manufacturing processes
-
Upload
vinit-ahluwalia -
Category
Documents
-
view
124 -
download
2
description
Transcript of manufacturing processes
![Page 1: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/1.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Chapter 0
General Introduction
![Page 2: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/2.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Materials in an Automotive Engine
Figure I.1 Section of an automotive engine - the Duratec V-6 - showing various components and the materials used in making them. Source: Courtesy of Ford Motor Company. Illustration by David Kimball.
![Page 3: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/3.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
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.)
• All components are manufactured.
• Manufacturing means, literally, “Made by Hand”.
![Page 4: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/4.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
History of Manufacturing (until 1700)
![Page 5: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/5.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
History of Manufacturing (1700-1960)
![Page 6: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/6.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
History of Manufacturing (1960-2000s)
![Page 7: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/7.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Materials Selection for Paper Clips
Figure I.2 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?
![Page 8: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/8.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacture of Light Bulbs
Figure I.3a Components of a common incandescent light bulb. Source: Courtesy of General Electric Company.
Figure I.3b Manufacturing steps in making an incandescent light bulb. Source: Courtesy of General Electric Company.
![Page 9: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/9.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Figure I.4 (a) Chart showing the various steps involved in design and manufacturing a product. Depending on the complexity of the product and the type of materials used, the time span between the original concept and the marketing of the product may range from a few months to many years. (b) Chart showing general product flow in concurrent engineering, from market analysis to selling the product. Source: After S. Pugh, Total Design. Addison-Wesley, 1991.
Product Design Process
![Page 10: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/10.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Redesign of Parts
Figure I.5 Redesign of parts to facilitate assembly. Source: Reprinted from G. Boothroyd and P. Dewhurst, Product Design for Assembly, 1989. Courtesy of Marcel Dekker, Inc.
![Page 11: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/11.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Characteristics of Alloys
![Page 12: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/12.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Baseball Bat Cross-sections
Figure I.6 Cross-sections of baseball bats made of aluminum (top portion) and composite material (bottom portion).
![Page 13: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/13.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Processes: Casting
Figure I.7a Schematic illustration of various casting processes
![Page 14: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/14.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Processes: Forming and Shaping
Figure I.7b Schematic illustration of various bulk deformation processes
![Page 15: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/15.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Processes: Forming and Shaping
Figure I.7c Schematic illustration of various sheet metal forming processes
![Page 16: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/16.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Processes: Forming and Shaping
Figure I.7d Schematic illustration of various polymer processing methods
![Page 17: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/17.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Processes: Machining
Figure 1.7e Schematic illustrations of various machining and finishing processes.
![Page 18: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/18.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Processes: Joining
Figure I.7f Schematic illustration of various joining processes
![Page 19: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/19.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Laser Cutting
Figure I.8 Cutting sheet metal with a laser beam. Source: Courtesy of Rofin-Sinar, Inc. and Manufacturing Engineering Magazine, Society of
Manufacturing Engineers
![Page 20: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/20.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Hip Replacement
Figure 1.9 Components of a total hip replacement. Source: Courtesy of Zimmer, Inc.
![Page 21: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/21.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing of Hip Replacement
Figure 1.10 (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.
![Page 22: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/22.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Microscopic Components
Figure I.11 (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.
![Page 23: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/23.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Salt and Pepper Shakers
Figure I.12 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.
![Page 24: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/24.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automated welding of automobiles
Figure I.13 Automated spot welding of automobile bodies in a mass production line. Source: Courtesy of Ford Motor Company.
![Page 25: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/25.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Application of CAD/CAM to make sunglasses mold
Figure I.14 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.
![Page 26: manufacturing processes](https://reader031.fdocuments.us/reader031/viewer/2022031811/55cf9de3550346d033afb34d/html5/thumbnails/26.jpg)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Hourly Compensation for Production Workers