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Introduction to Manufacturing Process
2
What is Manufacturing?
 Manufacturing is the application of physical
and chemical processes to alter the geometry,
properties, and appearance of a starting
material to make parts or products for a given
application
Material-Process-Geometry Relationships
3
IE 337: Materials & Manufacturing
Processes
Function
Process
Material Geometry
Role of Prod
Engr
Role of Mfg
Engr
Master Engineering &
Management
Production System
5
Purpose of Manufacturing
 Manufacturing is the transformation of materials
into items of greater value by means of one or more
processing and/or assembly operations
Manufacturing
“The Process of Converting Raw
Materials Into Products”
Manufacturing a Product: General
Considerations
 Material Selection
 Processing Methods
 Final Shape and Appearance
 Dimensional and Surface Finish
 Economics of Tooling
 Design Requirements
 Safety and Environmental Concerns
Choosing Methods of Production
Use a Selection Chart
Manufacturing Processes for Metals
 Casting: expendable mold and permanent mold.
 Forming and Shaping: rolling, forging, extrusion,
drawing, sheet forming, powder metallurgy, molding
 Machining: turning, boring, drilling, milling, planing,
shaping, broaching, grinding, ultrasonic machining,
chemical machining, electrical discharge machining (EDM),
electrochemical machining, high-energy beam machining
 Joining: welding, brazing, soldering, diffusion bonding,
adhesive bonding, mechanical joining
 Finishing: honing, lapping, polishing, burnishing,
deburring, surface treating, coating, plating
Casting Processes
Introduction of molten metal into a mold cavity;
upon solidification, metal conforms to the shape
of the cavity.
Die Casting Sand Casting
Forming and Shaping Processes
Bulk deformation processes that induce shape
changes by plastic deformation under forces
applied by tools and dies.
Forging
Extrusion
Machining Processes
Material removal from a work piece: cutting,
grinding, nontraditional machining processes.
Milling Lathe Machine
NC Machine Tool and Controller
NC Punch Press Machine
Manufacturing Processes
for Plastics
 Plastics are shipped to manufacturing plants
as pellets or powders and are melted just
before the shaping process. Polymers melt at
relatively low temperatures and are easy to
handle.
 Plastics can be molded and formed, as well as
machined and joined, into many shapes with
relative ease.
Injection Molding of Plastics
Selective Laser Sintering System
Courtesy of the University of Texas
Unit 2 Manufacturing Operations
Sections:
1. Manufacturing Industries and Products
2. Manufacturing Operations
3. Production Facilities
4. Product/Production Relationships
5. Lean Production
6. Manufacturing Metrics
 Manufacturing Lead Time
 Rate of Production
 Production Capacity
 Work in Progress
 Design Times
 Utilisation/Availability
Classification of Industries
1. Primary industries – cultivate and exploit natural
resources
 Examples: agriculture, mining
2. Secondary industries – convert output of primary
industries into products
 Examples: manufacturing, power generation,
construction
3. Tertiary industries – service sector
 Examples: banking, education, government, legal
services, retail trade, transportation
Manufacturing Industry
 Transformation Operations
 Machine Processing
 Assembly
 Adding value*
 Other Operations
Material handling
Inspection and testing
Coordination and control
Transformation
Process
Raw
Material
Part or
Product
Power
Tools
Machin
es
Labour
Scrap or
Waste
