Introduction to Manufacturing Processes Products and Manufacturing Product

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Introduction to Manufacturing Processes

Introduction to Manufacturing Processes

Products and Manufacturing Product Creation Cycle Design → Material Selection → Process Selection →

Products and Manufacturing Product Creation Cycle Design → Material Selection → Process Selection → Manufacture → Inspection → Feedback Typical product cost breakdown

Manufacturing Process A sequence of operations and processes designed to create a specific product

Manufacturing Process A sequence of operations and processes designed to create a specific product The process of turning materials into a product ©i. Stockphoto. com

Engineers in Manufacturing Engineer Select and coordinate specific processes and equipment Industrial Engineer Responsible

Engineers in 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

Manufacturing System Designs Job Shop Small quantities of products Large variety of products Products

Manufacturing System Designs Job Shop Small quantities of products Large variety of products Products move through the shop to various machines General-purpose machines ©i. Stockphoto. com

Manufacturing System Designs Flow Shop Larger quantities of products Production line Special purpose machines

Manufacturing System Designs Flow Shop Larger quantities of products Production line Special purpose machines ©i. Stockphoto. com

Manufacturing System Designs Linked-Cell Shop Manufacturing and subassembly cells connected to final assembly Lean

Manufacturing System Designs Linked-Cell Shop Manufacturing and subassembly cells connected to final assembly Lean production system One piece flow system ©i. Stockphoto. com

Manufacturing System Designs Project Shop Product being manufactured cannot be easily moved during production

Manufacturing System Designs 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 ©i. Stockphoto. com

Manufacturing System Designs Continuous Process Large plants Utilized in the manufacture of liquids, oils,

Manufacturing System Designs Continuous Process Large plants Utilized in the manufacture of liquids, oils, gases, and powders ©i. Stockphoto. com

Manufacturing System Designs Lean Manufacturing 100% “good” units flow from process to process Integrated

Manufacturing System Designs Lean Manufacturing 100% “good” units flow from process to process Integrated quality control (IQC) All employees are inspectors ©i. Stockphoto. com

Basic Manufacturing Processes Casting and Foundry Forming or Metalworking Machining Joining and Assembly Rapid

Basic Manufacturing Processes Casting and Foundry Forming or Metalworking Machining Joining and Assembly Rapid Prototyping Other

Casting and Foundry Processes In one step raw materials are transformed into a desirable

Casting and Foundry Processes In one step raw materials are transformed into a desirable shape Parts require finishing processes Excess material is recyclable ©i. Stockphoto. com

Basic Casting Process A mold is created – A cavity that holds the molten

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

Forming and Metalworking Processes Utilizes material that has been cast Modify the shape, size,

Forming and Metalworking Processes Utilizes material that has been cast Modify the shape, size, and physical properties of the material Hot and cold forming ©i. Stockphoto. com

Forming and Metalworking Processes Rolling – Material passes through a series of rollers, reducing

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)

Forming and Metalworking Processes Extrusion – Material is compressed and forced through a die

Forming and Metalworking Processes Extrusion – Material is compressed and forced through a die to produce a uniformed cross section Wire, rod, and tube drawing – Material is pulled through a die to produce a uniformed cross section ©i. Stockphoto. com

Forming and Metalworking Processes Cold forming and forging – Slugs of material are squeezed

Forming and Metalworking Processes Cold forming and forging – Slugs of material are squeezed into dies

Machining Processes Controlled removal of material from a part to create a specific shape

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 ©i. Stockphoto. com

Machining Processes Turning Processes Operations that create cylindrical parts Work piece rotates as cutting

Machining Processes Turning Processes Operations that create cylindrical parts Work piece rotates as cutting tool is fed into the work ©i. Stockphoto. com

Machining Processes Turning Processes Lathes and turning centers Processes include: Straight, taper, contour turning,

Machining Processes Turning Processes Lathes and turning centers Processes include: Straight, taper, contour turning, facing, forming, necking, parting, boring, threading, and knurling ©i. Stockphoto. com

Machining Processes Milling Processes Operations that create flat or curved surfaces by progressively removing

Machining Processes 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 Mills – Vertical and horizontal Processes include: Surfacing, shaping, forming, slotting, T-slotting,

Machining Processes Mills – Vertical and horizontal Processes include: Surfacing, shaping, forming, slotting, T-slotting, angle, straddle, dovetailing, and slab milling

Machining Processes Drilling Processes Operations that create holes Cutting tools rotate and are fed

Machining Processes Drilling Processes Operations that create holes Cutting tools rotate and are fed into nonmoving secured work pieces

Machining Processes Drilling and boring machines Processes include: Drilling, counter drilling, step drilling, boring,

Machining Processes Drilling and boring machines Processes include: Drilling, counter drilling, step drilling, boring, countersinking, reaming, spot facing, and tapping

Machining Processes Shearing Processes Operations that break unwanted material away from the part A

Machining Processes Shearing Processes Operations 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 Shearing Processes Automated hole punch, squaring shear, and rotary cutter Processes include:

Machining Processes Shearing Processes Automated hole punch, squaring shear, and rotary cutter Processes include: Shearing, blanking, cutoff, and parting; punching, perforating, and slotting; notching, lacing, and trimming

Machining Processes Abrasive Machining Processes Operations in which small particles of materials (abrasives) remove

Machining Processes Abrasive Machining Processes Operations 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 Thermal and Chemical Processes Operations that cut and shape materials through chemical

Machining Processes Thermal and Chemical Processes Operations that cut and shape materials through chemical means No mechanical force is used Electrical discharge, electrochemical, laser, electron beam, flame cutting, and plasma-arc cutting Processes include: Grinding, sawing, cutting, machining, milling, blanking, and etching

Heat Treating Processes Controlled heating and cooling of a material to alter its properties

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

Heat Treating Processes To aid in the manufacturing process, materials can be treated to

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

Joining and Assembly Processes Can you think of a product with only one part?

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

Joining and Assembly Processes Mechanical Fastening Use physical force to hold parts together Mechanical

Joining and Assembly Processes Mechanical Fastening Use physical force to hold parts together Mechanical fasteners or part design Screws, bolts, nails, rivets, cotter pins, retaining clips, and edge design ©i. Stockphoto. com

Joining and Assembly Processes Welding Operations that use heat, pressure, or both to permanently

Joining and Assembly Processes Welding Operations that use heat, pressure, or both to permanently join parts Gas, arc, stud, spot, forge, roll laminating, resistance, and induction welding ©i. Stockphoto. com

Joining and Assembly Processes Adhesive bonding Bonding of adjoining surfaces by filling the gap

Joining and Assembly Processes Adhesive bonding Bonding of adjoining surfaces by filling the gap between each surface with a bonding material Glue, cement, thermoplastic, thermosetting, and elastomers ©i. Stockphoto. com

Joining and Assembly Processes Soldering and Brazing Operation in which metal surfaces are bonded

Joining and Assembly Processes Soldering 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 ©i. Stockphoto. com

Rapid Prototyping Additive process Parts are produced directly from software applications Common rapid prototyping

Rapid Prototyping Additive 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)

Rapid Prototyping Finished parts can be field tested depending upon building material Created parts

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

Other Manufacturing Processes Testing Transportation Material handling Packaging ©i. Stockphoto. com

Other Manufacturing Processes Testing Transportation Material handling Packaging ©i. Stockphoto. com

Material-Specific Manufacturing Processes Plastic Processes Ceramic Processes ©i. Stockphoto. com

Material-Specific Manufacturing Processes Plastic Processes Ceramic Processes ©i. Stockphoto. com

Plastics Manufacturing Processes Extrusion A rotating screw forces plastic through a heating chamber and

Plastics Manufacturing Processes Extrusion A rotating screw forces plastic through a heating chamber and then through a heated die Produces long plastic parts with uniform cross sections

Plastics Manufacturing Processes Injection Molding Heated plastic is forced by a movable plunger through

Plastics Manufacturing Processes Injection Molding 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 Processes Casting Plastic is melted and poured into a mold – No

Plastics Manufacturing Processes Casting Plastic is melted and poured into a mold – No pressure or fillers are required. Rotational Molding 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.

Plastics Manufacturing Processes Blow Molding A solid bottom hollow tube is placed between two

Plastics Manufacturing Processes Blow Molding 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.

Plastics Manufacturing Processes Thermoforming Plastic sheets are heated over an open mold to a

Plastics Manufacturing Processes Thermoforming 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. Reaction Molding Liquid reactants are mixed and then pressurized into a mold. No heat is needed. Curing time is typically less than 1 minute.

Ceramic Manufacturing Processes Two distinct classes of materials and processes exist. Glass is heated

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 Ceramics Material is shaped and then heated to produce a permanent solid.

Manufacturing Importance Typical product cost breakdown

Manufacturing Importance Typical product cost breakdown