Intro 1: Fabrication Technology in manufacturing Technology

7/29/2019 Intro 1: Fabrication Technology in manufacturing Technology

1/39

Introduction1

Fabrication Technology or

Manufacturing Technology

les 1: IntroductionHerman Terryn

Professor Vrije Universiteit Brussel (VUB)

Research Group Electrochemical and Surface Engineering (SURF)

Department Materials and Chemistry

Pleinlaan 2, 1050 Brussels, Belgium

Tel:+ 3226293537 (secr 3255) Fax:+3226293200 [email protected]

www.vub.ac.be/SURF

part time Professor M2i Materials Innovations Institute

Department of Materials Science and Engineering, Tu Delft

Surfaces and Interfaces Group, Corrosion Technology and Electrochemistry

Mekelweg 2,2628CD Delft,The Netherlands

www.m2i.nl


2/39

Introduction2

Reference book

Manufacturing, Engineering & Technology, Fifth Edition, by

Serope Kalpakjian and Steven R. Schmid.

ISBN 0-13-148965-8. 2006 Pearson Education, Inc.,Upper Saddle River, NJ. All rights reserved.

Slides are based on that book


3/39

Introduction3

Manu Factus: Latin for made by hand

Definition:

A Well organized method of converting raw material to end product

End Product: Value and utility added to output.


4/39

Introduction4

Materials in an Automotive Engine

Figure I.1 Section of an automotive engine - the Duratec V-6 - showing

various components and the materials used in making them. Source:

Courtesy of Ford Motor Company. Illustration by David Kimball.


5/39Introduction5

AISI 1010,swaged

and cadmium plated

AISI 1020,forging and

chromium plated

AISI 1010, luster finished coil

stock,profile milled,resistance

welded and chromium plated

formed,welded and plated

AISI 1008, press

formed,welded and plated

Cold drawn medium carbon

steel,( similar to AISI 1035)

bright zinc plated

Headed brass,nickel plated

Aluminum permanent mold

casting,machined , polished

and buffed Hardened high-carbon

steel,thread rolled and

chromium plated

AISI 1010,stamped and

chromium plated

Case hardened forging

quality steel parts, black

oxide coating

AISI 1040 forging,carburized

and chromium plated

AISI 1010,stamped and

coined and chromium plated

AISI 1010, stamped and

chromium plated

Aluminum alloy forging,

polished and buffedForged aluminum

tubing(alloy similar to 6063)

polished and buffed

AISI 1010 welded tubing,

assembly resistance welded

and electrostatically painted

AISI 1008,press formed

resistance welded and painted

AISI 1020 tubing, machine

threaded and painted

Seamless AISI 1020 tubing

swaged tube sections brazed

into fork crown,painted

Manufacturing of

a bicycle


6/39Introduction6

Components in Products Some products are a single

components (nail, bolt, fork, coat

hanger, etc.)

Some products are assemblies of

many components (ball point pens,

automobiles, washing machines, etc.) All components are manufactured.

Manufacturing means, literally, Madeby Hand.


7/39Introduction7

History of Manufacturing (until 1700)


8/39Introduction8

History of Manufacturing (1700-1960)


9/39

Introduction9

History of Manufacturing (1960-2000s)


10/39

Introduction10

Materials Selection for Paper Clips

Figure I.2 Examples of the wide variety of materials andgeometries for paper clips.

Questions for consideration:

What material properties are

required?

What manufacturing attributes are

required?

Would the material and processingstrategy change if the desired

quantity was 10,000 vs. 1 million per

day?


11/39

Introduction11

Manufacture of Light Bulbs

Figure I.3a Components of a common

incandescent light bulb. Source:Courtesy of General Electric Company.

Figure I.3b Manufacturing steps

in making an incandescent light

bulb. Source: Courtesy of GeneralElectric Company.


12/39

Introduction12

Figure I.4 (a) Chart showing the

various steps involved in design

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 the product may

range from a few months to many

years.

(b) Chart showing general

product flow in concurrent

engineering, from market analysis

to selling the product. Source:After S. Pugh,Total Design.

Addison-Wesley, 1991.