Production Facilities and Layout
 Facilities organised in the most efficient way to serve the
particular mission of the plant and depends on:
 Types of products manufactured
 Production quantity
 Product variety
Production Quantity (Q)
 Number of units of a given part or product produced
annually by the plant
 Three quantity ranges:
1. Low production – 1 to 100 units
2. Medium production – 100 to 10,000 units
3. High production – 10,000 to millions of units
Product Variety (P)
 Number of different product or part designs or types
 ‘Hard’ product variety – products differ greatly
 Few common components in an assembly
 ‘Soft’ product variety – small differences between
products
 Many common components in an assembly
Low Production Quantity (Qlow)
Job shop – makes low quantities of specialized and
customized products
 Products are typically complex (e.g., specialized
machinery, prototypes, space capsules)
 Equipment is general purpose
 Plant layouts:
 Fixed position
 Process layout
Fixed-Position Layout
Process Layout
Medium Production Quantities (Qmed)
1. Batch production – A batch of a given product is
produced, and then the facility is changed over to
produce another product
 Changeover takes time – setup time
 Typical layout – process layout
 Hard product variety
2. Cellular manufacturing – A mixture of products is
made without significant changeover time between
products
 Typical layout – cellular layout
 Soft product variety
Cellular Layout
High Production (Qhigh)
1. Quantity production – Equipment is dedicated to the
manufacture of one product
 Standard machines tooled for high production
(e.g., stamping presses, molding machines)
 Typical layout – process layout
2. Flow line production – Multiple workstations
arranged in sequence
 Product requires multiple processing or assembly
steps
 Product layout is most common
Product Layout
PQ Relationships
Q
P
Production quantity and variety
Production quantity: low (<100), medium
(102-104), high
(>104)
Production variety: low, medium,
high
soft, hard
Selecting manufacturing processes
 Manufacturing process decisions
 Deformation processes
 Casting processes
 Sheet metalworking
 Polymer processing
 Machining
 Finishing
 Assembly
 Material compatibilities / Process capabilities
 Material costs, Tooling costs, Processing costs
Types of manufacturing processes
Extrusion
Forging
Rolling
Bar drawing
Wiredrawing
Deformation
Centrifugal
Die casting
Investment
Permanent mold
Sand casting
Casting
Bending
Blanking
Drawing
Punching
Shearing
Spinning
Sheet
Metal
Blow molding
Casting
Compression molding
Extrusion
Injection Molding
Thermoforming
Transfer molding
Polymer
Processes
Boring
Drilling
Facing
Grinding
Milling
Planing
Turning
Sawing
ECM, EDM
Machining
Anodizing
Honing
Painting
Plating
Polishing
Finishing
Automated
Bonding
Brazing
Manual
Riveting
Soldering
Welding
Assembly
Manufacturing
Processes
How is the input
material changed?
Deformation processes
 Rolling
 Extrusion
 Drawing
 Forging
Rolling (of ductile materials)
Plastic deformation
Rollers in compression
thick
slab
thin
sheet
Rolling
slab
bloom
billet
sheet
coil
bar rod
structural
ingot
Extrusion
Ram
Cross
sections
Extrusion
die
Billet
Extrusion
Typical use: ductile metals (Cu, Steel, Al, Mg),
Plastics, Rubbers
Common products:
Al frames of white-boards, doors, windows, …
hydraulic
piston
chamber
chamber
stock
die
extruded shape
hydraulic
piston
chamber
chamber
stock
die
extruded shape
hydraulic
piston
chamber
chamber
stock
die
extruded shape
Extrusion: Schematic, Dies
Exercise: how can we get hollow parts?
