material in manufacturing

8/4/2019 Material in Manufacturing

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Introduction to ManufacturingEngineering and Technology

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How do we make these?

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How do we make these?

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manufacturing consists of the conversion of

raw materials into final products Forming and shaping materials can be carried

out by four approaches: Phase changes

Solid to liquid (mostly) g\Gas to solid (specialty materials)

Deformation In the bulk in sheet

Powders Additive methods ( new)

The method chosen depends on the materialand the shape and properties required

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Custome

r

needs

Societal pressures, Governmentregulations, company plans and policies,etc

People, money, machines and automation

Products

manufacturingRawmaterial

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Raw

Material

Materials Science, Statics, Dynamics, Thermodynamics, Fluiddynamics

Machines and Automation

Assembly

MaterialTransformation

Processes

Products

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Products

Ingot

casting

Molten

Material

Powders

Casting

Shapes

Rolling Forging/

Press forming

Stamping

Pressing

Sheet metal

forming

Continuous

Casting/Rolling

Injection

Molding

Machining

Finishing

Assembly

Raw

Material

Special

Extruding

Single crystalpulling

Firing/Sintering

SLS

Increasing level of detail

Blow

molding

Assem

bly

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Critically dependent on function Requires a clear understanding of the

interrelationship among Function

Material properties

Materials process capabilities

Process costs Commercial availability of material form

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Mechanical properties (Strength, Hardness,Fatique, Ductility, Resistance to environment)

Tolerances

Surface finish

Resistance to corrosion and abrasion

Electrical properties

Thermal Properties

Appearance/surface finish

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Source:KalpakjianP 1225

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Cast metals tend to be brittle Forging adds strength along flow lines

Machining is cost effective for small lotsizes

Casting, forging and extrusion have highsetup costs but low production costs

Heat treatments affect harness, strength,

corrosion resistance and fatigue properties Machining results in lots of scrap (the buy

to fly ratio)

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Source: Kalpakjian p 1229

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You cannot design any hardware without

taking into account the production processused to make that product

Manufacturing considerations must beincluded in the design as early as possible

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Product Creative Characteristics (How newproducts differ from previous ones)

Product Size (physical dimension) Product Complexity/Sophistication Scale Material Flow Degree of Automation Organization

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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)

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A individual device on a computer chip A computer chip A television An automobile A Navy cruiser

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A nail A TV

A car or truck A 777 aircraft A satellite Mars sojourner

A CPU chip (5 millioncomponents)

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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

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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)

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How much automation exists on the shopfloor Manual

Machine assisted Computer controlled - islands of automation Computer integrated manufacturing

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Casting Pour a fluid into a "cavity which has the negative of

the shape you want to create Fluid flows into all the crevices, and seeks its own level

change the phasee from liuid to solid by

Extracting heaat

Removing the liguid component of a slurry

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Takes =advantage of the plastic flowbehaviro of many materials under differentsrain sates Compressive Tensile Shear Combinations

Tensile - drawing Compressive

Rolling, forging Shear

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No waste of any kind Material waste

No scrap - process right each time

Work-in-Process

Pull material flow (KANBAN system)

Personnel waste Cross functional teams

Design product so there is only one way to assembleproduct (poke-a-yoke)

Time Waste

Concurrency in operations where possible

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The ability to manufacturing multiple

products on a single line

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Customer responsiveness Physical plant and equipment responsiveness

Human Resource responsiveness

Global market responsiveness

Teaming as a core competency Responsive business practices and cultures

Source: Next Generation Manufacturing - A Framework for Action: Volume II, published by theAgility Forum, Bethlehem, PA, 1997

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http://www.agilityforum.org/NGM/index.htmlhttp://www.agilityforum.org/NGM/index.htmlhttp://www.agilityforum.org/NGM/index.htmlhttp://www.agilityforum.org/NGM/index.htmlhttp://www.agilityforum.org/NGM/index.htmlhttp://www.agilityforum.org/NGM/index.htmlhttp://www.agilityforum.org/NGM/index.htmlhttp://www.agilityforum.org/NGM/index.html


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Employee security without lifetime employment Simultaneous satisfaction of all stakeholder needs

Practicing collaboration within knowledge-basedcompetition

Controlling core competencies without owning them Managing assets when the most valuable asset is

knowledge

Keeping domestic jobs while developing globalmarkets

Rewarding learning in a reward for doingenvironment

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From MP GROOVER

INTRODUCTION TOMANUFACTURINGENGINEERING


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2007 John Wiley & Sons,Inc. M P Groover,

Fundamentals of ModernManufacturing 3/e

1. What is Manufacturing?2. Materials in Manufacturing

3. Manufacturing Processes

4.

