Lect1 Small
Transcript of Lect1 Small
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Definition of "Manufacturing"• "Manufacturing" is a process for converting ideas
and market or customer needs into artifacts;
Includes design, procurement, test,finance, human resources, marketing,etc.
• manufacturing is the conversion of rawmaterials into useful products
– Main Focus of This Course
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Little "m" manufacturing is all about
• Creating shapes b various means and assemblingthese shapes into a useful product
• !he processes used to transform raw material intofinished products
• phsical product alwas has a shape – Function – Aesthetics
• !hese shapes are created b a wide variet of
processes• #tudents must remember that these processes e$istonl in the conte$t of the larger Manufacturingprocess
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Manufacturing
C u s t om er
n e e d
s
People, money, machines and automation
Societal pressures, o!ernment regulations,
company plans and policies, etc
manufacturing
a#
material
%roducts
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Material!ransformation
%rocesses " a #
M a t e r i a
l A s s e
m b
l y
P r o d u c
t s
Machines and Automation
Materials Science, Statics, Dynamics, Thermodynamics, Fluiddynamics
The manufacturing Process
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
TABLE 1.2 Shapes and Some Common Methods of Production
Shapes and Production Method
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
FIGURE 1.4 An outline of engineering materials
$ngineering Materials
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
FIGURE 1.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b)
forging or upsetting, (c) etrusion, (d) machining, (e) !oining two pieces"
Production Methods for a Simple
Part
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Fundamentals of manufacturing %
Manufacturing Concepts• !he method chosen depends on the material
and the shape and properties re&uired
• Formability• Machinability• &ardenability
• Castability• Compactability• Sinterability
• 'eldability
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
'hy is Manufacturing (mportant)• Impact on econom
– Ma*or #ealth creation engines – ross Domestic Product – *obs
• Most decisions made during design are
impacted b production'manufacturingprocesses
• Critical (ecisions'!rade)offs – function !s cost !s schedule
• Choose materials• Choose process+es
– Cost determined by the material and theprocesses used to create the shape
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Some functional parameters
affected by production processes
• Mechanical properties *#trength, +ardness,ati&ue, (uctilit, -esistance to environment
• !olerances• #urface finish• -esistance to corrosion and abrasion•
/lectrical properties• !hermal %roperties• ppearance'surface finish
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Commercially A!ailable
Materials
#$%&' "*Material Available as
$luminum
Copper and brass
Magnesium
Steels and stainless steels
Precious metals+inc
Plastics
'lastomers
Ceramics (alumina)
lass
raphite
P, -, %, #, ., S, /
P, f, %, #, ., s, /
P, %, #, w, S, /
P, %, #, ., S, /
P, -, %, t, ., /P, -, 0, ., /
P, f, %, #, w
P, b, #
p, %, #, s
P, %, #, ., s
P, %, #, ., s Note: P, plate or sheet1 -, foil1 %, bar1 #, tubing1 ., wire1 S,
structural shapes1 /, ingots for casting" &owercase letter
indicates limited a2ailability" Most of these materials are also
a2ailable in powder form"
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Manufacturing Process
Capabilities-igure "3Manufacturing
process capabilitiesfor minimum partdimensions" Source:4" $" Schey,
Introduction to Manufacturing Processes (5d ed")"
Mcraw67ill, *89"
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Dimensional Tolerance
-igure " 0imensional tolerance capabilities of 2arious manufacturing processes"
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Dimensional Tolerance and
Surface Finish-igure "; <elationship between relati2emanufacturing cost and dimensional tolerance"
-igure "= <elati2e production time, as a function of surfacefinish produced by 2arious manufacturing processes" Source:$merican Machinist" See also -ig" 5;"33"
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
$-amples of eneral
Function.Process elationships
• Cast metals tend to be brittle• orging adds strength along flow lines• Machining is cost effective for small lot si0es
• Casting, forging and e$trusion have highsetup costs but low production costs
• +eat treatments affect hardness, strength,corrosion resistance and fatigue properties
• Machining results in lots of scrap *the bu tofl ratio
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
/uy to Fly atio
!he weight of the purchased raw materialdivided b the weight of the final part
Process /uy to fly ratio
Machining 1.1 ) 23+ot closed die forging 1.4)1.2
#heet metal forming 1.1)1.42
/$trusion 1.1)1.5
%ermanent mold casting 1.3)1.4%owder metallurg 1.3)1.32
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Critical Fact
• 6ou cannot design an hardware withouttaking into account the production processused to make that product
• Manufacturing considerations must beincluded in the design as earl as possible
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
'hat is Manufacturing %
Dimensions
• %roduct Creative Characteristics *+ow newproducts differ from previous ones
• %roduct #i0e *phsical dimension• %roduct Comple$it'#ophistication• #cale• Material low
• (egree of utomation• 7rgani0ation
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Product Creati!e Characteristics
• +ow new products differ from previous ones
– Selection design +Lego houses – Configuration design +automobiles – Parametric design +portable generators – edesign +0e# 1C – 2riginal design +the original 1C, the Space
Shuttle
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Product Si3e +physical dimension
• individual device on a computer chip• computer chip• television• n automobile
• 8av cruiser
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
0umber of parts.amount of
electronics.intelligence
• nail• !9
• car or truck• ::: aircraft• satellite• Mars soourner
• C%< chip *2 millioncomponents
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Scale
• 8umber of people and disciplines involved – Artisan – arage machine shop
– eneral Motors, Arlington Plant – /oeing Commercial Aircraft – $ngineering firms #ho ma4e bridges, chemical
plants or dams
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Material Flo#
• +ow the work is organi0ed on the shop floor – Discrete parts +traditional *ob shop – Cellular +0e# machine shops – Semicontinuous
– Continuous flo# +bottle ma4ing – Process +chemical industry and oil refineries
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Degree of Automation
• +ow much automation e$ists on the shop floor – Manual – Machine assisted
– Computer controlled % islands of automation – Computer integrated manufacturing
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Manufacturing Engineering and Technology Assiut Univ.-Mech. Eng. dept Lecture-1
Company 2rgani3ation
• +ow the enterprises organi0e to produce – Traditional – Lean – Agile
– 0e-t eneration