Drawing
Pulling
force
Cross
sections
Drawing die
Billet
Drawing
Commonly used to make wires from round bars
stock (bar)
F (pulling force)
wire
die
stock (bar)
F (pulling force)
wire
die
Similar to extrusion, except: pulling force is applied
Forging (closed-die)
Blocked
preform
Gutter
Ram pressure
Flash
Casting Processes
 Sand casting
 Die casting
 Investment casting
Sand casting (closed-mold)
Core
Riser
Sprue
Runner
Drag
Flask
Cope
Gate
Parting
line
Die casting
Parting line
Plunger
Sprue
Moving
die
Stationary
die
Ejector pins
Molten
metal
Investment casting
Wax pattern
is cast
Wax removed
by melting
Molten metal
solidifies in cast
Ceramic mold is
removed
Ceramic mold
(hardened slurry)
4-part pattern tree
Sheet Metalworking
 Bending
 Blanking
 Drawing
 Punching
 Shearing
 Spinning
Sheet metal drawing
Blank
Drawn part
Clamp
force
Blank
holder
Die
Punch
Punch ram
Polymer Processes
 Compression molding
 Transfer Molding
 Blow molding
 Injection molding
Compression molding
Charge
Heated
mold
Part
Ram Pressure
Transfer molding
Charge
Ram
Heated
mold
Sprue
Part
Ram pressure
Blow molding
Extruder
air injector
parison
Part is
removed
Air
blown
into
parison
Mold
halves
close
Molten
parison is
extruded
Injection molding
Shear-heating
Cavity half
of mold
Core half
of mold
Ejector pins
Moving
Feed hopper
Sprue
Fixed
Barrel
Pellets
Mold closure direction
Parting
plane/surface
Machining processes
Extrusion
Forging
Rolling
Bar drawing
Wiredrawing
Deformation
Centrifugal
Die casting
Investment
Permanent mold
Sand casting
Casting
Bending
Blanking
Drawing
Punching
Shearing
Spinning
Sheet
Metal
Blow molding
Casting
Compression molding
Extrusion
Injection Molding
Thermoforming
Transfer molding
Polymer
Processes
Boring
Drilling
Facing
Grinding
Milling
Planing
Turning
Sawing
ECM, EDM
Machining
Anodizing
Honing
Painting
Plating
Polishing
Finishing
Automated
Bonding
Brazing
Manual
Riveting
Soldering
Welding
Assembly
Manufacturing
Processes
Machining – removal of material…
Sawing –using a toothed blade.
Milling – from a flat surface by a rotating cutter tool.
Planing – using a translating cutter as workpiece feeds.
Shaping - from a translating workpiece using a stationary cutter.
Boring - increasing diameter of existing hole by rotating the workpiece.
Drilling- using a rotating bit forming a cylindrical hole.
Reaming – to refine the diameter of an existing hole.
Turning - from a rotating workpiece.
Facing - from turning workpiece using a radially fed tool.
Grinding - from a surface using an abrasive spinning wheel.
Electric discharge machining - by means of a spark.
Finishing processes
Extrusion
Forging
Rolling
Bar drawing
Wiredrawing
Deformation
Centrifugal
Die casting
Investment
Permanent mold
Sand casting
Casting
Bending
Blanking
Drawing
Punching
Shearing
Spinning
Sheet
Metal
Blow molding
Casting
Compression molding
Extrusion
Injection Molding
Thermoforming
Transfer molding
Polymer
Processes
Boring
Drilling
Facing
Grinding
Milling
Planing
Turning
Sawing
ECM, EDM
Machining
Anodizing
Honing
Painting
Plating
Polishing
Finishing
Automated
Bonding
Brazing
Manual
Riveting
Soldering
Welding
Assembly
Manufacturing
Processes
protection?
Assembly processes
– fastening / joining of 2 or more components
Extrusion
Forging
Rolling
Bar drawing
Wiredrawing
Deformation
Centrifugal
Die casting
Investment
Permanent mold
Sand casting
Casting
Bending
Blanking
Drawing
Punching
Shearing
Spinning
Sheet
Metal
Blow molding
Casting
Compression molding
Extrusion
Injection Molding
Thermoforming
Transfer molding
Polymer
Processes
Boring
Drilling
Facing
Grinding
Milling
Planing
Turning
Sawing
ECM, EDM
Machining
Anodizing
Honing
Painting
Plating
Polishing
Finishing
Automated
Bonding
Brazing
Manual
Riveting
Soldering
Welding
Assembly
Manufacturing
Processes
permanent?

