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ME477: Manufacturing Processes Introduction Manufacturing Concept Introduction Design • Manufacturing? Organization Make or Buy – Making goods and articles ME477: – Shaping and treating Materials Virtual Product to perform desirable functions Organization • Manufacturing Processes Manufacturing Processes – Casting – Powder Processing (Shape, Raw Materials Material, – Forming Tolerance Patrick Kwon – Machining & Cost) Manufacturing – Surface processing Process Department of Mechanical Engineering – Joining Michigan State University • To make good and articles - A Manufacturing sequence of processes must be Process East Lansing, Michigan chosen, based on shape, material, tolerance and cost Manufacturing • Before MFG, a Make or Buy Process decision – Process Design 1 – Production Systems Part 2 Manufacturing as a set of Manufacturing processes • Manufacturing: 20% of U.S. GNP Power Management • Service sector: 70% of U.S. GNP (retail, transportation, banking, education, Labor Facility Machine communication, insurance and government). • Agriculture, Construction etc.: 10% of U.S. GNP • Manufacture comes from the Latin words manus A set Raw Materials Part (hand) and factus (make). of Processes • Definition: the application of physical and Concurrent or chemical processes to alter the geometries, Simultaneous Waste properties and appearance of a starting material Engineering in order to make and assemble it into a product. 3 4 Manufacturing Processes More Manufacturing Processes Deformation Processing Machining Polymer Processing Composite Processing Microelectronic Processing Casting Process Open Die Forming Turning Extrusion • Polymer Matrix Composite • Crystal Growth Ingot Casting Impression Die Forming Boring Blow Molding Pultrusion Czochoralski growth Crystal Growing Closed Die Forming Facing Injection Molding Filament Winding Float Zone Crystal Growth Sand Casting Rolling Forming Reaction Injection Molding Braiding • Wafer Processing Shell Molding Extrusion Drilling Compression Molding Autoclave Molding Slicing, Etching, Polishing Slurry Molding Drawing Milling Transfer Molding Compression Molding •Surface Processing Investment Casting Deep Drawing Threading Casting Resin Transfer Molding •Oxidation Evaporative Casting Swaging Broaching Thermoforming Hand Lay-up •Lithograph Die Casting Shearing Sawing, Filing Rotational Molding Spray-up •Wet Etching Centrifugal Casting Bending Grinding Solid State Molding Automatic Tape Lay-up •Dry Etching Squeeze Casting Stretch forming Honing Diaphragm Molding • Packaging Rheocasting Bulging Lapping Solid State Molding Beading, Flanging, Ultrasonic Machining • Metal Matrix Composite Powder Processing Hemming & Seaming Buffing Hot Pressure Bonding Pressing Explosive forming Polishing Hot Isostatic Pressing Hot Isostatic Pressing Electrohydraulic forming Chemical Machining Liquid Metal Infiltration Cold Isostatic Pressing Magnetic-pulse forming Electrochemical Machining Electrodeposition Pressureless Sintering Superplastic forming Laser Machining Plasma Spray deposition Plasma Arc Cutting Electron Beam Machining5 6 1 Historical Note The importance of manufacturing Underestimated in the development of civilization. • Powder processing (Clay) (4000BC) • Cultures with better manufacturing capabilities were • Casting - Lost Wax…Centrifugal casting (2500BC- 1850) more successful. • The First Industrial Revolution (1760-1830) • Better tools, better crafts & weapons – Adam Smith (1723-1790) - division of labor – Damascus and Samurai Swords – James Watt – Steam Engine – Shaving blade – John Wilkinson – Machine tools – Turbine blade – Eli Whitney (1797) – Interchangeable parts • Making Superalloys • Henry Ford (1913) – Assembly line • Coolded blade - Small holes to cool off • The Second Industrial Revolution (1950-) • Directionally solidified – Invention and Use of computers • To a significant degree, the history of civilization is the – Microchips history of humans' ability to make things 7 8 Manufacturing Industries Materials in Manufacturing •Metals • Industry consists of enterprises and – Ferrous – steels and cast iron (¾ of metals organizations that produce or supply used) – Nonferrous – aluminum, titanium, nickel… goods and services •Ceramics – Primary – Agriculture, Forestry, Mining, Fishing – A compounds of metallic (semi-metallic) and Metal nonmetallic Aerospace, Automotive, Electronics etc. – Secondary – • Polymers Composites – Tertiary – service sectors such as Banking, Education, – Thermoplastic Ceramics Polymer Government – Thermosetting • Consumer goods and Capital goods –Elastomers • Composites – Matrix & Second phases • Discrete vs. Continuous production • Thermomechanical Behavior • Production quantity and variety – Elastic, plastic, fatigue, thermal – Electrical, Magnetic, Optical, Chemical 9 10 Production and Energy Geometric Attributes (Shape) World Production (106Mg) Energy Consumption (MJ/kg) Shape 0 1 2 3 4 5 6 7 Materials 1972 1994 From Ore From Scrap Uniform Change Change Spatial Closed Closed Transverse Irregular Classification at end at center Curve One End Both End element Iron 634 750 35 14 Round Aluminum 11 19.4 240 13 Bar Copper 7 11.5 120 20 Zinc 5.2 7.1 70 20 Section Lead 3.6 5.4 30 10 Tube Nickel 0.6 0.9 150 16 Flat Magnesium 0.26 0.34 380 10 Titanium 0.06 0.1 550 Spherical Plastics 130 170 Undercut Plywood 10 Tolerance and Surface Roughness 11 12 2 Manufacturing Processes - Scope and Purpose Classification Liquid or • Processing Casting, Molding – Information – Nature of process, Process variety semifluid Powder – Physical Principal Shaping Particulate • Standard Ductile Process Deformation Solid – American National Standard Institute (ANSI) Operation – American Society for Testing and Materials (ASTM) Material Removal Solid – American Society of Mechanical Engineers (ASME) – American Society of Precision Engineering (ASPE) Property Enhancing Heat Treating •Society Surface Treatment – ASME, Society of Manufacturing Engineers (SME), Surface Enhancing ASPE Assembly Coating • Units – SI (and English Unit) Operation Permanent joining & Mechanical fastening 13 14 Solidification Processes Particulate Processing • Starting material is heated sufficiently to transform it into a liquid or highly plastic state • (1) Starting materials: powders of metals or • Examples: Casting for metals, molding for ceramics plastics • (2) Pressing • (3) Sintering, 15 16 Deformation Processing Material Removal Processes • Excess material removed from the starting workpiece • Starting workpart is shaped by application of so what remains is the desired geometry forces that exceed the yield strength of the • Examples: machining such as (a) turning, (b) drilling, material and (c) milling; also grinding and nontraditional • Examples: (a) forging, (b) extrusion and etc. processes chamber Die Die Ram Starting Extruded cross sectio billet Die Die 17 18 3 Alternative Processes Other Processing Operation Design: Geometry, Material, Surface finish, Tolerance • Property Enhancing Processes – Heat Treatment: Improve physical properties of the material without changing its shape – Alloying: Processes – Composites • Surface Processing – cleaning, surface treatment and coating deposition Casting or PM Forging Extrusion Machining Joining 19 20 Example (from Ashby & Jones) Manufacturing Capability • Turbine blade • Technical process capability – High Temperature Alloy – Directional Solidification – A capable set of manufacturing processes – Cooling – making holes • Physical product limitation on High Temperature Alloys – Size and weight limitation • Production capacity – An important influence on the way its people, facilities, and procedures are organized 21 22 Production Systems Manufacturing Support Systems • Production facilities • A company must organize itself – Low-quantity Production (1~100 units/year) – job – To design the processes and equipment, shop, prototyping – To plan and control the production orders, and – Medium-quantity Production (100~10,000 units/year) – To satisfy product quality requirements – Batch production and cellular manufacturing • Manufacturing support systems to manages its – High-quantity Production (10,000~millions of production operations units/year) – mass production – Manufacturing Engineering – planning mfg processes – Two categories of mass production: – Production planning and control – logistics problems 1.Quantity production - Mass production of single parts on in manufacturing single machine or small numbers of machines – Quality control 2.Flow line production - Multiple machines or workstations arranged in sequence, e.g., production line 23 24 4.
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