Production Systems5. Organization of the Book

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Technologically Economically

Historically

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Technology - the application ofscience to provide society and itsmembers with those things that areneeded or desired

Technology provides the productsthat help our society and its memberslive better

What do these products have incommon? They are all manufactured

Manufacturing is the essential factorthat makes technology possible

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2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Manufacturing isone way by which

nations creatematerial wealth

U.S. economy:

Sector% ofGNP

Manufacturing 20%

Agriculture, minerals, etc. 5%

Construction & utilities 5%

Service sector

retail,transportation, banking,communication, education, andgovernment

70%

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Throughout history, human culturesthat were better at making things weremore successful

Making better tools meant better

crafts & weapons Better crafts allowed people to live better

Better weapons allowed them to conquerother cultures in times of conflict

To a significant degree, the history ofcivilization is the history of humans'ability to make things

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The word manufactureis derived from twoLatin words manus(hand) and factus(make);the combination means made by hand

Made by hand accurately described the

fabrication methods that were used when theEnglish word manufacture was first coinedaround 1567 A.D.

Most modern manufacturing operations are

accomplished by mechanized and automatedequipment that is supervised by humanworkers

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Figure 1.1 (a)Manufacturin

gas a technicalprocess

Application of physical and chemicalprocesses to alter the geometry, properties,and/or appearance of a starting material tomake parts or products

Manufacturing also includes assembly Almost always carried out as a sequence ofoperations

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Figure 1.1 (b)Manufacturing

as an economicprocess

Transformation of materials into items ofgreater value by means of one or moreprocessing and/or assembly operations

Manufacturing adds valueto the materialby changing its shape or properties, or bycombining it with other materials

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Industry consists of enterprises andorganizations that produce or supplygoods and services

Industries can be classified as:

1. Primary industries - those that cultivateand exploit natural resources, e.g.,farming, mining

2. Secondary industries - take the outputs ofprimary industries and convert them into

consumer and capital goods -manufacturing is the principal activity

3. Tertiary industries - service sector

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Secondary industries includemanufacturing, construction, andelectric power generation

Manufacturing includes severalindustries whose products are notcovered in this book; e.g., apparel,beverages, chemicals, and foodprocessing

For our purposes, manufacturing

means production of hardware Nuts and bolts, forgings, cars, airplanes,

digital computers, plastic parts, andceramic products

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The quantity of products Qmade by afactory has an important influence on theway its people, facilities, and proceduresare organized

Annual production quantities can beclassified into three ranges:

Production range AnnualQuantity Q

Low production 1 to 100 units Medium production 100 to 10,000

units High production 10,000 to

millions of

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Product variety Prefers to differentproduct types or models produced inthe plant

Different products have differentfeatures

They are intended for different markets Some have more parts than others

The number of different product typesmade each year in a factory can becounted

When the number of product typesmade in the factory is high, thisindicates high product variety

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Figure 1.2 P-Q Relationship

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Although Pis a quantitative parameter,

it is much less exact than Qbecausedetails on how much the designs differis not captured simply by the numberof different designs

Soft product variety- small differences

between products, e.g., between carmodels made on the same productionline, with many common parts amongmodels

Hard product variety- products differ

substantially, e.g., between a small carand a large truck, with few commonparts (if any)

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A manufacturing plant consists ofprocessesand systems(and people, ofcourse) designed to transform a certainlimited range ofmaterialsinto productsof increased value

The three building blocks - materials,processes, and systems - are thesubject of modern manufacturing

Manufacturing capability includes:

