2.810 manufacturing processes and systems

Prof. Tim Gutowski, [email protected] September 5, 2018

Prereq: 2.001, 2.006, 2.008 (translation: solid & fluid mech, heat transfer, mfg)

1 Today’s Agenda • Business – Administrative stuff – Your background • Concepts – Manufacturing Enterprise – Big Picture – Processes – Systems

2 Basic info can be found on the 2.810 webpage

page: http://web.mit.edu/2.810/www

Instructor: Prof. T. G. Gutowski Rm. 35-234 [email protected]

T.A.: John Lewandowski Rm 35- 135 [email protected]

Tech Inst: Mr. Paul Carson Rm. 35-112 [email protected]

Text: Manufacturing Engineering and Technology, 7th Ed. Kalpakjian and Schmid, 2014. Prentice Hall.

3 Paul Carson & the Bldg 35 Shop

[email protected] 4 Hands-on Experience Processes to Systems

5 2.810 Schedule

* https://www.youtube.com/watch?v=ICjQ0UzE2Ao 6 2.810 team project

7 2.810 Labs

Labs 9-12 M, T, R, F; Building 35 shop

Week of September 10 Safety, Shop Orientation, Car Review

Week of September 17 /Flashlight Project

Week of September 24 Machining /Flashlight Project

Week of October 1 Machining /Flashlight Project

Week of October 8 CAD/CAM (extra flashlight if needed) Week of October 15 Finish up Lab (QUIZ Week)

Week of October 22 Car Project (this continues through term)

Lab Maximum 16 people

8 Teams and Labs are Different

• Labs occur at the beginning of the term:

basic skills some CNC

• Teams are to build cars: you select your team members, usually 4 to 6 per team

9 Key dates for project

Sept 17 - Teams finalized October 1 - Kits assembled Week of Oct 1 - Preliminary design concept review (schedule a time for group to meet with Paul) Week of Oct 15 - Injection mold wheels October 22 - Chassis drawings due (waterjet file and dimensioned ) Week of Oct 29 - Production chassis cut on waterjet November 7 - Oral Progress Reports December 10 - Contest December12 - Evaluation & Clean up

Available at 2.810 Website 10 Please fill out information form; background, interests, skills

•Basic information

•Experience in shop

•Experience in mfg

11 12 Lab Sign-up

• See Google Doc: web & email

• State your availability & preference

• See schedule (don’t miss first 5 weeks)

13 Labs & Copies (9 per sheet Y_ or N_?)

14 15 The Mfg Enterprise – Big Picture

• Industrialization and Economic Growth

• Big Push Industrialization

• Divergence

• Democracy and Political Development

• The Future: Growth? Employment? Environment?

16 What caused this surge in per capita income around 1800 AD?

Ref. p 22817 http://www.historydiscussion.net/history/industrial-revolution/history-of-the-industrial-revolution/1784

18 The Industrial Revolution • England 1760 – 1830s • Coal • Steam power • Textile mills • Steel • Railroads

https://sites.google.com/a/online.sd71.bc.ca/human-rights-morgan-rachel-rylee/the-industrial-revolution 19 20 The importance of Manufacturing to economic growth

The plot shows the correlation, both in logs, of current GDP per capita (1820 -1950: Maddison), and past levels of industrialization per capita ( 50 or 70 years earlier: Bairoch). 21 Reference; Jeffrey G. Williamson, “ Trade and Poverty” MIT Press, 2011, p 50 The Great Divergence

R.C. Allen 2011 22 How do you join the developed? • “Big Push Industrialization” – Do everything at once – Trust – Planning Authority – Then Transition… • Required GDP growth – ~6% over 60years

23 How do you join the developed? • “Big Push Industrialization” – Japan – South Korea – Taiwan • Less successful – Russia – South America

24 The Importance of Manufacturing for Economic Development

• The rise of China and Manufacturing

Marc Levinson, Cong. Res. Ser. 2018

25 Global Mfg Shares 1750-2006

R.C. Allen 2011

26 The Role of Economic Growth in Political Development

Ref. p 43

27 How Democracy might develop…

Ref. p 43

28 Future trends: “the bounty & the spread” Inequality, Control & Environment

29 30 Basic Concepts for 2.810

1. Manufacturing 2. Manufacturing Processes Systems – Abstraction – Physical part – Performance – Required machines Attributes – Process steps – Classification – Equipment Schemes arrangements

