Post on 31-Mar-2015
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Dr. HABEEB HATTAB HABEEB
Office: BN-Block, Level-3, Room-088
Email: hbuni61@yahoo.comExt. No.: 7292
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
University TENAGA National
College Of EngineeringMechanical Department
Lecture NoteLecture Note
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Introduction To Manufacturing
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Japanese sword reworked for hard and soft metal parts
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Space Shuttle
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
The Transistor
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Everyday products
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Manufacturing derived from:Manufacturing derived from:
“Manufacturing” (derived from Latin)
= “manus” (hand) + “factus” (made) = “made by hand”
“Manufacturing” (derived from Latin)
= “manus” (hand) + “factus” (made) = “made by hand”
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Manufacturing is an industrial activity that converts raw materials to useful products by the means of machines.
Definition of Manufacturing:Definition of Manufacturing:
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Materials Materials
Development of Manufacturing depends on:
Development of Manufacturing depends on:
Machine-ToolsMachine-Tools
Computer-aided Design (CAD)&Computer-aided mfg (CAM).
Computer-aided Design (CAD)&Computer-aided mfg (CAM).
RoboticsRobotics
ElectronicsElectronics
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University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Evolution of the Enterprise Evolution of the Enterprise
Evolution Steps:Evolution Steps:
Hand Tool Hand Tool
Animals Animals
Water Power Water Power
Steam Engines Steam Engines
Electrical Motors Electrical Motors
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1-1
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
The MFG System:The MFG System:
INPUT INPUT PROCESS PROCESS OUTPUT OUTPUT
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Customer Demand
Customer Demand
Material Material
Money Money
Energy Energy
HR HR
Education Education
R & D R & D
INPUT INPUT
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
PROCESS PROCESS
Design Design
Production Production
Management Management
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
OUTPUT OUTPUT
Consumer Goods Consumer Goods
Capital Goods Capital Goods
Quality Quality
Cost Effectiveness Cost Effectiveness
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
`
Money Money
- Working Capital (Money for employee) - Working Capital (Money for employee)
- Fixed Capital (For machine tools and buildings)
- Fixed Capital (For machine tools and buildings)
INPUT INPUT
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Energy Energy
- Electricity To run the machines - Electricity To run the machines
- Compressed air To run the pneumatic systems and clean machines and products
- Compressed air To run the pneumatic systems and clean machines and products
- Steam To run the turbines and utilized in produce of polystyrene (Expansion OP.)
- Steam To run the turbines and utilized in produce of polystyrene (Expansion OP.)
- Gas To use it in Furness, welding operations and boilers.
- Gas To use it in Furness, welding operations and boilers.
INPUT INPUT
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
- Creating plans for new products- Creating plans for new products
- Lowering the product cost at maintained high quality
- Lowering the product cost at maintained high quality
DesignDesignPROCESS PROCESS
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
- Designated at the design stage- Designated at the design stage
- Machine tools types- Machine tools types
PROCESS PROCESS
ProductionProduction
- Machining processes- Machining processes
- People are selected at the design stage
- People are selected at the design stage
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
GoodsGoods
- Consumers goods: People use them (Food, Cars, ….)
- Consumers goods: People use them (Food, Cars, ….)
OUTPUT OUTPUT
ProductsProducts
- Capital goods: Products used to make other consumer goods (Machine tools, Plant, ….)
- Capital goods: Products used to make other consumer goods (Machine tools, Plant, ….)
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
The Classification of basic Manufacturing
The Classification of basic Manufacturing
Mass productionMass production
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ModerateModerate Job-lotJob-lot
a b c
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Mass Production Features: Mass Production Features:
- Goods are produced at a high volume for considerable period of time ( >100.000 parts per year).
- Goods are produced at a high volume for considerable period of time ( >100.000 parts per year).
- Machine are not flexible (They are not able to produce other types of products).
- Machine are not flexible (They are not able to produce other types of products).
- Products of this type of mfg are the cheapest.
- Products of this type of mfg are the cheapest.
a
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Moderate production Features: Moderate production Features:
- Variable products (depends on the sale order and the market demand) (2,500-100,000 parts per year).
- Variable products (depends on the sale order and the market demand) (2,500-100,000 parts per year).