1. Technological processing capability2. Physical product limitations3. Production capacity

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The available set of manufacturingprocesses in the plant (or company) Certain manufacturing processes are

suited to certain materials By specializing in certain processes, the

plant is also specializing in certain materials Includes not only the physical processes,

but also the expertise of the plantpersonnel

Examples: A machine shop cannot roll steel A steel mill cannot build cars

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Given a plant with a certain set ofprocesses, there are size and weightlimitations on the parts or productsthat can be made in the plant

Product size and weight affect: Production equipment Material handling equipment

Production, material handlingequipment, and plant size must beplanned for products that lie within acertain size and weight range

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Defined as the maximum quantity thata plant can produce in a given timeperiod (e.g., month or year) underassumed operating conditions

Operating conditions refer to number of

shifts per week, hours per shift, directlabor manning levels in the plant, and soon

Usually measured in terms of output

units, such as tons of steel or numberof cars produced by the plant

Also called plant capacity

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Most engineering materials can beclassified into one of three basiccategories:1. Metals2. Ceramics

3. Polymers Their chemistries are different Their mechanical and physical

properties are dissimilar

These differences affect themanufacturing processes that can beused to produce products from them

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Figure 1.3 Venndiagram of threebasic materialtypesplus composites

Nonhomogeneous mixtures of the otherthree basic types rather than a uniquecategory

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Usually alloys, which are composed oftwo or more elements, at least one ofwhich is metallic

Two basic groups:1. Ferrous metals - based on iron,

comprises about 75% of metal tonnagein the world:

Steel = Fe-C alloy (0.02 to 2.11% C)

Cast iron = Fe-C alloy (2% to 4% C)

2. Nonferrous metals - all other metallicelements and their alloys: aluminum,copper, magnesium, nickel, silver, tin,titanium, etc.

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Compounds containing metallic (orsemi-metallic) and nonmetallicelements.

Typical nonmetallic elements areoxygen, nitrogen, and carbon

For processing, ceramics divide into:1. Crystalline ceramics includes:

Traditional ceramics, such as clay(hydrous aluminum silicates)

Modern ceramics, such as alumina(Al2O3)

2. Glasses mostly based on silica (SiO2)

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Compound formed of repeatingstructural units called mers, whoseatoms share electrons to form verylarge molecules

Three categories:

1. Thermoplastic polymers - can besubjected to multiple heating and coolingcycles without altering molecularstructure

2. Thermosetting polymers - molecules

chemically transform (cure) into a rigidstructure cannot be reheated

3. Elastomers - shows significant elasticbehavior

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Material consisting of two or more

phases that are processed separatelyand then bonded together to achieveproperties superior to its constituents

Phase- homogeneous mass ofmaterial, such as grains of identical

unit cell structure in a solid metal Usual structure consists of particles or

fibers of one phase mixed in a secondphase

Properties depend on components,

physical shapes of components, andthe way they are combined to form thefinal material

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Two basic types:1. Processing operations - transform a work

material from one state of completion to amore advanced state

Operations that change the geometry,properties, or appearance of the startingmaterial

2. Assembly operations - join two or more

components to create a new entity

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Fundamentals of ModernManufacturing 3/eABS KP6523 CAD/CAM


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Alters a materials shape, physicalproperties, or appearance in order toadd value

Three categories of processingoperations:

1. Shaping operations - alter thegeometry of the starting work material2. Property-enhancing operations -

improve physical properties withoutchanging shape

3. Surface processing operations - toclean, treat, coat, or deposit materialon exterior surface of the work

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1. Solidification processes - startingmaterial is a heated liquid orsemifluid

2. Particulate processing - starting

material consists of powders3. Deformation processes - startingmaterial is a ductile solid(commonly metal)

4.

Material removal processes -starting material is a ductile orbrittle solid

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Starting material is heated sufficiently totransform it into a liquid or highly plasticstate

Examples: metal casting, plastic molding

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Starting materials are powders of metals orceramics

Usually involves pressing and sintering, inwhich powders are first compressed and then

heated to bond the individual particles

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Starting workpart is shaped by application offorces that exceed the yield strength of thematerial

Examples: (a) forging, (b) extrusion

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Excess material removed from thestarting piece so what remains is thedesired geometry

Examples: machining such as turning,

drilling, and milling; also grinding andnontraditional processes

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Desirable to minimize waste in part

shaping Material removal processes are wasteful

in unit operations, simply by the waythey work

Most casting, molding, and particulate

processing operations waste littlematerial

Terminology for minimum wasteprocesses: Net shapeprocesses - when most of the

starting material is used and nosubsequent machining is required

Near net shapeprocesses - when minimumamount of machining is required

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Performed to improve mechanical orphysical properties of work material

Part shape is not altered, exceptunintentionally Example: unintentional warping of a

heat treated part

Examples: Heat treatment of metals and glasses

Sintering of powdered metals andceramics

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Cleaning - chemical andmechanical processes to removedirt, oil, and other contaminantsfrom the surface

Surface treatments - mechanicalworking such as sand blasting,and physical processes likediffusion

Coating and thin film deposition -coating exterior surface of theworkpart

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2007 John Wiley & Sons,Inc. M P Groover,Fundamentals of ModernManufacturing 3/e

Two or more separate parts arejoined to form a new entity

Types of assembly operations:1. Joining processes create a

permanent joint

Welding, brazing, soldering, andadhesive bonding

2. Mechanical assembly fastening bymechanical methods

Threaded fasteners (screws, boltsand nuts); press fitting, expansionfits

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People, equipment, and proceduresused for the combination of materialsand processes that constitute a firm'smanufacturing operations

A manufacturing firm must have

systems and procedures to efficientlyaccomplish its type of production

Two categories of production systems: Production facilities Manufacturing support systems

Both categories include people (peoplemake the systems work)

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A company designs its manufacturing

systems and organizes its factories toserve the particular mission of eachplant

Certain types of production facilitiesare recognized as the most appropriatefor a given type of manufacturing:1. Low production 1 to 1002. Medium production 100 to 10,0003. High production 10,000 to >1,000,000

Different facilities are required for eachof the three quantity ranges

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Job shopis the term used for thistype of production facility

A job shop makes low quantities ofspecialized and customizedproducts Products are typically complex, e.g.,

space capsules, prototype aircraft,special machinery

Equipment in a job shop is general

purpose Labor force is highly skilled Designed for maximum flexibility

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Two different types of facility, depending onproduct variety:

Batch production

Suited to hard product variety

Setups required between batches Cellular manufacturing

Suited to soft product variety

Worker cells organized to process parts without

setups between different part styles

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Often referred to as mass production High demand for product

Manufacturing system dedicated tothe production of that product

Two categories of mass production:1. Quantity production

2. Flow line production

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Mass production of single parts on singlemachine or small numbers of machines

Typically involves standard machinesequipped with special tooling

Equipment is dedicated full-time to theproduction of one part or product type

Typical layouts used in quantity productionare process layout and cellular layout

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Multiple machines or workstations arrangedin sequence, e.g., production lines

Product is complex Requires multiple processing and/or assembly

operations Work units are physically moved through the

sequence to complete the product

Workstations and equipment are designed

specifically for the product to maximizeefficiency

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A company must organize itself to

design the processes and equipment,plan and control production, andsatisfy product quality requirements

Accomplished by manufacturing

support systems - people andprocedures by which a companymanages its production operations

Typical departments:

1. Manufacturing engineering2. Production planning and control

3. Quality control

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Figure 1.10 Overview of production system and majortopics in Fundamentals of Modern Manufacturing.

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2007 John Wiley & Sons,Inc. M P Groover,Fundamentals of ModernManufacturing 3/eABS KP6523 CAD/CAM


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A robotic arm performsunloading and loadingoperation in a turningcenter using a dual gripper

(photo courtesy ofCincinnati Milacron).

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Metal chips fly in a highspeed turning operationperformed on a computernumerical control turningcenter (photo courtesy ofCincinnati Milacron).

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Two welders perform arcwelding on a large steelpipe section (photocourtesy of Lincoln

Electric Company).

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Automated dispensing ofadhesive onto componentparts prior to assembly(photo courtesy of EFD,

Inc.).

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Assembly workers on anengine assembly line(photo courtesy of FordMotor Company).

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Assembly operationson the Boeing 777(photo courtesy ofBoeing Commercial

Airplane Co.).

material in manufacturing

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