31 MACHINING PROCESSES DEFORMATION PROCESSES METAL AND POWDER PROCESSES SINGLE POINT MACHINING • TURNING OPEN- CASTING • BORING IMPRESSION-DIE FORGING CASTING OF INGOTS • FACING CLOSED-DIE FORGING CONTINUOUS CASTING • • PRECISION OR FLASHLESS FORGING • SHAPING,PLANNING • SAND CASTING • HEADING, PIERCING, , COGGING, SHELL MOLDING MULTIPOINT MACHINING FULLERING, EDGING, ROLL FORGING, SLURRY MOLDING • DRILLING SKEW INVESTMENT CASTING (LOW-WAX PROCESS) • MILLING ROLLING EVAPORATIVE CASTING • SAWING, FILING • FLAT, RING, THREAD, GEAR, PIERCING DIE CASTING • BROACHING, THREAD CUTTING (GRAVITY-FEED, PRESSURIZED…) • DIRECT, INDIRECT HYDROSTATIC, CENTRIFUGAL CASTING GRINDING IMPACT, BACKWARD SQUEEZE CASTING • SURFACE GRINDING DRAWING RHEOCASTING • CYLINDRICAL GRINDING • ROD & WIRE, FLAT STRIP, TUBES • CENTERLESS GRINDING CRYSTAL GROWING • INTERNAL GRINDING • CRYSTAL-PULLING • FORM GRINDING • ZONE MELTING BENDING ABRASIVE WIRE CUTTING • PRESS-BRAKE FORMING, ROLL FORMING Electro forming HONING TUBE FORMING Plasma Spraying LAPPING BEADING, FLANGING, HEMMING, SEAMING ULTRASONIC MACHINING STRECH FORMING POWDER BUFFING, POLISHING BULGING PRESSING URNISHING DEEP DRAWING ISOSTATIC PRESSING TUMBLING PRESS FORMING SINTERING GRIT BLASTING RUBBER FORMING SPINNING JOINING PROCESSES CHEMICAL MACHINING • ENGRAVING MECHANICAL JOINING • MAGNETIC-PULSE FORMING • BOLTS, SCREWS, RIVETS • CHEMICAL BLANKING SUPERPLASTIC FORMING SOLID-STATE • DIFFUSION, FORGING, FRICTION, ELECTROCHEMICAL MACHINING DEFORMATION ELECTRICAL DISCHARGE MACHINING LIQUID STATE WELDING LASTER MACHINING • RESISTANCE WELDING ELECTRON BEAM MACHINING • ARC WELDING PLASMA-ARC CUTTING • THERMAL WELDING FLAME CUTTING, WATER JET CUTTING HIGH-ENERGY BEAM WELDING • ELECTRONIC BEAM, LASER LIQUID-SOLID STATE BONDING • • Manufacturing processes, … ADHESIVE BONDING • PLASTICS AND COMPOSITES JOINING (MECHANICAL, HEATING, SOLVENTS, ULTRASONICS…) 32 33 POLYMER PROCESSES COMPOSITES PROCESSES MICROELECTRONICS PROCESSING EXTRUSION (POLYMER COMPOSITES) FIBER SPINNING CRYSTAL GROWTH CALANDERING PULTRUSION • CZOCHRALSKI CRYSTAL GROWTH FILM BLOWING FILAMENT WINDING • FLOAT-ZONE CRYSTAL GROWTH COATING PULL FORMING WAFER PROCESSING (MELTS, SOLUTION, PLASMA, ELECTROSTATIC, BRAIDING • SLICING, ETCHING, POLISHINNG PLASTISOL, UV CURABLE…) AUTOCLAVE MOLDING SURFACE PROCESSES BLOW MOLDING COMPRESSION MOLDING (SMC) • CHEMICAL VAPOR DEPOSITION (CVD) INJECTION MOLDING RESIN TRANSFER MOLDING • EPITAXIAL FILM GROWTH REACTION INJECTION MOLDING (RIM) AUTOCOMP MOLDING • POLY CRYSTALLINE FILM GROWTH • S 0 FILMS COMPRESSION MOLDING HAND LAY-UP 1 2 TRANSFER MOLDING SPRAY-UP • OTHER (DIELECTRICS, METALS) CASTING AUTOMATIC TAPE LAY-UP OXIDATION THERMOFORMING • ION IMPLANTATION ROTATIONAL MOLDING DIAPHGRAM FORMING • PHYSICAL VAPOR DEPOSITION SOLID STATE FORMING INJECTION MOLDING • SPUTTERING (FILLED THERMOPLASTICS, BMC…) • EVAPORATION MACHINING REINFORCED REACTION INJECTION MOLDING LITHOGRAPHY ETCHING SOLVENT PROCESSING (RRIM) • PHOTORESIST FOAMING • ELECTRON BEAM, X-RAY, ION BEAM BONDING (METAL MATRIX COMPOSITES) LITHOGRAPHY IMPREGNATING WET ETCHING PAINTING HOT PRESSURE BONDING • CHEMICAL HOT ISOSTATIC PRESSING DRY ETCHING LIQUID METAL INFILTRATION • PLASMA ELECTRODEPOSITION • SPUTTER PLASMA SPRAY DEPOSITION • REACTIVE ION PACKAGING CERAMICS PROCESSES • DICING • DIE ATTACHMENT POWER PROCESSES • WIRE BONDING • CONSOLIDATION • ENCAPSULATION • SINTERING MELT PROCESSES • CRYSTALLINE MATERIALS (SILICON) • GLASSES • DRAWING, CASTING, BLOWING, TEMPERING (OPTICAL & STRUCTURAL FILTERS) • COATING SOL-GEL CERAMICS PROCESSING

