introduction to manufacturing processes pt. 1 © 2012 project lead the way, inc.principles of...
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Introduction to Manufacturing Processes
Pt. 1
© 2012 Project Lead The Way, Inc.Principles Of Engineering
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Product Creation CycleDesign → Material Selection → Process Selection → Manufacture → Inspection → Feedback
Typical product cost breakdown
Products and Manufacturing
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Manufacturing Process
A sequence of operations and processes designed to create a specific product
The process of turning materials into a product
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Engineers in Manufacturing
Manufacturing EngineerSelect and coordinate specific processes and equipment
Industrial EngineerResponsible for the manufacturing system design
Materials EngineerDevelop and select materials based on desired material properties and manufacturing processes
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Manufacturing System Designs
Small quantities of products Large variety of productsProducts move through the shop to various machinesGeneral-purpose machines
Job Shop
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Manufacturing System Designs
Flow ShopLarger quantities of productsProduction lineSpecial purpose machines
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Manufacturing System Designs
Linked-Cell ShopManufacturing and subassembly cells connected to final assemblyLean production systemOne piece flow system
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Manufacturing System DesignsProject Shop
Product being manufactured cannot be easily moved during productionProduction processes are brought to the productExamples: Bridges, ships, large airplanes, locomotives, large machinery
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Manufacturing System Designs
Continuous ProcessLarge plantsUtilized in the manufacture of liquids, oils, gases, and powders
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Manufacturing System Designs
Lean Manufacturing100% “good” units flow from process to process Integrated quality control (IQC)All employees are inspectors
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Basic Manufacturing ProcessesCasting and Foundry Forming or MetalworkingMachiningJoining and AssemblyRapid PrototypingOther
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Casting and Foundry ProcessesIn one step raw materials are transformed into a desirable shape
Parts require finishing processes
Excess material is recyclable
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Basic Casting ProcessA mold is created – A cavity that holds the molten material in a desired shape until it is solidified Multiple-use mold
Single-use molds
Material is heated to a specified temperature
Molten material is poured into a mold cavity
Molten material solidifies into the shape of the cavity
Casting or mold is removed
Casting is cleaned, finished, and inspected
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Utilizes material that has been cast
Modify the shape, size, and physical properties of the material
Hot and cold forming
Forming and Metalworking Processes
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Forming and Metalworking Processes
Rolling – Material passes through a series of rollers, reducing its thickness with each pass
Forging – Material is shaped by the controlled application of force (blacksmith)
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Wire, rod, and tube drawing – Material is pulled through a die to produce a uniformed cross section
Extrusion – Material is compressed and forced through a die to produce a uniformed cross section
Forming and Metalworking Processes
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Cold forming and forging – Slugs of material are squeezed into dies
Forming and Metalworking Processes
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Machining ProcessesControlled removal of material from a part to create a specific shape or surface finish
Cutting element is used
Movement must exist between the part and cutting element
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Turning ProcessesOperations that create cylindrical parts
Work piece rotates as cutting tool is fed into the work
Machining Processes
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Turning ProcessesLathes and turning centers
Processes include: Straight, taper, contour turning, facing, forming, necking, parting, boring, threading, and knurling
Machining Processes
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Milling ProcessesOperations that create flat or curved surfaces by progressively removing material
Cutting tools rotate as the work piece is secured and fed into the tool
Machining Processes
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Milling ProcessesMills – Vertical and horizontal
Processes include: Surfacing, shaping, forming, slotting, T-slotting, angle, straddle, dovetailing, and slab milling
Machining Processes
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Drilling ProcessesOperations that create holes
Cutting tools rotate and are fed into nonmoving secured work pieces
Machining Processes
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Drilling ProcessesDrilling and boring machines
Processes include: Drilling, counter drilling, step drilling, boring, counter boring, countersinking, reaming, spot facing, and tapping
Machining Processes
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Shearing ProcessesOperations that break unwanted material away from the part
A material is placed between a stationary and movable surface. The movable surface (blade, die, or punch) applies a force to the part that shears away the unwanted material.
Machining Processes
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Automated hole punch, squaring shear, and rotary cutter
Processes include: Shearing, blanking, cutoff, and parting; punching, perforating, and slotting; notching, lacing, and trimming
Shearing ProcessesMachining Processes
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Abrasive Machining ProcessesOperations in which small particles of materials (abrasives) remove small chips of material upon contact
Drum, disc, and belt sanders; surface, vertical and horizontal spindle; disc grinders; media blaster; tumblers
Machining Processes
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Thermal and Chemical ProcessesOperations that cut and shape materials through chemical means
No mechanical force is used
Machining Processes
Electrical discharge, electrochemical, chemical, laser, electron beam, flame cutting, and plasma-arc cutting
Processes include: Grinding, sawing, cutting, machining, milling, blanking, and etching