- Multipurpose machine tools and CNC machine tools are usually used in this type of mfg.
- Multipurpose machine tools and CNC machine tools are usually used in this type of mfg.
- Product Ex.: Tools, Moulds, Radio transmitters.
- Product Ex.: Tools, Moulds, Radio transmitters.
b
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Job-lot production Features: Job-lot production Features:
- The plant does not any specific type of products but it is able to produce any type of product that the market is in need of.
- The plant does not any specific type of products but it is able to produce any type of product that the market is in need of.
- Products move in lots between mfg processes (10-500 parts per lot).
- Products move in lots between mfg processes (10-500 parts per lot).
- Machine are more flexible and universal.- Machine are more flexible and universal.
c
- Product Ex: Airplanes, Automobile parts, and Plastic products .
- Product Ex: Airplanes, Automobile parts, and Plastic products .
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Organization for Manufacturing Organization for Manufacturing
-A plant needs an affective organizing method for manufacturing in order to manage its resources /
Employees Money Power
Materials Machines .
*A good mfg strategy is needed.
-A plant needs an affective organizing method for manufacturing in order to manage its resources /
Employees Money Power
Materials Machines .
*A good mfg strategy is needed.
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University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Concurrent Engineering CE Concurrent Engineering CE
- It is a philosophy that promotes interactive design and manufacturing efforts to develop product and processes . CE is not an engineering discipline.
- CE Objective: Optimizing the use of companyresources and reducing time to market cycle.
- It is a philosophy that promotes interactive design and manufacturing efforts to develop product and processes . CE is not an engineering discipline.
- CE Objective: Optimizing the use of companyresources and reducing time to market cycle.
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
General CE phases for a new project: General CE phases for a new project:
Technology and concept development Technology and concept development Ph.-1
Product and Process Development and Prototype validation -CE Function
Product and Process Development and Prototype validation -CE Function
Ph.-2
Process Validation and Product Design Confirmation
Process Validation and Product Design Confirmation
Ph.-3
Production and continuous improvementProduction and continuous improvementPh.-4
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Design, Material and Production Design, Material and Production 1-3
-According to the existing machine tools and the designed product we choose the raw materials.
On the other hands, according to the existing materials and required quality we choose the machine tools.
-According to the existing machine tools and the designed product we choose the raw materials.
On the other hands, according to the existing materials and required quality we choose the machine tools.
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
- In order to attain a high production rate with a low labor cost, Automatic features have been built gradually in different machine tools. Nowadays we deal with fully automatic machine tools and computer aided design and manufacturing (CAD/CAM). But the problem is that maintenance of such automatic machines is very expensive.
- In order to attain a high production rate with a low labor cost, Automatic features have been built gradually in different machine tools. Nowadays we deal with fully automatic machine tools and computer aided design and manufacturing (CAD/CAM). But the problem is that maintenance of such automatic machines is very expensive.
- Efficiency of production :- Efficiency of production :
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
- The quality and accuracy must
be maintained for the whole mfg processes so at the output we produce parts that can be quickly assembled (interchangeable).
- The quality and accuracy must
be maintained for the whole mfg processes so at the output we produce parts that can be quickly assembled (interchangeable).
Cont….. Efficiency of production
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
- Economical production is determined by:
- Economical production is determined by:
A functional simple design that has appropriate quality (no more or less).
A functional simple design that has appropriate quality (no more or less). 1
A material choice that represents the best compromise among physical properties, cost, and machinability.
A material choice that represents the best compromise among physical properties, cost, and machinability.
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The selection of mfg processes that provide the plant with required quality and accuracy (no more accuracy than necessary) at the lowest possible cost.
The selection of mfg processes that provide the plant with required quality and accuracy (no more accuracy than necessary) at the lowest possible cost.
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University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
MaterialsMaterials
Engineering MaterialsEngineering Materials
Metallic Metallic Non-Metallic Non-Metallic
Ferrous Ferrous
Non-Ferrous Non-Ferrous
OrganicOrganic
Non- Organic Non- Organic
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Materials Application ChainMaterials Application Chain
ProcessingProcessing
StructureStructure
PropertiesProperties
PerformancePerformance
SelectionSelection
Field ApplicationField Application
* SELECTION is the Critical Step for
Technologists.