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Introduction to manufacturing-week1.ppt

  • 2. 2 What is Manufacturing?  Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and appearance of a starting material to make parts or products for a given application
  • 3. Material-Process-Geometry Relationships 3 IE 337: Materials & Manufacturing Processes Function Process Material Geometry Role of Prod Engr Role of Mfg Engr
  • 5. 5 Purpose of Manufacturing  Manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations
  • 6. Manufacturing “The Process of Converting Raw Materials Into Products”
  • 7. Manufacturing a Product: General Considerations  Material Selection  Processing Methods  Final Shape and Appearance  Dimensional and Surface Finish  Economics of Tooling  Design Requirements  Safety and Environmental Concerns
  • 8. Choosing Methods of Production Use a Selection Chart
  • 9. Manufacturing Processes for Metals  Casting: expendable mold and permanent mold.  Forming and Shaping: rolling, forging, extrusion, drawing, sheet forming, powder metallurgy, molding  Machining: turning, boring, drilling, milling, planing, shaping, broaching, grinding, ultrasonic machining, chemical machining, electrical discharge machining (EDM), electrochemical machining, high-energy beam machining  Joining: welding, brazing, soldering, diffusion bonding, adhesive bonding, mechanical joining  Finishing: honing, lapping, polishing, burnishing, deburring, surface treating, coating, plating
  • 10. Casting Processes Introduction of molten metal into a mold cavity; upon solidification, metal conforms to the shape of the cavity. Die Casting Sand Casting
  • 11. Forming and Shaping Processes Bulk deformation processes that induce shape changes by plastic deformation under forces applied by tools and dies. Forging Extrusion
  • 12. Machining Processes Material removal from a work piece: cutting, grinding, nontraditional machining processes. Milling Lathe Machine
  • 13. NC Machine Tool and Controller
  • 14. NC Punch Press Machine
  • 15. Manufacturing Processes for Plastics  Plastics are shipped to manufacturing plants as pellets or powders and are melted just before the shaping process. Polymers melt at relatively low temperatures and are easy to handle.  Plastics can be molded and formed, as well as machined and joined, into many shapes with relative ease.
  • 17. Selective Laser Sintering System Courtesy of the University of Texas
  • 18. Unit 2 Manufacturing Operations Sections: 1. Manufacturing Industries and Products 2. Manufacturing Operations 3. Production Facilities 4. Product/Production Relationships 5. Lean Production 6. Manufacturing Metrics  Manufacturing Lead Time  Rate of Production  Production Capacity  Work in Progress  Design Times  Utilisation/Availability
  • 19. Classification of Industries 1. Primary industries – cultivate and exploit natural resources  Examples: agriculture, mining 2. Secondary industries – convert output of primary industries into products  Examples: manufacturing, power generation, construction 3. Tertiary industries – service sector  Examples: banking, education, government, legal services, retail trade, transportation
  • 20. Manufacturing Industry  Transformation Operations  Machine Processing  Assembly  Adding value*  Other Operations Material handling Inspection and testing Coordination and control Transformation Process Raw Material Part or Product Power Tools Machin es Labour Scrap or Waste
  • 21. Production Facilities and Layout  Facilities organised in the most efficient way to serve the particular mission of the plant and depends on:  Types of products manufactured  Production quantity  Product variety
  • 22. Production Quantity (Q)  Number of units of a given part or product produced annually by the plant  Three quantity ranges: 1. Low production – 1 to 100 units 2. Medium production – 100 to 10,000 units 3. High production – 10,000 to millions of units
  • 23. Product Variety (P)  Number of different product or part designs or types  ‘Hard’ product variety – products differ greatly  Few common components in an assembly  ‘Soft’ product variety – small differences between products  Many common components in an assembly
  • 24. Low Production Quantity (Qlow) Job shop – makes low quantities of specialized and customized products  Products are typically complex (e.g., specialized machinery, prototypes, space capsules)  Equipment is general purpose  Plant layouts:  Fixed position  Process layout
  • 27. Medium Production Quantities (Qmed) 1. Batch production – A batch of a given product is produced, and then the facility is changed over to produce another product  Changeover takes time – setup time  Typical layout – process layout  Hard product variety 2. Cellular manufacturing – A mixture of products is made without significant changeover time between products  Typical layout – cellular layout  Soft product variety
  • 29. High Production (Qhigh) 1. Quantity production – Equipment is dedicated to the manufacture of one product  Standard machines tooled for high production (e.g., stamping presses, molding machines)  Typical layout – process layout 2. Flow line production – Multiple workstations arranged in sequence  Product requires multiple processing or assembly steps  Product layout is most common
  • 32. Production quantity and variety Production quantity: low (<100), medium (102-104), high (>104) Production variety: low, medium, high soft, hard
  • 33. Selecting manufacturing processes  Manufacturing process decisions  Deformation processes  Casting processes  Sheet metalworking  Polymer processing  Machining  Finishing  Assembly  Material compatibilities / Process capabilities  Material costs, Tooling costs, Processing costs
  • 34. Types of manufacturing processes Extrusion Forging Rolling Bar drawing Wiredrawing Deformation Centrifugal Die casting Investment Permanent mold Sand casting Casting Bending Blanking Drawing Punching Shearing Spinning Sheet Metal Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding Polymer Processes Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM Machining Anodizing Honing Painting Plating Polishing Finishing Automated Bonding Brazing Manual Riveting Soldering Welding Assembly Manufacturing Processes How is the input material changed?
