manufacturing processes
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Introduction to Manufacturing Processes
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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 products
Production line
Special purpose machines
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Manufacturing System Designs
Linked-Cell ShopManufacturing and subassembly cells connected to final assembly
Lean production system
One piece flow system
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Manufacturing System Designs
Project ShopProduct 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 plants
Utilized 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 Processes
Casting and Foundry
Forming or Metalworking
Machining
Joining and Assembly
Rapid Prototyping
Other
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Casting and Foundry Processes
In one step raw materials are transformed into a desirable shape
Parts require finishing processes
Excess material is recyclable
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Basic Casting Process
A 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 Processes
Controlled 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 Processes
Operations 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 Processes
Mills – 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
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Heat Treating Processes
Controlled heating and cooling of a material to alter its properties while maintaining its shape
Properties include: Strength, toughness, machinability, wear resistance, and corrosion resistance
90% of heat treating is preformed on steel and other ferrous metals
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Heat Treating Processes
To aid in the manufacturing process, materials can be treated to be weak and ductile and then can be re-treated to provide high strength.
Can also occur incidentally during the manufacturing process
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Joining and Assembly Processes
Can you think of a product with only one part?
Most products consist of multiple parts that are assembled to form a finished product.
Typical assembly processes include: Mechanical fastening; soldering and brazing, welding; adhesive bonding
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Joining and Assembly ProcessesMechanical Fastening
Use physical force to hold parts together
Mechanical fasteners or part design
Screws, bolts, nails, rivets, cotter pins, retaining clips, and edge design
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Joining and Assembly ProcessesWelding
Operations that use heat, pressure, or both to permanently join parts
Gas, arc, stud, spot, forge, roll laminating, resistance, and induction welding
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Joining and Assembly ProcessesAdhesive bonding
Bonding of adjoining surfaces by filling the gap between each surface with a bonding material
Glue, cement, thermoplastic, thermosetting, and elastomers
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Joining and Assembly ProcessesSoldering and Brazing
Operation in which metal surfaces are bonded together by an alloy
Heated molten alloy flows between the adjoining surfaces
When the heat is removed, the molten metal solidifies and the metal surfaces are bonded
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Rapid PrototypingAdditive process
Parts are produced directly from software applications
Common rapid prototyping systems include: stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), laminated object manufacturing (LOM), digital light processing (DLP)
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Rapid Prototyping
Finished parts can be field tested depending upon building material
Created parts can be used to create a mold
Modifications to design can be implemented quickly
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Other Manufacturing Processes
Testing
Transportation
Material handling
Packaging
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Material-Specific Manufacturing Processes
Plastic ProcessesCeramic Processes
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Plastics Manufacturing Processes
A rotating screw forces plastic through a heating chamber and then through a heated die
Produces long plastic parts with uniform cross sections
Extrusion
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Heated plastic is forced by a movable plunger through a nozzle and then into a mold. The material fills the mold and then is cooled.
Most widely used high-volume production process
Plastics Manufacturing ProcessesInjection Molding
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Plastic is melted and poured into a mold – No pressure or fillers are required.
Plastics Manufacturing ProcessesCasting
A closed mold is filled with a predetermined amount of plastic. The mold is heated, rotated, and then cooled to create a hollow plastic object with uniform wall thickness.
Rotational Molding
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Plastics Manufacturing Processes
A solid bottom hollow tube is placed between two mold halves and heated. The heated tube is then expanded into the sides of the mold with compressed air.
Blow Molding
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Plastics Manufacturing Processes
Liquid reactants are mixed and then pressurized into a mold.
No heat is needed. Curing time is typically less than 1 minute.
Reaction Molding
Plastic sheets are heated over an open mold to a working temperature. Once workable, a vacuum is applied to the mold, forcing the plastic sheet to take the shape of the mold.
Thermoforming
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Ceramic Manufacturing Processes
Two distinct classes of materials and processes exist.
Glass is heated to a molten state, shaped by viscous flow, and then cooled to produce a solid.
Crystalline CeramicsMaterial is shaped and then heated to produce a permanent solid.
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Manufacturing Importance
Typical product cost breakdown