Energy processesUltrasonic, Water Jet, Electrochemical machiningEDM,Electron Beam/Laser Beam MachiningChem Machining

Heat Treatment of MetalsSurface Processing

Cleaning,Diffusion/ion implant,Plating/electroformingConversion coatings, Vapor depositionOrganic coatings

Welding :Fundimentals/Joints/physicsProcesses: Arc, Oxy/fuel, Acetalyene, FusionSolid state

Braze/Solder/Adhesive bondMechanical AssemblyRapid Prototype processes

Survey of Additive Manufacturing processes SLA, Fused Deposition, Powder basedInk/liquid basedOthers are developed

Micro/Nano fabrication technologies

Advanced ManufacturingME 10405/10505Course Outline – Second Half

Production Systems/process planning

Survey of Automation/Manufacturing SystemsCNCCells and work flow/part families'Flexible Machine Cells'Lean'CIM'

Discussion of life cycle data driven mfg/standards.Quality

Process CapabilityStatistical Process Control

FuturesExtrapolating today to tomorrow (incorporate through the semester?)Supply Chain considerations – global issues

Final Exam

What is Manufacturing?

The word manufacture is derived from two Latin words, manus (hand) and factus (make)

Taken together the combination means made by hand, which is how things were made in 1567 when the word first entered the English language

Today manufacturing can be defined two ways: Technologically Economically

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Technological Definition of Manufacturing

The application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products

It also includes assembly of multiple parts to make products


Economic Definition of Manufacturing

The transformation of materials into items of greater value by means of one or more processing and/or assembly operations

Manufacturing adds value


Manufacturing Industries

Industries can be classified as: Primary industries:– Cultivate and exploit natural resources (e.g.,

agriculture and mining) Secondary industries:– Take the output of the primary industries and convert

them into consumer and capital goods (e.g., manufacturing, construction, power utilities)

Tertiary industries:– Service sector (e.g., retail, financial, education,

transportation, government)©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufactured Products

Final products made by the manufacturing industries can be divided into two major classes:

Consumer goods – products purchased directly by consumers (e.g., cars, personal computers, TVs, tires,, and tennis rackets)

Capital goods – products purchased by companies to produce goods and/or provide services (e.g., aircraft, trucks and buses, machine tools, construction equipment)


Manufacturing and Gross Domestic Product (GDP)

In the U.S: Manufacturing accounts for about 12% of GDP– And the service sector accounts for more than

75% of GDP BUT! Manufactured capital goods purchased by the

service sector are the enablers of that sector Without these manufactured products, the service

industries could not function


Production Quantity and Product Variety

Production quantity = the number of units produced annually of a given product type Three ranges:

Low production (1 to 100 units per year) Medium production ( 100 to 10,000 units) High production (10,000 to millions of units)

Product variety refers to the number of different types of products made


Production Quantity and Product Variety

Manufacturing plants tend to specialize in a combination of production quantity and product variety that lies inside the diagonal band shown below


How would you 'break' the curve?

Manufacturing Capability

Refers to the technical and physical limitations of a manufacturing firm and its individual plants

Three dimensions of manufacturing capability:

1. Technological processing capability – available set of manufacturing processes

2. Physical product limitations – size and weight of the products that can be made

3. Production capacity – production quantity that can be produced in a given time period


Materials in Manufacturing

Most engineering materials fall into one of 3 basic categories:

Metals:

Ferrous (e.g., steel and cast iron)

Nonferrous (e.g., aluminum, copper, nickel)

Ceramics

Crystalline ceramics (e.g., clay, alumina)

Glass

Polymers

Thermoplastics (e.g., polyethylene)

Thermosets (e.g., epoxies)

Elastomers (e.g., rubber)©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing Processes

A manufacturing process is a designed procedure that results in physical and/or chemical changes to a starting work material with the intention of increasing the value of that material

Usually carried out as a unit operation, which is a single step in the sequence of steps required to transform the material into as final product


Two Basic Types of Manufacturing Operations

1. Processing operations – transforms a work material from one state of completion to a more advanced state that is closer to the final desired product Usually performed on discrete workparts

2. Assembly operations – joins two or more components to create a new entity, called an assembly, subassembly, or other term (e.g., weldment)



Manufacturing Taxonomy

Processing Operations

General types:

1. Shaping operations – alter the geometry of the starting work material

2. Property-enhancing operations – improve the physical properties of the material without changing its shape

3. Surface processing operations – performed to clean, treat, coat, or deposit material onto the surface of the work


Shaping Processes

Four categories based on the state of the starting material:

1. Solidification processes

2. Particulate processes

3. Deformation processes

4. Material removal processes


Solidification Processes

Starting material is a heated liquid or semifluid that cools and solidifies to form the part geometry


Particulate Processes

Starting material is a powder, and the powders are formed to create geometry and heated to strengthen


Deformation Processes

Starting material is a ductile solid (commonly metal) that is deformed to shape the part

Forging Extrusion


Material Removal Processes

Starting material is a solid (ductile or brittle), from which material is removed so that what remains has the desired geometry

Turning Drilling Milling


Property-Enhancing Processes

Involves heat treatments, which include: Annealing and strengthening processes performed

on metals and glasses Sintering of powdered metals and crystalline

ceramics


Surface Processing Operations:

Cleaning – chemical and mechanical processes to remove dirt, oil, and other contaminants

Surface treatments – mechanical working (e.g., sand blasting) and physical processes (e.g., diffusion)

Coating and thin-film deposition – apply a coating to the exterior surface of the work (e.g., electroplating, painting, physical vapor deposition)


Assembly Operations

Permanent Joining processes Welding Brazing Soldering Adhesive bonding

Mechanical Fastening Joints can be disassembled (e.g., threaded

fasteners) Joints are permanent (e.g., rivets)


Production Machines

Machine tools – power-driven machines used to operate cutting tools

Other production machines developed subsequently: Presses for stamping operations Forge hammers Rolling mills Welding machines Insertion machines for assembly


Categories of Production Equipment

General-purpose machines More flexible and adaptable to a variety of jobs Commercially available for any manufacturing

company to invest in Special-purpose machines

Usually designed to produce a specific part or product in very large quantities

Achieve high efficiencies and short cycle times


Tooling

Production machines usually require tooling that customizes the equipment for a particular part or product

In many cases, the tooling must be designed specifically for the part or product (e.g., a mold)

When used with general-purpose equipment, the tooling can be exchanged at the end of a production run


Production Equipment and Tooling for Various Processes

Process Equipment Special tooling

Casting (various types) Mold

Molding Molding machine Mold

Forging Forge hammer Forging die

Extrusion Extrusion press Extrusion die

Stamping Stamping press Stamping die

Machining Machine tool Cutting tool

Grinding Grinding machine Grinding wheel


Some Resources (outside of the book)


I. The Library of Manufacturing: good companion resource to book for process information – http://thelibraryofmanufacturing.com/index.html

II. Industry Week website – news, white papers– http://www.industryweek.com/

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