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