INTRODUCTION AND OVERVIEW OF MANUFACTURING 1 What is

Manufacturing is Important § Technologically § Economically © 2007 John Wiley & Sons, Inc.

Manufacturing - Technologically Important • Technology - the application of science to provide society

Manufacturing - Economically Important U. S. economy: • Manufacturing is one way by which

Manufacturing - Technologically • Application of physical and chemical processes to alter the geometry,

Manufacturing - Economically • Transformation of materials into items of greater value by means

• Manufacturing Industries Industry consists of enterprises and organizations that produce or supply

Manufacturing Industries - continued § Secondary industries include manufacturing, construction, and electric power generation

Methods of Manufacture FIGURE 1. 6 Various methods of making a simple part: (a)

Manufacturing Processes • Two basic types: 1. Processing operations - transform a work material

Figure 1. 4 Classification of manufacturing processes © 2007 John Wiley & Sons, Inc.

• § Processing Operations Alters a material’s shape, physical properties, or appearance in

Shaping Processes – Four Categories 1. Solidification processes - starting material is a heated

Solidification Processes - Casting • Starting material is heated sufficiently to transform it into

Open Molds and Closed Molds Figure 10. 2 Two forms of mold: (a) open

Figure 11. 1 A large sand casting weighing over 680 kg (1500 lb) for

Shell Molding Casting process in which the mold is a thin shell of sand

Permanent Mold Casting © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals

Die Casting © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Centrifugal Casting © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Forming Processes: Deformation • Starting workpart is shaped by application of forces that exceed

Forming Processes: Deformation • Bulk Deformation • Sheet Metal Forming

Bulk Deformation Processes Rolling Extrusion Forging Drawing

Rolled Products Made of Steel Figure 19. 2 Some of the steel products made

Sheet Metal Forming Processes Cutting Deep Drawing V-Bending

Presses Figure Schematic representation of the various types of press drive mechanisms.

Types of Press Frame Figure 17 -60 (Left) Inclinable gap-frame press with sliding bolster

Drop Hammer Details Figure 19. 20 Diagram showing details of a drop hammer for

Stamping Press Figure 20. 32 Components of a typical mechanical drive stamping press ©

Forming: Particulate Processing • Starting materials are powders of metals or ceramics § Usually

Forming: Material Removal Processes -Machining • Excess material removed from the starting piece so

Forming: Material Removal Processes -Machining • Turning examples Standard Turning Threading: Facing

Two Forms of Milling Figure 21. 3 Two forms of milling: (a) peripheral milling,

Joining Processes: Welding, a Permanent Joining Process Figure 31. 1 Basic configuration of an

Arc Welding A pool of molten metal is formed near electrode tip, and as

Gas Metal Arc Welding 31. 4 Gas metal arc welding (GMAW). © 2007 John

Resistance Spot Welding Resistance welding, showing the components in spot welding, the main process

Oxyacetylene Welding Figure 31. 21 A typical oxyacetylene welding operation (OAW). © 2007 John

Brazing - Soldering: Permanent Joining Processes – Weak Bonding, Lower Temperatures Figure 32. 4

Joining Process: Adhesive Bonding Figure 32. 10 Types of stresses that must be considered

Slides: 44

Download presentation

INTRODUCTION AND OVERVIEW OF MANUFACTURING 1. What is Manufacturing? 2. Materials in Manufacturing 3. Manufacturing Processes 4. Production Systems © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Manufacturing - Technologically Important • Technology - the application of science to provide society and its members with those things that are needed or desired § Technology provides the products that help our society and its members live better § What do these products have in common? • They are all manufactured § Manufacturing is the essential factor that makes technology possible © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Manufacturing - Economically Important U. S. economy: • Manufacturing is one way by which nations create material wealth Sector % of GNP Manufacturing 20% Agriculture, minerals, etc. 5% Construction & utilities 5% Service sector – retail, transportation, banking, communication, education, and government 70% © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Manufacturing - Technologically • Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a starting material to make parts or products § § Manufacturing also includes assembly Almost always carried out as a sequence of operations Manufacturing as a technical Process: © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Manufacturing - Economically • Transformation of materials into items of greater value by means of one or more processing and/or assembly operations § Manufacturing adds value to the material by changing its shape or properties, or by combining it with other materials Manufacturing as an economic process © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