  • 35. Deformation processes  Rolling  Extrusion  Drawing  Forging
  • 36. Rolling (of ductile materials) Plastic deformation Rollers in compression thick slab thin sheet
  • 39. Extrusion Typical use: ductile metals (Cu, Steel, Al, Mg), Plastics, Rubbers Common products: Al frames of white-boards, doors, windows, …
  • 42. Drawing Commonly used to make wires from round bars stock (bar) F (pulling force) wire die stock (bar) F (pulling force) wire die Similar to extrusion, except: pulling force is applied
  • 44. Casting Processes  Sand casting  Die casting  Investment casting
  • 47. Investment casting Wax pattern is cast Wax removed by melting Molten metal solidifies in cast Ceramic mold is removed Ceramic mold (hardened slurry) 4-part pattern tree
  • 48. Sheet Metalworking  Bending  Blanking  Drawing  Punching  Shearing  Spinning
  • 49. Sheet metal drawing Blank Drawn part Clamp force Blank holder Die Punch Punch ram
  • 50. Polymer Processes  Compression molding  Transfer Molding  Blow molding  Injection molding
  • 53. Blow molding Extruder air injector parison Part is removed Air blown into parison Mold halves close Molten parison is extruded
  • 54. Injection molding Shear-heating Cavity half of mold Core half of mold Ejector pins Moving Feed hopper Sprue Fixed Barrel Pellets Mold closure direction Parting plane/surface
  • 55. Machining processes Extrusion Forging Rolling Bar drawing Wiredrawing Deformation Centrifugal Die casting Investment Permanent mold Sand casting Casting Bending Blanking Drawing Punching Shearing Spinning Sheet Metal Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding Polymer Processes Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM Machining Anodizing Honing Painting Plating Polishing Finishing Automated Bonding Brazing Manual Riveting Soldering Welding Assembly Manufacturing Processes
  • 56. Machining – removal of material… Sawing –using a toothed blade. Milling – from a flat surface by a rotating cutter tool. Planing – using a translating cutter as workpiece feeds. Shaping - from a translating workpiece using a stationary cutter. Boring - increasing diameter of existing hole by rotating the workpiece. Drilling- using a rotating bit forming a cylindrical hole. Reaming – to refine the diameter of an existing hole. Turning - from a rotating workpiece. Facing - from turning workpiece using a radially fed tool. Grinding - from a surface using an abrasive spinning wheel. Electric discharge machining - by means of a spark.
  • 57. Finishing processes Extrusion Forging Rolling Bar drawing Wiredrawing Deformation Centrifugal Die casting Investment Permanent mold Sand casting Casting Bending Blanking Drawing Punching Shearing Spinning Sheet Metal Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding Polymer Processes Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM Machining Anodizing Honing Painting Plating Polishing Finishing Automated Bonding Brazing Manual Riveting Soldering Welding Assembly Manufacturing Processes protection?
  • 58. Assembly processes – fastening / joining of 2 or more components Extrusion Forging Rolling Bar drawing Wiredrawing Deformation Centrifugal Die casting Investment Permanent mold Sand casting Casting Bending Blanking Drawing Punching Shearing Spinning Sheet Metal Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding Polymer Processes Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM Machining Anodizing Honing Painting Plating Polishing Finishing Automated Bonding Brazing Manual Riveting Soldering Welding Assembly Manufacturing Processes permanent?