manufacturing processes - magpulsemagpulse.co.in/pdf/5.others/manufacturing_processes.pdf ·...

Manufacturing Processes

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Context: “Prototype” vs. “Product”

Little

$5-10

5,000

Toy RC carProduct

Very little

$10,000+

10,000

AutomobileProduct

Can be a lotVariability

$200 in parts+ your effort

Mfg. cost

1Quantity

ME72 DevicePrototype

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Prototype -> Product

• Prototypes are one-offs• Products are to be manufactured• What if someone wanted you to make 1,000 of your

device for $50 each?– What would you change?

• How do you make it to meet scale, cost, andrepeatability?– “Better, faster, cheaper”– Manufacturing Processes

• What processes should you use?– Design for manufacturability

• How do you design so it is easily made/assembled?

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METAL CASTING AND POWDER PROCESSESCASTINGCASTING OF INGOTSCONTINUOUS CASTINGSAND CASTINGSHELL MOLDINGSLURRY MOLDINGINVESTMENT CASTING (LOW-WAX PROCESS)EVAPORATIVE CASTINGDIE CASTING(GRAVITY-FEED, PRESSURIZED…)CENTRIFUGAL CASTINGSQUEEZE CASTINGRHEOCASTINGCRYSTAL GROWING

•CRYSTAL-PULLING•ZONE MELTING

Electro formingPlasma SprayingPOWDER METALLURGYPRESSINGISOSTATIC PRESSINGSINTERING

JOINING PROCESSESMECHANICAL JOINING

•BOLTS, SCREWS, RIVETSSOLID-STATE WELDING

•DIFFUSION, FORGING, FRICTION,DEFORMATION

LIQUID STATE WELDING•RESISTANCE WELDING•ARC WELDING•THERMAL WELDING

HIGH-ENERGY BEAM WELDING•ELECTRONIC BEAM, LASER

LIQUID-SOLID STATE BONDING•BRAZING•SOLDERING

ADHESIVE BONDING•PLASTICS AND COMPOSITES JOINING(MECHANICAL, HEATING, SOLVENTS,ULTRASONICS)

MACHINING PROCESSESSINGLE POINT MACHINING

•TURNING•BORING•FACING•FORMING•SHAPING,PLANNING

MULTIPOINT MACHINING•DRILLING•MILLING•SAWING, FILING•BROACHING, THREAD CUTTING,GRINDING•SURFACE GRINDING•CYLINDRICAL GRINDING•CENTERLESS GRINDING•INTERNAL GRINDING•FORM GRINDING

ABRASIVE WIRE CUTTINGHONINGLAPPINGULTRASONIC MACHININGBUFFING, POLISHINGBURNISHINGTUMBLINGGRIT BLASTINGCHEMICAL MACHINING

•ENGRAVING•CHEMICAL MILLING•CHEMICAL BLANKING

ELECTROCHEMICAL MACHININGELECTRICAL DISCHARGE MACHININGLASTER MACHININGELECTRON BEAM MACHININGPLASMA-ARC CUTTINGFLAME CUTTING, WATER JET CUTTING

DEFORMATION PROCESSESOPEN-DIE FORGINGIMPRESSION-DIE FORGINGCLOSED-DIE FORGING

•PRECISION OR FLASHLESS FORGING•COINING•HEADING, PIERCING, HUBBING, COGGING,

FULLERING, EDGING, ROLL FORGING,SKEW ROLLINGROLLING

•FLAT, RING, THREAD, GEAR, PIERCINGEXTRUSION

•DIRECT, INDIRECT HYDROSTATIC, IMPACT,BACKWARD DRAWING•ROD & WIRE, FLAT STRIP, TUBES

SWAGINGSHEARINGBENDING

•PRESS-BRAKE FORMING, ROLL FORMINGTUBE FORMINGBEADING, FLANGING, HEMMING, SEAMINGSTRECH FORMINGBULGINGDEEP DRAWINGPRESS FORMINGRUBBER FORMINGSPINNINGEXPLOSIVE FORMINGELECTROHYDRAULIC FORMINGMAGNETIC-PULSE FORMINGSUPERPLASTIC FORMING

Source: Gutowski

Manufacturing process(page 1)

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MICROELECTRONICS PROCESSINGCRYSTAL GROWTH

•CZOCHRALSKI CRYSTAL GROWTH•FLOAT-ZONE CRYSTAL GROWTH

WAFER PROCESSING•SLICING, ETCHING, POLISHINNG

SURFACE PROCESSES•CHEMICAL VAPOR DEPOSITION (CVD)•EPITAXIAL FILM GROWTH•POLY CRYSTALLINE FILM GROWTH•S102 FILMS•OTHER (DIELECTRICS, METALS)

OXIDATION•ION IMPLANTATION•PHYSICAL VAPOR DEPOSITION•SPUTTERING•EVAPORATION

LITHOGRAPHY•PHOTORESIST•ELECTRON BEAM, X-RAY, ION BEAM

LITHOGRAPHYWET ETCHING

•CHEMICALDRY ETCHING

•PLASMA•SPUTTER•REACTIVE ION

PACKAGING•DICING•DIE ATTACHMENT•WIRE BONDING•ENCAPSULATION

POLYMER PROCESSESEXTRUSIONFIBER SPINNINGCALANDERINGFILM BLOWINGCOATING(MELTS, SOLUTION, PLASMA, ELECTROSTATIC,PLASTISOL, UV CURABLE…)BLOW MOLDINGINJECTION MOLDINGREACTION INJECTION MOLDING (RIM)COMPRESSION MOLDINGTRANSFER MOLDINGCASTINGTHERMOFORMINGROTATIONAL MOLDINGSOLID STATE FORMINGMACHININGETCHING SOLVENT PROCESSINGFOAMINGBONDINGIMPREGNATINGPAINTING

