MAE364

Manufacturing ProcessesSpring 2005

Instructor: T. Kesavadas (Prof. Kesh)Associate Professor, Mechanical and Aerospace Engineering,1006 Furnas Hall.

http://wings.buffalo.edu/courses/sp04/mae/364/

Teaching Assistants (more details later):Govindarajan Srimathveeravalli Sridhar Seshadri

What is Manufacturing?(1)(2)(3)(4)(5)

Manu Factus : Latin for ‘made by hand’

Definition:

A Well organized method of converting raw material to end product

End Product: Value and utility added to output.

Manufacturing Process

History of Manufacturing

• Manufacturing started during 5000 – 4000 BCWood work,ceramics,stone and metal work

• Steel Production 600-800 AD• Industrial Revolution 1750 AD: Machine tools run by

invention of steam engine• Mass Production and Interchangeable Parts• Computer Controlled Machines 1965• CNC,FMS systems

Historical development of materials - The Early Days

Period Metals and Casting Forming ProcessEgypt ~3100 B.C. to ~ 300 B.CGreece ~1100 B.C. to ~146 B.CRoman Empire ~500 B.C. to 476 A.DMiddle Ages 476 to 1492Renaissance 14th to 16th centuries

Before 4000 B.C

Gold,copper and meteoritic iron

Hammering

4000-3000 B.C.

Copper casting,stone and metal molds,lost wax process,silver,lead,tin,bronze

Stamping Jewelry

3000-2000 B.C.

Bronze casting Wire by cutting and drawing, gold leaf

2000-1000 B.C.

Wrought iron,brass

1000-1 B.C. Cast iron, cast steel Stamping of coins

1A.D – 1000 A.D

Zinc steel Armor,coinage,forging steel swords

1000-1500 A.D.

Blast furnace, type metals,casting of bells,pewter

Wire drawing,gold silver smith work

Industrial Revolution1750-1850

1500-1600 A.D. Cast iron cannon, tinplate Water power for metal working,rolling mill for coinage

1600-1700 A.D. Permanent mold casting,brass from copper and metallic zinc

Rolling(lead,gold,silver)Shape rolling(lead)

1700-1800 A.D. Malleable cast iron,crucible steel

Extrusion (lead pipe), deep drawing, rolling(iron bars and rods)

1800-1900 A.D. Centrifugal casting,Bessemer process,electrolytic aluminum,nickel steels,Babbitt, galvanized steel, powder metallurgy, tungsten steel, open hearth steel

Steam hammer, steel rolling,seamless tube piercing,steel rail rolling, continuous rolling , electroplating

Historical development of materials - The Industrial Revolution

WW I and WW II 1900-1920 A.D.

Tube rolling, hot extrusion

1920-1940 A.D.

Die casting Tungsten wire from powder

1940-1950 A.D.

Lost wax for engineering parts

Extrusion (steel),swaging, powder metal for engineering parts

Space Age 1950-1960 A.D.

Ceramic mold, nodular iron, semiconductors,continuous casting

Cold extrusion (steel),explosive forming,thermo mechanical treatment

1960-1970 A.D Squeeze casting, single crystal turbine blades

Hydrostatic extrusion,electroforming

1970-1980 s Compacted graphite,vacuum casting,organically bonded sand,automation of molding and pouring, large aluminum castings for aircraft structures rapid solidification technology

Precision forging,isothermal forging, super plastic forming,die design by analytical methods, net shape forming

Historical development of materials - The Modern Age

Req. for a good manufacturingsystem

Requirements of a good manufacturing system

• Product should meet design requirement• Economical Process• Quality should be built into the system• Should be flexible and responsive to new technology• High productivity: Best utilization of man, material,

machine, capital and available resources.

Steps in Modern Manufacturing

Production drawings; Instruction manuals

Conceptual design and

evaluation Feasibility study

Design analysis;codes/standards

review; physical and analytical models

Prototype production

testing and evaluation

Definition of product need, marketing information

Material Specification; process

and equipment selection; safety review

Pilot Production

Production

Inspection and quality

assurance

Packaging; marketing and

sales literature

Product

CAD

CAM and CAPP

Manufacturing of a Paper Clip• What is the function• How long does it last• How critical is the part• MaterialMetallic - what type

Non metallic – plastic• Dimension Diameter of clip

Shape of clip• Method of manufacturing Manual

Automated• Function based design Stress, Strain

Life of clipStiffness

• Style Appearance,Color,FinishPlating,painting

AISI 1010,swaged and cadmium plated

AISI 1020,forging and chromium plated

AISI 1010, luster finished coil stock,profile milled,resistance welded and chromium plated formed,welded and plated

AISI 1008, press formed,welded and plated

Cold drawn medium carbon steel,( similar to AISI 1035) bright zinc plated

Headed brass,nickel plated

Aluminum permanent mold casting,machined , polished and buffed Hardened high-carbon

steel,thread rolled and chromium plated

AISI 1010,stamped and chromium plated

Case hardened forging quality steel parts, black oxide coating

AISI 1040 forging,carburized and chromium plated

AISI 1010,stamped and coined and chromium plated

AISI 1010, stamped and chromium plated

Aluminum alloy forging, polished and buffed Forged aluminum

tubing(alloy similar to 6063), polished and buffed

AISI 1010 welded tubing, assembly resistance welded and electrostatically painted

AISI 1008,press formed resistance welded and painted

AISI 1020 tubing, machine threaded and painted

Seamless AISI 1020 tubing swaged tube sections brazed into fork crown,painted

Manufacturing of a bicycle

Assignment 1

• Select a simple product of your choice– Try to analyze the different materials,

processes, etc – Use library resources– We will discuss this in the class on Friday

Selection of Process: Topic to be covered

Casting• Sand/Expandable Mold,Permanent Mold

Forming and Shaping• Rolling,forging,extrusion,powder metallurgy

Machining•

Turning,Boring,Drilling,Milling,Planing,Broaching,Grinding

Selection of Process

Unconventional Method• EDM,ECM,Ultrasound,High Energy

Beam,machiningJoining• Welding,Brazing,SolderingFinishing• Honing,Lapping,Polishing,Burnishing,Deburring

Objectives of this course and what is expected of you

• Manufacturing processes and fundamentals• Selection of appropriate process to meet design

requirements• Effect of process parameters and variables on the

quality of parts produced• Effect of material properties on a given process• Decision and methods for different product size and

mix• Effect of design on manufacturability• Overview of computer aided methods in traditional

manufacturing processes

Lower Die

work piece

Upper die

Explosive

water

pressure

Two methods of forming a dish shaped part from sheet metal

Left: conventional hydraulic/mechanical press using male and female dies

Right: explosive forming using only one die.

Three methods of casting turbine blades

A: conventional casting with ceramic mold

B: directional solidification

C: Method to produce single crystal blade

Selection of Process depends on

• Dimensional and surface finish requirements• Operational Cost• Design and strength requirements• Consequences of various methods

Design for Assembly

• Design of the product to permit assembly• Possibility of multipurpose parts• Capability of manufacturing process to consistently

produce parts which can be assembled without problem

• Method or process of assemblyAutomated Systems,Manual Systems etc

Design for Assembly

Automation and Impact of Computers

Machine Control SystemsComputer Numerical Control machines,

Robots,Machines,ProcessesComputer Integrated Technology• Responsive to market change• Better use of process,man,machining management etc• CAD/CAM: Computer Aided Design And Manufacturing• FMS: Flexible Manufacturing System• GT: Group Technology• VR: Virtual Reality