04/19/2304/19/23

Advanced Manufacturing

Choices MAE 165-265

Spring 2013, Dr. Marc MadouClass 1

04/19/23

Advanced Manufacturing Choices

• Manufacturing processes can be organized by considering the type of energy required to shape the work-piece. In this course, sources of energy considered for manufacturing are: – Mechanical energy such as in cutting and shaping– Electrical energy– Heat energy such as in laser cutting,– Chemical energy such as in electro chemical machining.

• Categorizing is often not that simple (e.g., chemical and thermal). It is easier to categorize in the case of subtractive than in the case of additive manufacturing.

04/19/23

Advanced Manufacturing Choices

• Students, guided by product specifications and a design will be able to decide: – 1) When to apply mechanical machining vs. lithography based

machining, – 2) What type of mechanical machining and what type of

lithography based machining to apply, – 3) When to employ bottom-up vs. top-down manufacturing, – 4) When to choose serial, batch or continuous manufacturing and – 5) What rapid prototyping method to select.

• A logical decision tree will be presented to sort out the machining options.

• Examples will include a variety of products ranging in size from nanometers to centimeters.

04/19/23

Advanced Manufacturing

Choices

• The size of things

04/19/23

Advanced Manufacturing Choices• Syllabus: Topics

1. Serial, batch and continuous manufacturing processes.

2. Relative tolerances vs. absolute machining tolerances.3. Principles of manufacturing processes I. Mechanical

energy: e.g., Cutting, Shaping, Forging, Ultrasonic Machining, Sputtering.

4. Principles of manufacturing processes II. Electrical energy: e.g., Electron Discharge Machining (EDM)

5. Principles of manufacturing processes III. Heat energy: e.g. , Laser machining, plastic molding.

04/19/23

Advanced Manufacturing Choices

6. Principles of manufacturing processes IV. Chemical energy: Electrochemical Machining (ECM), Chemical Machining

7. Next generation lithography tools, 8. Nanomachining tools.9. Top-down vs. bottom-up machining.10. Rapid prototyping, layered manufacturing.11. Matching manufacturing processes to product specification

and design.12. Manufacturing process decision tree.

04/19/23

Class 1• Definition of manufacturing• Serial, batch and continuous

manufacturing processes.• Relative tolerances vs. absolute

machining tolerances.

04/19/23

Definition of Manufacturing

• Manufacturing is the use of machines, tools and labor to make things for use or sale. The term may refer to a range of human activity, from handicraft to high tech, but is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale. Such finished goods may be used for manufacturing other, more complex products, such as household appliances or automobiles, or sold to wholesalers, who in turn sell them to retailers, who then sell them to end users - the "consumers". Wikipedia

04/19/23

Serial, batch and continuous manufacturing processes.

• Single unit production or serial production

• The primary characteristic of batch production is that a group of identical components are completed at a workstation before they move to the next one (e.g., IC fabrication).

• Continuous production is a method used to manufacture, produce, or process materials without interruption

04/19/23

Serial, batch and continuous manufacturing

processes.

04/19/23

Serial, batch and continuous manufacturing

processes.

04/19/23

Relative tolerances vs. absolute machining

tolerances.• A dimension is a numerical value

expressed in appropriate units of measure and used to define size, location, orientation, form or other geometric characteristics of a part.

• A tolerance is the acceptable variation of feature from the specified dimension

• Relative tolerance: tolerance on dimension over dimension

Dimension with Limit Tolerance

Dimension with Plus-Minus Tolerance

04/19/23

Relative tolerances vs. absolute machining

tolerances.

04/19/23

Relative tolerances vs. absolute machining

tolerances.• Lithography (e.g. Si-

micromachining) is excellent for small absolute tolerances

• For relative tolerances, ultra-fine diamond milling is better

• In some cases we might want to keep our micromachine somewhat larger to optimize relative tolerances

10 km1 km100 m10 m1 m10 cm1 cm1 mm100 µm10 µm1 µm0.1 µm0.01 µm1 nm1 ÅAbsolute size Absolute tolerancePrecision Machining Application DomainLinear dimensionLinear dimension0.01 %Relative ToleranceCityHouseArmOpticalfiber

VirusAtomRelative tolerances for buildinga house and a lithography based micromachine

Bacteria100 m1 m1 cm100 µm1 µm0.01 µmPrecision Machining1%100 %10 %0.1 %0.0001 %0.01 %

04/19/23

Relative tolerances vs. absolute machining

tolerances.• “The total amount by

which a given dimension may vary, or the difference between the limits” - ANSI Y14.5M-1982(R1988) Standard [R1.4]

• Nominal tolerances for steel (see figure)

• Tighter tolerances => increase cost $