Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 MANUFACTURING PROCESSES I IE 351...
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Transcript of Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 MANUFACTURING PROCESSES I IE 351...
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
MANUFACTURING PROCESSES I
IE 351
Lecture 2 -- Manufacturing
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
What is Manufacturing?
How do we make these?
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
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 raw materials into useful products– Main Focus of This Course
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Manufacturing
Cu
sto
me
r n
ee
ds
People, money, machines and automation
Societal pressures, Government regulations, company plans and policies, etc
manufacturingRaw
material
Products
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Little "m" manufacturing is all about
• Creating shapes by various means and assembling these shapes into a useful product
• A physical product always has a shape– Function– Aesthetics
• These shapes are created by a wide variety of processes
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
MaterialTransformation
ProcessesRa
w
Ma
teri
al A
ssemb
ly
Pro
du
cts
Machines and Automation
Materials Science, Statics, Dynamics, Thermodynamics, Fluid dynamics
The manufacturing Process
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.
Production Methods for a Simple Part
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Fundamentals of manufacturing - Manufacturing Concepts
• The method chosen depends on the material and the shape and properties required.
• Formability• Machinability• Hardenability
• Castability• Compactability• Sinterability• Weldability
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Why is Manufacturing Important?
• Impact on economy – Major wealth creation engines – Gross Domestic Product – Jobs
• Most decisions made during design are impacted by production/manufacturing processes
• Critical Decisions/Trade-offs – function vs cost vs schedule
• Choose materials • Choose process(es)
– Cost determined by the material and the processes used to create the shape
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Some functional parameters affected by production processes
• Mechanical properties (Strength, Hardness, Fatique, Ductility, Resistance to environment)
• Tolerances• Surface finish• Resistance to corrosion and abrasion• Electrical properties• Thermal Properties• Appearance/surface finish
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Commercially Available MaterialsTABLE 40.1
Material Available asAluminumCopper and brassMagnesiumSteels and stainless steelsPrecious metalsZincPlasticsElastomersCeramics (alumina)GlassGraphite
P, F, B, T, W, S, IP, f, B, T, W, s, IP, B, T, w, S, IP, B, T, W, S, IP, F, B, t, W, IP, F, D, W, IP, f, B, T, wP, b, Tp, B, T, sP, B, T, W, sP, B, T, W, s
Note: P, plate or sheet; F, foil; B, bar; T, tubing; W, wire; S,structural shapes; I, ingots for casting. Lowercase letter indicates limited availability. Most of these materials are alsoavailable in powder form.
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Manufacturing Process CapabilitiesFigure 40.3 Manufacturing process capabilities for minimum part dimensions. Source: J. A. Schey, Introduction to Manufacturing Processes (2d ed.). McGraw-Hill, 1987.
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Dimensional Tolerance
Figure 40.4 Dimensional tolerance capabilities of various manufacturing processes.
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Dimensional Tolerance and Surface FinishFigure 40.5 Relationship between relative manufacturing cost and dimensional tolerance.
Figure 40.6 Relative production time, as a function of surface finish produced by various manufacturing processes. Source: American Machinist. See also Fig. 25.33.
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Examples of General Function/Process Relationships
• Cast metals tend to be brittle• Forging adds strength along flow lines• Machining is cost effective for small lot sizes• Casting, forging and extrusion have high setup costs
but low production costs• Heat treatments affect hardness, strength, corrosion
resistance and fatigue properties• Machining results in lots of scrap (the buy to fly ratio)
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Buy to Fly Ratio
The weight of the purchased raw material divided by the weight of the final part
Process Buy to fly ratio
Machining 1.1 - 50
Hot closed die forging 1.2-1.5
Sheet metal forming 1.1-1.25
Extrusion 1.1-1.3
Permanent mold casting 1.0-1.2
Powder metallurgy 1.0-1.05
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Critical Fact
• You cannot design any hardware without taking into account the production process used to make that product
• Manufacturing considerations must be included in the design as early as possible
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
What is Manufacturing - Dimensions
• Product Creative Characteristics (How new products differ from previous ones)
• Product Size (physical dimension)• Product Complexity/Sophistication• Scale• Material Flow• Degree of Automation• Organization
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Product Creative Characteristics
• How new products differ from previous ones– Selection design (Lego houses)– Configuration design (automobiles)– Parametric design (portable generators)– Redesign (New VCR)– Original design (the original VCR, the Space
Shuttle)
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Product Size (physical dimension)
• A individual device on a computer chip• A computer chip • A television• An automobile• A Navy cruiser
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Number of parts/amount of electronics/intelligence
• A nail• A TV• A car or truck• A 777 aircraft• A satellite• Mars sojourner• A CPU chip (5 million
components)
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Scale
• Number of people and disciplines involved– Artisan– Garage machine shop– General Motors, Arlington Plant– Boeing Commercial Aircraft– Engineering firms who make bridges, chemical
plants or dams
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Material Flow
• How the work is organized on the shop floor– Discrete parts (traditional job shop)– Cellular (New machine shops)– Semicontinuous – Continuous flow (bottle making)– Process (chemical industry and oil refineries)
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Degree of Automation
• How much automation exists on the shop floor– Manual– Machine assisted– Computer controlled - islands of
automation– Computer integrated manufacturing
Manufacturing Processes IE 351 KSU .-Industrial. Eng. dept Lecture-2
Company Organization
• How the enterprises organize to produce– Traditional– Lean– Agile– Next Generation