COMPOSITES PROCESSES(POLYMER COMPOSITES)PULTRUSIONFILAMENT WINDINGPULL FORMINGBRAIDINGAUTOCLAVE MOLDINGCOMPRESSION MOLDING (SMC)RESIN TRANSFER MOLDINGAUTOCOMP MOLDINGHAND LAY-UPSPRAY-UPAUTOMATIC TAPE LAY-UPSTAMPINGDIAPHGRAM FORMINGINJECTION MOLDING(FILLED THERMOPLASTICS, BMC…)REINFORCED REACTION INJECTION MOLDING(RRIM)(METAL MATRIX COMPOSITES)HOT PRESSURE BONDINGHOT ISOSTATIC PRESSINGLIQUID METAL INFILTRATIONELECTRODEPOSITIONPLASMA SPRAY DEPOSITION

CERAMICS PROCESSESPOWER PROCESSES•CONSOLIDATION•SINTERINGMELT PROCESSES•CRYSTALLINE MATERIALS (SILICON)•GLASSES•DRAWING, CASTING, BLOWING, TEMPERING(OPTICAL & STRUCTURAL FILTERS)•COATINGSOL-GEL CERAMICS PROCESSING

Source: Gutowski

Manufacturing process(page 2)

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Materials used in a car

Source: K. H. Grote

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Effect of manufacturing ongeometry

Source: Magrab

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Performance measures

• What makes a good manufacturing process?– Rate

• Material flow through system

– Time• Order to receipt• Setup time + part process time

– Cost• Material + Labor + Tooling + Equipment

– Quality• Deviation from target

Source: Gutowski

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Manufacturing processes

1. Subtractive– Material removal

2. Additive– Material addition, often in layers

3. Continuous– Continuous output (wire, rod)

4. Net shape– Output is the same as (or near) final shape

Source: Gutowski

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1. Subtractive Processes

• Machining– Turning– milling– boring– grinding

• Non-traditional machining– Chemical milling– Waterjet machining

• Micro-electronics processes– etching processes using either masks or beam

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Milling

Basic Types of MillingCutters and Operations

Source: K. H. Grote and Kalpakjian

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Non-traditional machining

• Laser machining

• Waterjet machining

Source: K. H. Grote

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2. Additive Processes

• Joining– Welding, soldering, adhering

• Rapid Prototyping/Layered manufacturing– Stereolithography, 3D printing

• Composites

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Welding

• Shielded Metal-Arc Welding Process. 50% ofall industrial welding employs this.

Source: K. H. Grote

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Stereolithography (SLA)

• Photopolymers are exposed by laser andcured from a liquid to a solid.

Source: http://cybercut.berkeley.edu/mas2/html/processes/stereolith/more.html

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3D printing• Thin layer of powder spread over surface• Like an ink-jet printer, binder material selectively

joins particles to form the object

Source: http://web.mit.edu/tdp/www/whatis3dp.html

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From: http://web.mit.edu/tdp/www/applications.html

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Composites

• Hand lay-up of layers of resin and fiber.• Lightweight & strong, but process is labor

intensive.

Source: http://www.saint-gobain-vetrotex.com.br/process_handlay.htm#01

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3. Continuous Processes

• Extrusion of metals• Plastic Extrusion• Pultrusion of composites

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Metal extrusion

Indirect Hydrostatic

Source: K. H. Grote and Kalpakjian

Direct extrusion

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Plastic extrusion

Source: http://www.telfordsmith.com.au/products/

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Pultrusion

• For composites• Fiber reinforcing material is pulled through

resin bath and into a die.

Source: http://users.techline.com/lord/manu.html

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4. Net Shape forming

• Solids– Metal Forming – stamping, forging– Powders

• Liquids– Casting– Injection Molding, thermoforming, blow molding

• Mixtures– Infiltration– Viscoelastics

• Tolerances not as tight

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Drawing and stretching

• Sheet metal

From: http://www.tms.org/pubs/journals/JOM/9911/Hosford-9911-figure1.html

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Forging

• Metal workpiece pressed under greatpressure into high strength parts

Closed die forging

workpiece

From: http://www.forging.org/facts/idproc.htm

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Investment/lost wax Casting

• A wax pattern is surrounded with investmentmaterial (sand), baked out, then metal is poured inthe cavity.

1. Create waxpattern

2. Assemblepatterns

3. Applyinvestment

4. Dewax 5. Fill shell 6. Knockout 7. Cutoff

8. Finished castings

From: http://www.hitchiner.com/home.html

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Compression Molding

Rubber trivet

Source: Byars 1998

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1.Compressionmoldingmachine

2. Slabs ofHTVsiliconerubber

3. Trimexcess

4. Finishedtrivets

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Injection Molding

From: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm

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Injection molding example

Cutlery made ofbiodegradablestarch

Source: Byars 1998

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1. Starch 2. Pelletsare formed

3. Injectionmolded forkson stem

4.Decomposingcutlery

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Thermoforming

• Very inexpensive for low volumes

From: http://www.kenplas.com/topic/thermoforming.aspx

Plastic sheet

Pattern

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