هﺎﮔرﺎﻛ و ﺪﯿﻟﻮﺗ يﺎﻬﺷور production techniques · production...

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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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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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

Materials diversity in Manufacturing

Section of an automotive engine - the Duratec V-6,Source: Courtesy of Ford Motor Company (ref. [1])



Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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



Dep. of Mech. Eng.

History of Manufacturing (until 1700)

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Dep. of Mech. Eng.

History of Manufacturing (1700-1960)

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History of Manufacturing (1960-2000s)

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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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?



Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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

Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

Manufacturing Characteristics of Alloys

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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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



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)



Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.

Hip Replacement

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

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Dep. of Mech. Eng.

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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Dep. of Mech. Eng.39

Global competitiveness and manufacturing costs

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