lecture01 introduction to manufacturing d1

8/3/2019 Lecture01 Introduction to Manufacturing d1

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Lesson Outcomes

By the end of this lesson, studentsshould be able to:

Understand the essence ofmanufacturing

Be familiarized with the variousrocesses in manufacturin

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What is manufacturing?

The process of converting raw materials into products.

Manufacturing also involves activities in which the manufacturedpro uc , se , s use o ma e o er pro uc s.

Ex. Large presses to shape sheet metal for appliances and carbodies.

Value added-When a clay is made into the ceramic part of sparkplug, a vase, cutting tool, or an electrical insulator, value is

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anu ac ur ng s genera y a comp ex ac v yinvolving a wide variety of resources and activities,such as the following: pro uc es gn

Machinery and tooling process planning materials

purchasing production control Support services

sales shipping

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customer service


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It is essential that manufacturing activities beresponsive to several demands and trends:

1. A product must fully meet design requirements,product specifications, and standards.

2. A product must be manufactured by the mosteconomical and environmentall friendl methods.

3. Quality must be built into the product at each stage,

,quality testing after the product is manufactured

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4. n t e g y compet t ve env ronment o to ay,production methods must be sufficiently flexible torespond to changing market demands, types ofpro ucts, pro uct on rates, pro uct on quant t es, anto provide on-time delivery to the customer.

5. Continuous developments in materials, production

methods, and computer integration of both

manufacturing organization must be evaluatedconstantly with a view to their appropriate, timely, and

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6. Manufacturing activities must be viewed as a largesystem, all parts of which are interrelated to varyingdegrees. Such systems can now be modeled in order

market demands, product design, materials, andproduction methods on product quality and cost.

7. The manufacturer must work with the customer for

timely feedback for continuous product.

8. The manufacturing organization constantly strive for

,use of all its resources such as materials, machines,energy, capital, labor, and technology; output per

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The following are the general types of material used inmanufacturin either individuall or in combination

with other materials:

, , ,and die steels

, , ,nickel, titanium, superalloys, refractory metals,beryllium, zirconium, low-melting alloys, and preciousmetals

Plastics (polymers): thermoplastics, thermosets,

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Ceramics, glasses, glass ceramics, graphite,diamond, and diamond like materials.

Composite materials: reinforced plastics, metal--

engineered materials.

Nonomaterials, shape-memory alloys, armophousalloys, semiconductor, superconductors, and

properties.

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Properties of Materials

Selecting materials for products are considered asfollows:

Mechanical properties: strength, toughness,ductility, hardness, elasticity, fatigue, and creep

Physical properties: density, specific heat, thermalexpansion and conductivity, melting point, andelectrical and ma netic ro erties

Chemical properties: Oxidation, corrosion, generaldegradation of properties, toxicity, and flammability of

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Manufacturing properties of materials: whetherthey can be cast, formed, machined, joined, and heat-

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General cate ories of manufacturinprocesses:

.

2. Forming and shaping: Rolling, forging, extrusion,, , ,

molding.

. ac n ng: urn ng, or ng, r ng, m ng, p ann ng,shaping, broaching, and grinding, ultrasonicmachining: chemical, electrical, and electrochemical

- ,category also includes micromachining for producingultraprecision parts.

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4. Joining: Welding, brazing, soldering, diffusionbonding, adhesive bonding, and mechanical joining.

5. Finishing: Honing, lapping, polishing, burnishing,deburring, surface treating, coating, and plating

6. Nanofabrication: It is the most advanced technologyand is capable of producing parts with dimensions atthe nano level one billionth it t icall involves

processes such as etching techniques, electron-beams, and laser-beams

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Casting

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Casting

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lecture01 introduction to manufacturing d1

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