• Stress & Strain
• Dislocations & Deformation
• Elasticity & Plasticity
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Mechanical PropertiesMechanical Properties
• Mechanical Testing• Mechanical Properties• Strengthening
Mechanisms• Failure Analysis
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
TestsTests
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
The Evolution of Materials
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Classes of MaterialsClasses of Materials
BasicBasic
MetalsMetals
CeramicsCeramics
PolymersPolymers
AdvancedAdvanced
CompositesComposites SemiconductorsSemiconductors BiomaterialsBiomaterials
• Materials that are normally combinations of "metallic elements".
• Metals usually are good conductors of heat and electricity.
• Metals are quite strong but malleable and tend to have
a lustrous look when polished
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
MetalsMetals
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Ceramic materials developed for gas turbine rotors are used in aircraft and diesel engine parts.
CeramicsCeramics
Ceramics are generally compounds between Metallic and NONmetallic elements and include such compounds as:
-Oxides-Nitrides
-Carbides
Typically they are insulating and resistant to high temperatures and harsh environments.
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Using advanced polymer materials, organic light emitting diode (OLEDs) displays produce bright, high-contrast display panels with a wide viewing angle. OLED panels are emissive, eliminating the need for the backlight required in display technologies such as liquid crystal displays (LCDs).
PlasticsPlastics Plastics (or polymers) are generally compounds based
upon carbon and hydrogen (Organic Compounds). They are very large molecular structures. Usually they are low density and are not stable at high
temperatures.
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
SemiconductorsSemiconductors
SEMIconductors have electrical properties intermediate between Metallic conductors and Ceramic insulators.
Also, the electrical properties are strongly dependent upon small amounts of Impurities.
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
CompositesComposites
Composites consist of more than one material type. Fiberglass, a combination of glass and a polymer, is
an example. Concrete and plywood are other familiar composites.
Many new combinations include ceramic fibers in a metal or polymer matrix.
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
CompositesComposites
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
CompositesComposites
Graphite MatrixComposite Shaft
Liquid MetalFacePlate
Golf Clubs
Hand bagGhost airplane
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
BioMaterialsBioMaterials
Materials compatible with an organism (e.g. Humans)
that can be used to make implants, prostheses, and
surgical instruments. Designed not to provoke rejection by our bodies (skin, blood,
bone, etc.), they can be natural (collagen, cellulose, etc.) or
synthetic (metallic, alloy, ceramic, plastic, and others).
Dental crowns and
contact-lenses
use biomaterials.
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Kingdom Family Class AttributesMember
• Ceramics• Polymers• Metals• Natural• Foams• Composites
Steels
Cu-alloys
Al-alloys
Ti-alloys
Ni-alloys
Zn-alloys
10002000300040005000600070008000
Materials
A material recordor “properties”
Density
Mechanical props.
Thermal props.
Electrical props.
Optical props.
Corrosion props.
Supporting information
-- specific
-- general
Structured
information
Unstructured
information
Data Organization of MaterialsData Organization of Materials
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
mount
Metallography: to see microstructures
metal
Steel (Fe-C)
Nickel Alloy 242
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
The goal of design:“To create products that perform their function effectively, safely, at acceptable cost”What do we need to know about materials to do this? More than just test data.
Test Test data
Data capture
Stat/Mathanalysis
Design data Successful applications
$
Economic analysisand business case
Selection ofmaterial and process
Potential applications
Mechanical Properties
Bulk Modulus 4.1 - 4.6 GPaCompressive Strength 55 - 60 MPaDuctility 0.06 - 0.07Elastic Limit 40 - 45 MPaEndurance Limit 24 - 27 MPaFracture Toughness 2.3 - 2.6 MPa.m1/2
Hardness 100 - 140 MPaLoss Coefficient 0.009- 0.026Modulus of Rupture 50 - 55 MPaPoisson's Ratio 0.38 - 0.42Shear Modulus 0.85 - 0.95 GPaTensile Strength 45 - 48 MPaYoung's Modulus 2.5 - 2.8 GPa
Characterization Selection and implementation
Materials Information for Design Materials Information for Design
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
THANK YOU
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI