Production techniques_Introduction
Mohsen Badrossamay 1
Dep. of Mech. Eng.
DEPARTMENT OF MECHANICAL ENGINEERINGISFAHAN UNIVERSITY OF TECHNOLOGY
روشهاي تولید و كارگاهPRODUCTION TECHNIQUES
مقدمهINTRODUCTION
Dep. of Mech. Eng.
Session Overview1. Course objectives
2. Course materials
3. Syllabus
4. Course schedule
5. Form of assessment
6. General introduction to manufacturing processes
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Production techniques_Introduction
Mohsen Badrossamay 2
Dep. of Mech. Eng.
Course Objectives
Overall aim:
To provide a basic information and state-of-the-art on manufacturing processes
Upon completion of the module you should be able to:
Understand the basic knowledge on engineering materials
Demonstrate a comprehensive knowledge of production
techniques
Understand the needs for manufacturing processes
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Dep. of Mech. Eng.
Course Materials[1] Manufacturing engineering and technologies, S. Kalpakjian, S.
Schmid, Fifth edition (2006)
[2] Materials and processes in manufacturing, E. P. Degarmo, J. T.
Black, R. A. Kohser, Ninth edition (2003)
[3] Manufacturing processes for engineering materials, S. kalpakjian,
S. Schmid, Fifth edition (2008)
[4] Fundamentals of Modern Manufacturing, M. P. Groover, Second
edition (2002)
[5] Teaching handouts
[6] Extra reading materials (for each process is introduced individually)
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Syllabus General introduction
Fundamentals of Materials behaviour and manufacturing
properties (metals and non-metals)
Metal-casting processes
Forming and shaping processes
Machining processes and machine tools
Additive manufacturing processes
Joining processes
Micromanufacturing and fabrication of microelectronic devices
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Form of Assessment 5 x (Assignments / quiz) (10%)
Group project (15%)
Seminar presentation (5 minutes each member team)
Written reports (group and individual)
Mid-term examination (30%)
Final examination: written (45%)
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General Introduction
What is Manufacturing?
The process of converting raw materials into products
Manufacturing means, literally, “Made by Hand”
All components are manufactured
Adding value
Discrete (individual) or continuous products
The higher the level of manufacturing, the higher the
standard of living
Production dates back to 5000 – 4000 B.C.
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Materials diversity in Manufacturing
Section of an automotive engine - the Duratec V-6,Source: Courtesy of Ford Motor Company (ref. [1])
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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.)
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Manufacturing Importance
Importance of manufacturing to national economies. Thetrends shown are from 1982 until 2006. Source: After J.A.Schey with data from the World Development Report, WorldBank, various years (ref [3]) 10
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History of Manufacturing (until 1700)
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History of Manufacturing (1700-1960)
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History of Manufacturing (1960-2000s)
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Resources and Activities
Manufacturing involves:
Product design Production control Machinery and tooling Support services Process planning Marketing Materials Sales Purchasing Shipping Manufacturing Customer services
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Manufacturing Activities Responsibility
Fully meet design requirements, product specifications, and standards Economical and environmental friendly Quality (from design to assembly) Flexible Continuous developments in materials, production methods, and computer integration System Continuous product improvement through customer feedback
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Materials Selection for Paper Clips
Examples of the wide variety of materials and geometries for paper clips.
Questions for consideration:
• What material properties are required?
• What manufacturing attributes are required?
• Would the material and processing strategy change if the desired quantity was 10,000 vs. 1 million per day?
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Product Design Process
(a) various steps involved in design and manufacturing of a product
(b) general product flow in concurrent engineering, from market analysis to selling the product.
Source: After S. Pugh, Total Design. Addison-Wesley, 1991 (ref [1])
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Life-Cycle Engineering
A well-designed product:
functional (design) well manufactured (production) well packages durable (function effectively for its intended purpose) maintainable resource efficient (recyclable)
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Redesign of Parts
Redesign of parts to facilitate assembly. Source:Reprinted from G. Boothroyd and P. Dewhurst, Product Design for Assembly, 1989. Courtesy of Marcel Dekker, Inc (ref [1]) 19
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Selecting Materials
Materials used in manufacturing:
Ferrous metals Nonferrous metals Plastics (polymers) Ceramics, glasses, glass ceramics, graphite, diamond Composite materials Nanomaterials, shape-memory alloys
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Selecting Materials
Considerations:
Properties of materials
Mechanical properties
Physical properties
Chemical properties
Manufacturing properties
Cost and availability
Appearance, service life, and recycling
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Manufacturing Characteristics of Alloys
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Salt and Pepper Shakers
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 from Success Stories on P/M Parts, Metal Powder Industries Federation, Princeton, NJ, 1998. (ref [1])
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Methods of Manufacture
Various methods of making a simple part:(a) casting or powder metallurgy,(b) forging or upsetting,(c) extrusion,(d) machining,(e) joining two pieces.
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Selecting Manufacturing Processes Casting
Forming and shaping
Material removal processes
Additive manufacturing processes
Joining processes
Finishing
Nanofabrication
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Manufacturing Processes: Casting
Schematic illustration of various casting processes (ref [1])26
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Dep. of Mech. Eng.Schematic illustration of various bulk deformation processes (ref [1]) 27
Forming and Shaping (bulk deformation)
Dep. of Mech. Eng.Schematic illustration of various sheet metal forming processes 28
Forming and Shaping (sheet deformation)
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Forming and Shaping (polymers)
Schematic illustration of various polymer processing methods (ref [1])
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Machining
Schematic illustrations of various machining and finishing processes (ref [1])
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Manufacturing Processes: Joining
Schematic illustration of various joining processes (ref [1])
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Laser Cutting
Cutting sheet metal with a laser beam. Source: Courtesy of Rofin-Sinar, Inc. and Manufacturing Engineering Magazine, Society of Manufacturing Engineers (ref [1])
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Microscopic Components
(a) Microscopic gears with dust mite. Source: Courtesy Sandia National Laboratory;
(b) A movable micromirror component of a light sensor. Source: Courtesy of Richard Mueller, University of California at Berkeley. (ref [1])
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Automated welding of automobiles
Automated spot welding of automobile bodies in a mass production line. Source: Courtesy of Ford Motor Company. (ref [1])
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Manufacture of Light Bulbs
Components of a common incandescent light bulb. Source: Courtesy of General Electric Company.
Manufacturing steps in making an incandescent light bulb. Source: Courtesy of General Electric Company.
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Hip Replacement
Components of a total hip replacement. Source: Courtesy of Zimmer, Inc.
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Manufacturing of Hip Replacement
(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.
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Application of CAD/CAM to make sunglasses mold
Machining a mold cavity for making sunglasses.
(a) Computer model of the sunglass as designed and viewed on the monitor.
(b) Machine the die cavity using a computer numerical-control milling machine(c) Final product. Source: Courtesy of Mastercam/CNC Software, Inc.
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Global competitiveness and manufacturing costs