Product Design Process


13/39

Introduction13

Manufacturing Characteristics of Alloys


14/39

Introduction14

Manufacturing Processes: Casting

Figure I.7a Schematic illustration of various casting processes

Manufacturing Processes: Forming and Shaping


15/39

Introduction15


Figure I.7b Schematic illustration of various bulk deformation processes


16/39

Introduction16


Figure I.7c Schematic illustration of various sheet metal forming processes


17/39

Introduction17


Figure I.7d Schematic illustration of various polymer processing methods

Manufacturing Processes: Machining


18/39

Introduction18

Manufacturing Processes: Machining

Figure 1.7e Schematic illustrations of various machining and finishing processes

Manufacturing Processes: Joining


19/39

Introduction19

Manufacturing Processes: Joining

Figure I.7f Schematic illustration of various joining processes


20/39

Introduction20

Laser CuttingFigure I.8 Cutting sheet metal with

a laser beam. Source: Courtesy ofRofin-Sinar, Inc. and ManufacturingEngineering Magazine, Society ofManufacturing Engineers


21/39

Introduction21

Hip Replacement

Figure 1.9 Components of a total hip replacement. Source: Courtesy of Zimmer, Inc.


22/39

Introduction22

Manufacturing of Hip Replacement

Figure 1.10 (a) Manufacturing steps in the production of a roll-formed and machined total

hip replacement stem; (b) Manufacturing steps in the production of a forged stem. Hip

stems can also be produced by investment casting, metal injection molding, insert

injection molding, and assorted other processes. Source: Courtesy of Zimmer, Inc.


23/39

Introduction23

Salt and Pepper Shakers

Figure I.12 A salt and pepper mill set.

The two metal pieces (at the bottom) for

the pepper mill are made by powder-

metallurgy techniques. Source:Reproduced with permission fromSuccessStories on P/M Parts, MetalPowder Industries Federation,

Princeton, NJ, 1998.


24/39

Introduction24

Automated welding of

automobiles

Figure I.13 Automated

spot welding of

automobile bodies in a

mass production line.Source: Courtesy of FordMotor Company.


25/39

Introduction25

Application of CAD/CAM to make sunglasses mold

Figure I.14 Machining a moldcavity for making sunglasses.

(a) Computer model of the sunglass

as designed and viewed on the

monitor.

(b) Machine the die cavity using acomputer numerical-control milling

machine

(c) Final product. Source: Courtesy oMastercam/CNC Software, Inc.


26/39

Introduction26

Hourly Compensation for Production Workers


27/39

Introduction27

Requirements of a good manufacturing system

n Product should meet design requirement

n Economical Process

n Quality should be built into the system

n Should be flexible and responsive to new technologyn High productivity: Best utilization of man, material,

machine, capital and available resources.

Design for Assembl


28/39

Introduction28

Design for Assembly



29/39

Introduction29


Whole process of transformation from raw

material into a product

Fabrication of a Product

Selection of the Materials, mostly objects are constructed by assembling different components,often consisting of a variety of materials

Property driven

Production of the Material

Completely different

metals, polymers, ceramics en composites

Forming of the Material,

Producing its shape

Completely Different

metals, polymers, ceramics en composites

Surface Engineering

Joining of Materials

Durability

degradation (polymers)

corrosion (metal, glass)

End of LifeRecycling

Waste


30/39

Introduction30

R l ti C t f R i t St f


31/39

Introduction31

Relative Cost of Repair at Stages of

Product Development and Sale


32/39

Introduction32

Average Life

Expectancy for

Various

Products

Commercially Available Shapes of Materials


33/39

Introduction33

Commercially Available Shapes of Materials


34/39

Introduction34

Cost per Unit Volume for Wrought Metals and

Polymers Relative to Cost of Carbon Steel


35/39

Introduction35

Approximate Ranges of Scrap Produced

in Various Manufacturing Processes


36/39

Introduction36

Example: Material Changes in Transport Aircraft

Figure 40.1 Advanced materials in

the Lockheed C-5A transport aircraft.(Note: FRP is fiber-reinforcedplastic.)


37/39

Introduction37

Methods of Making a Part

Figure 40.6 Various methods of making a simple part: (a) casting or powder metallurgy,(b) forging or upsetting, (c) extrusion, (d) machining, and (e) joining two pieces


38/39

Introduction38

Two Methods of Making Dish-Shaped Sheet-Metal Part

Figure 40.7 Two methods of making a dish-shaped sheet-metal part:

(a) pressworking using a male and female die, (b) explosive forming

using one die only.


39/39

Introduction39

Three methods of casting turbine blades

A: conventional casting with ceramic mold

B: directional solidification

C: Method to produce single crystal blade

FIGURE 3.1 Turbine blades for jet engines, manufactured by three different methods: (a) conventionally cast;

(b) directionally solidified, with columnar grains, as can be seen from the vertical streaks; and (c) single crystal.

Although more expensive, single-crystal blades have properties at high temperatures that are superior to those of other blades.

Source: Courtesy of United Technologies Pratt and Whitney.

Intro 1: Fabrication Technology in manufacturing Technology

Documents

Transcript of Intro 1: Fabrication Technology in manufacturing Technology