172 processes + rapid prototyping + etc, etc 34 Abstraction of a Mfg Processes Noise

Raw material Hardware Energy Scrap & Waste Human Operators Process Heat Information

35 Process Classification

• Materials • Geometry

• Machines vs • Time

• Applications • Energy

36 Process Classification

• Geometrical transformation – Subtractive / Additive / Net • Time sequence – Serial / Parallel • Energy domain – Mechanical / Thermal / Chemical / Electrical

See “Manufacturing Processes and Process Control,” David E. Hardt 37 Geometrical classification

Additive

Net Shape

Part Mass, M Part Subtractive (serial) Subtractive (Parallel)

Time 38 39 * Taken from “Manufacturing Processes and Process Control,” David E. Hardt Performance measures

•Rate •Time •Cost •Quality •Flexibility •Environment See “Competitive Attributes…” T. Gutowski 40 Time – must be defined • Time at the machine – set-up, process, cycle time? • Customer lead time (order to receipt) – Release to shop floor – Queuing, waiting, inspection – Processing – Storage, transport

41 system boundaries Rate and Time  L, W 

– Little’s law: L =  W (all average values) • L = units in system ( inventory) •  = rate of material arrival • W = time in system – Takt Time = available time/units required • Time between products to meet demand

42 Direct Cost

Profit = Income - Expenses Manufacturing Cost = Material + Labor + Tooling + Equipment Economies of scale

• C = F + V X N C/N – C = Total cost – F = Fixed cost – V = Variable cost – N = number of units V N* N

43 Quality

• Satisfied Customer (systems level) • Deviation from target (process level) • material properties • geometry • appearance, etc

44 LSL USL Quality

Process Capability Index, Cp

• Cp = (USL-LSL) / 6 – USL = Upper Specification Limit – LSL = Lower Specification Limit –  = standard deviation of the process output • USL and LSL are something specified by design • The standard deviation is due to variation in the process

45 Flexibility

• Ability to accommodate different geometries, materials, production volumes • Measured as D cost, D time, etc,

46 Environmental performance

• LCA Process and Product • Enterprise Level • Global Level

47 From part to system

Physical Part Process Steps System Design

Shape, Equipment, Equipment Materials, Tools, arrangement, Tolerances Procedures Flows Skill Levels, other Resources Representation Process Plan - Cell or system-