• Manufacturing Industries Industry consists of enterprises and organizations that produce or supply goods and services § Industries can be classified as: 1. Primary industries - those that cultivate and exploit natural resources, e. g. , farming, mining 2. Secondary industries - take the outputs of primary industries and convert them into consumer and capital goods manufacturing is the principal activity 3. Tertiary industries - service sector © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Manufacturing Industries - continued § Secondary industries include manufacturing, construction, and electric power generation § Manufacturing includes several industries whose products are not covered in this book; e. g. , apparel, beverages, chemicals, and food processing § For our purposes, manufacturing means production of hardware • Nuts and bolts, forgings, cars, airplanes, digital computers, plastic parts, and ceramic products © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Methods of Manufacture FIGURE 1. 6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.

Manufacturing Processes • Two basic types: 1. Processing operations - transform a work material from one state of completion to a more advanced state • Operations that change the geometry, properties, or appearance of the starting material 2. Assembly operations - join two or more components to create a new entity © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

• § Processing Operations Alters a material’s shape, physical properties, or appearance in order to add value Three categories of processing operations: 1. Shaping operations - alter the geometry of the starting work material 2. Property‑enhancing operations - improve physical properties without changing shape 3. Surface processing operations - to clean, treat, coat, or deposit material on exterior surface of the work © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Shaping Processes – Four Categories 1. Solidification processes - starting material is a heated liquid or semifluid 2. Deformation processes - starting material is a ductile solid (commonly metal) 3. Particulate processing - starting material consists of powders 4. Material removal processes - starting material is a ductile or brittle solid © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Solidification Processes - Casting • Starting material is heated sufficiently to transform it into a liquid or highly plastic state § Examples: metal casting, plastic molding • © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Open Molds and Closed Molds Figure 10. 2 Two forms of mold: (a) open mold, simply a container in the shape of the desired part; and (b) closed mold, in which the mold geometry is more complex and requires a gating system (passageway) leading into the cavity. © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Figure 11. 1 A large sand casting weighing over 680 kg (1500 lb) for an air compressor frame (photo courtesy of Elkhart Foundry). © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Expanded Polystyrene Process

Investment Casting

Forming Processes: Deformation • Starting workpart is shaped by application of forces that exceed the yield strength of the material § Examples: (a) forging, (b) extrusion © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Forming Processes: Deformation • Bulk Deformation • Sheet Metal Forming

Bulk Deformation Processes Rolling Extrusion Forging Drawing

Sheet Metal Forming Processes Cutting Deep Drawing V-Bending

Presses Figure Schematic representation of the various types of press drive mechanisms.

Types of Press Frame Figure 17 -60 (Left) Inclinable gap-frame press with sliding bolster to accommodate two die sets for rapid change of tooling. (Courtesy of Niagara Machine & Tool Works, Buffalo, NY. ) Figure 17 -61 (Right) A 200 -ton (1800 -k. N) straight-sided press. (Courtesy of Rousselle Corporation, West Chicago, IL. )

Forming: Particulate Processing • Starting materials are powders of metals or ceramics § Usually involves pressing and sintering, in which powders are first compressed and then heated to bond the individual particles © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Forming: Material Removal Processes -Machining • Excess material removed from the starting piece so what remains is the desired geometry § Examples: machining such as turning, drilling, and milling; also grinding and nontraditional processes Turning: Machining of cylindrical parts Drilling Milling

Forming: Material Removal Processes -Machining • Turning examples Standard Turning Threading: Facing

Turning Machine: Lathe

Milling Machine:

Arc Welding A pool of molten metal is formed near electrode tip, and as electrode is moved along joint, molten weld pool solidifies in its wake Figure 31. 1 Basic configuration of an arc welding process. © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Resistance Spot Welding Resistance welding, showing the components in spot welding, the main process in the RW group. © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Brazing - Soldering: Permanent Joining Processes – Weak Bonding, Lower Temperatures Figure 32. 4 Several techniques for applying filler metal in brazing: (a) torch and filler rod. Sequence: (1) before, and (2) after. © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Joining Process: Adhesive Bonding Figure 32. 10 Types of stresses that must be considered in adhesive bonded joints: (a) tension, (b) shear, (c) cleavage, and (d) peeling. © 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e