part 1 introduction to manufacturing processs_color

Islamic University of Technology (IUT)

Universit Islamique de Technologie ORGANISATION OF ISLAMIC COOPERATION (OIC)

Dr. Mohammad Ahsan Habib Assistant Professor

E-mail: [email protected] Department of Mechanical and Chemical Engineering (MCE)

Room: 405, Level 4, First Academic Building

Part 1 Introduction to Manufacturing Processes

MCE 4321 Manufacturing Processes

Dr. Mohammad Ahsan Habib

Tentative Lecture Schedule Mon, 10 Feb, 2014

9:02:10 AM

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Part No. Topics

Part 1 Introduction to Manufacturing Processes

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Part 2 Metal Casting

Part 3 Metal Joining

Part 4 Machining Processes: Fundamentals of cutting

Part 5 Machining Processes: Cutting tool materials & Cutting fluids

Part 6 Machining Processes: Used to Produce Round and Various Shapes

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Part 7 Machining Processes: Abrasive Machining and Finishing Operations

Part 8 Metal Forming & Powder Metallurgy

Part 9 Surface Technology

Part 10 Automation of Manufacturing Processes



Mon, 10 Feb, 2014 9:02:05 AM

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Course Information Course Teacher: Dr. Mohammad Ahsan Habib Room: 405 (First Academic Building) E-mail: [email protected]

Grading Policy: Attendance: 10% Class Performance: 15% 4 Quiz or 3 Quiz 1 Assignment + Overall performance

Mid-term: 25% Final Exam: 50%

Textbook (reference only): Kalpakjian and Schmid, Manufacturing Engineering & Technology, 6th Edition in SI Units.



Products and Manufacturing Product Creation Cycle

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Typical product cost breakdown

Design

Material Selection

Process Selection

Manufacture

Inspection

Feedback



Manufacturing Need and concept The progress and the prosperity of human civilization are governed and

judged mainly by improvement and maintenance of standard of living through availability or production of ample and quality goods and services for mens material welfare () in all respects covering housing, clothing, medicine, education, transport, communication and also entertainment. It depends on: Availability of natural resources () Exertion of human effort (); both physical and mental Development and use of power tools and machines (),

This can be depicted in a simple form: : refers to air, water, heat and light, plants and animals and solid and liquid minerals : refers to power plants, chemical plants, steel plants, machine tools etc. which magnify human capability.

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Value addition by manufacturing Production or manufacturing can be simply defined as value addition processes by

which raw materials of low utility and value due to its inadequate material properties and poor or irregular size, shape and finish are converted into high utility and valued products with definite dimensions, forms and finish imparting some functional ability.

A lump of mild steel of irregular shape, dimensions and surface, which had almost no use and value, has been converted into a useful and valuable product like bolt by a manufacturing process which imparted suitable features, dimensional accuracy and surface finish, required for fulfilling some functional requirements.

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Production Engineering Production Engineering covers two domains:

(a) Production or Manufacturing Processes: This refers to science and technology of manufacturing products effectively, efficiently, economically and environment-friendly through Application of any existing manufacturing process and system Proper selection of input materials, tools, machines and environments. Improvement of the existing materials and processes Development of new materials, systems, processes and techniques

All such manufacturing processes, systems, techniques have to be Technologically acceptable Technically feasible Economically viable Eco-friendly

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Production Engineering (Cont. ) (b) Production Management: This is also equally important and essential in the manufacturing world. It mainly refers to planning, coordination and control of the entire manufacturing in most profitable way with maximum satisfaction to the customers by best utilization of the available resources like man, machine, materials and money. It may be possible to manufacture a product of given material and desired configuration by several processes or routes as schematically indicated in figure.

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Strategies of increasing profit The various process routes may be different in respect of principle, technique,

quality of products and time requirement and cost of manufacture. The best one is to be selected based on some criteria. Achieving the goal in manufacturing requires fulfillment of one or more of the following objectives: reduction of manufacturing time increase of productivity reduction of manufacturing cost increase in profit or profit rate

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The most significant and ultimate objective, i.e., Increase in Profit, , can be attained by i. reducing the overall manufacturing

cost, ii. increase in revenue, R by increasing

quality and reliability of the products iii. enhancement of saleable production



Broad classification of Manufacturing Processes All such manufacturing processes can be broadly classified in four

major groups as follows: a) Shaping or forming: Manufacturing a solid product of definite size and

shape from a given material taken in three possible states: in solid state e.g., forging rolling, extrusion, drawing etc. in liquid or semi-liquid state e.g., casting, injection molding etc. in powder form e.g., powder metallurgical process.

b) Removal process: Machining (Traditional or Non-traditional), Grinding etc. c) Joining process: Welding, brazing, soldering etc. d) Regenerative manufacturing: Production of solid products in layer by

layer from raw materials in different form: liquid e.g., stereo lithography powder e.g., selective sintering sheet e.g., LOM (laminated object manufacturing) wire e.g., FDM. (Fused Deposition Modeling)

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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 Engineer: Select and coordinate specific processes and equipment

Industrial Engineer: Responsible for the manufacturing system design

Materials Engineer: Develop and select materials based on desired material properties and manufacturing processes

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Manufacturing System Designs

Job Shop Small quantities of products Large variety of products Products move through the shop to various machines General-purpose machines

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Manufacturing System Designs (Cont. )

Flow Shop Larger quantities of products Production line Special purpose machines

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Linked-Cell Shop Manufacturing and subassembly cells connected to final assembly Lean production system One piece flow system

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Project Shop Product being manufactured cannot be easily moved during production Production processes are brought to the product Examples: Bridges, ships, large airplanes, locomotives, large machinery

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Continuous Shop Large plants Utilized in the manufacture of liquids, oils, gases, and powders

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Lean Manufacturing 100% good units flow from process to process Integrated quality control (IQC) All employees are inspectors

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Manufacturing of Hip Replacement Mon, 10 Feb, 2014

9:01:45 AM

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Components of a total hip replacement.

Source: Courtesy of Zimmer, Inc.

(a) Manufacturing steps in the production of a roll-formed and machined total hip replacement stem; (b) Manufacturing steps in the production of a forged stem. Hip stems can also be produced by investment casting, metal injection molding, insert injection molding, and assorted other processes. Source: Courtesy of Zimmer, Inc.



Automation in Manufacturing Mon, 10 Feb, 2014

9:01:39 AM

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Machining a mold cavity for making sunglasses. (a) Computer model of the sunglass as designed and viewed on the monitor.

(b) Machine the die cavity using a computer numerical-control milling machine (c) Final product.

Automated spot welding of automobile bodies in a mass production line. Source: Courtesy of Ford Motor

Company.

part 1 introduction to manufacturing processs_color

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