48 digital representation of parts

Downstream activities: processing, assembly, product performance, maintenance, end of life, supply chain, factory control,

http://www.nist.gov/el/msid/infotest/mbe-pmi-validation.cfm

49 CADCAM and CNC

OMAX Instruction- 1st team meeting Needs DXF file OMAX app available

50 From 2.810 report

51 52 Process Planning

• Identify machines • Tools • Settings • Steps required to produce a geometry to tolerance • Time estimation

53 # Machine Operation Fixtur Tool Run Debur (V = Volume e Change (R = r A = Area Rough Inspec P = Perimeter) F = t Process Plan Finish) Measu 1 1 Saw stock to ~ 4.125” 0.23 - 2.02 0.30Dre 0 A = 5.625 in2 0.05I Time Estimation P = 9 in

2 2 Mill two ends 0.20 2 0.13R 0.63D 0 to length 4” 0.20 0.75F 0.05I V = 0.703 in3 0.13M Rod A = 11.25 in2 P = 19 in Support 3 2 Mill width to 2” 0.20 - 0.46R 0.43D 0 V = 2.5 in3 0.67F 0.05I A = 10 in2 0.13M P = 13 in

4 2 Mill out 2”x1.5”x4” - - 2.19R 0.50D 0 V = 12 in3 0.93F 0.05I A = 14 in2 0.13M P = 15 in 0.13M

5 2 Drill hole 1” diameter 0.20 2 0.03 0.21D 0 -Center drill 2 0.05 0.05I -Pilot drill 1/2” 2 0.04 0.17M -Pilot drill 63/64” 2 0.01 -Ream 6 2 Bore 1” radius 0.20 2 0.96R 0.24D 0 V = 0.79 in3 0.10F 0.05I A = 1.57 in2 0.06M P = 7.28 in

7 3 Sand 0.5” radii 0.08 - 0.20R 0.10D 0 V = 0.05 in3 0.21F 0.05I A = 0.79 in2 0.06M P = 3.14 in 0.06M

Totals: 1.31 12.00 8.75 3.63 54 Engineering Drawing; Connecting Link

55 See Tolerance hand-out 56 # Machine Operation # Fixtur Tool Run (V = Volume Dims. e Change (R = A = Area Rough P = Perimeter) F = 10 1 Face end - 0.17 0.1 0.08 Finish) Process Plan Assume V = 0.075 in3 20 Turn diameter to 0.827” - - - 0.11 Time Estimate V = 0.105 in3 30 Turn diameter 1 - - 1.35 finish pass A = 23 in2 Connecting 40 Center drill 0.512” dia. - - 0.1 0.05 Link 50 Drill with 0.4688” drill - - 0.1 0.28 60 Bore to 0.512” 1 0.1 0.05 V = 0.033 in3 70 2 Grind to exact length of 1 0.04 - 0.11R 1.635” 0.01F Assume V = 0.075 in3 A = 0.331 in2 80 3 Fixture in collet on - 0.17 - - indexer to drill holes V = 1.65 in3 90 Center drill 0.1875” hole - - 0.5 0.05

10 Drill to 11/64” - - 0.5 0.17 0 11 Ream to 0.1875” 2 - 0.5 0.06 0 12 Index part - 0.1 - - 0 13 Center drill 0.1875” hole - - 0.5 0.05 0 14 Drill to 11/64” - - 0.5 0.17 0 15 Ream to 0.1875” 4 - 0.5 0.06 0 16 Deburr all edges - - - 0.72 0 P = 10.77 in 57 Totals: 9 0.48 3.40 3.32 Mfg. System Designs; (a) job shop (b) flow shop

58 Manufacturing Systems

• Configurations • Analysis tools (time performance) • Historical development • Current practice • Future trends

59 Check List  Hand in information sheets  Fill in Google doc for labs ASAP  Attend Lab next week  Read: 1. “Competitive Attributes…” 2. “Mfg Processes and Control” 3. “Geometric Tolerancing” 4. skim Kalpakjian Ch 1-9.  Homework #1

60 2.810 team project

http://www.youtube.com/watch?v=BcnwGV4tNNY 61