Manufacturing Processes I - Marmara...

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Manufacturing Processes I ME3013

Transcript of Manufacturing Processes I - Marmara...

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Manufacturing Processes I

ME3013

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Learning Outcomes

• understand scientific principles of manufacturing processes

• practice engineering with ethical standards and a responsibility to society

• develop creative solutions to problems of manufacturing processes

• apply the design the processes , including the consideration of different technical alternatives while bearing in mind cost, environmental concerns, safety, and other constraints

• based on first-hand design experience, to analyze, (construct, test), and evaluate a manufacturing process

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1 Introduction to manufacturing

2 Attributes of manufactured products

3 Metal casting

4 Metal casting

5 Bulk deformation processes

6 Bulk deformation processes

7 Sheet metal working processes

8 Midterm Exam

9 Powder Metallurgy

10 Processing of particulate metals and ceramics and glasses

11 Processing of polymers

12 Machining

13 Machining

14 Joining processes

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References:

Textbook

1. Manufacturing Engineering and Technology, Kalpakjian and Schmid, Prentice Hall, New Jersey, 2013.

Supplementary Textbooks:

2. Fundamentals of Modern Manufacturing, Mikell P. Groover, John Wiley & Sons, Inc, New Jersey, 2010.

3. Materials and Processes in Manufacturing, DeGarmo, Black, and Kohser, John Wiley & Sons, Inc, New York, 2011.

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Midterm %20

Lab %40

Final %40

Manufacturing is the process of converting raw materials into products.

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Manufacturing

• two Latin words manus (hand) and factus (make);

• literally means made by hand.

• Although modern manufacturing is accomplished by automated and

computer-controlled machinery

• the word manufacturing is still in use.

• The key point is that manufacturing adds value to the material

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Manufacturing is Central to the Economy

1. Manufacturing has been the path to development: the newly industrializing countries like Korea, Taiwan, and now China, the key to prosperity.

2. Manufacturing is the foundation of global “Great Power”: about 80% of the world’s production of factory machinery controlled by the “Great Powers.”

3. Manufacturing is the most important cause of economic growth: No machinery industries, no sustained, long-term economic growth.

4. Global trade is based on goods, not services: WTO, 80% of world trade among regions is merchandise trade — that is, only 20% of world trade is in services.

5. Services are dependent on manufactured goods: the health of the economy is critically dependent on the health of the manufacturing sector.

6. Manufacturing creates jobs: Most jobs, directly or indirectly, depend on manufacturing

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Manufacturing ProcessProduction Quantity (Q)

Number of units of a given part or product produced annually

Three quantity ranges:1.Low production – 1 to 100 units2.Medium production – 100 to 10,000 units3.High production – 10,000 to millions of units

Product Variety (P)

Number of different product or part designs or types

‘Hard’ product variety – products differ greatly

Few common components

‘Soft’ product variety – small differences between products

Many common components

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Manufacturing processes

• Manufacturing processes alter a material’s properties in a controlled manner to produce components of products.

Types of Processes

1. Material removal

2. Deform or shape material through heat or pressure

3. Join two or more materials

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(b) Manufacturing as an economic process

(a) Manufacturing as a technical process

physical and chemical processes to alterthe geometry, properties, and/orappearance

materials into items of greater value bymeans of one or more processing and/orassembly operations

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Manufacturing Industries Why we manufacture?

Industries in manufacturing is divided into three major categories;

1. Primary industries are those that cultivate and exploit natural resources, such as agriculture and mining.

2. Secondary industries are those that take the outputs of the primary industries and convert them into consumer and capital goods. (This type is of our concern because it is engaged directly in manufacturing).

3. Tertiary industries constitute the service sector of the economy..

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Materials in Manufacturing

• Metals- Ferrous: Steel (iron-carbon, 0,02% - 2,11% C)

Cast iron (iron + 2% - 4% C + silicon)

- Nonferrous: copper, aluminium, nickel, alloys

• Ceramics: clay, silica, carbides (Al, Si), nitrides (Ti)

• Polymers- Thermoplastic polymers: PE, PP, PS, PVC

- Thermosetting polymers: phenolics, epoxies

- Elastomers: rubber, neoprene, silicone, PU

• Composites: more phases, particles/fibres + matrix

glass reinforced plastic, Kevlar, WC in cobalt, WC (Tungsten Carbide)

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Manufacturing Processes

• Processing operations: use energy to alter a workpart’s shape, physical properties or appearance in order to add value to the material. There are three categories of processing operations:

• Shaping operations: alter the geometry of the work material by methods including casting, forging and machining.

• Property-enhancing operations: add value to the material by improving its physical properties without changing its shape; e.g. Heat treatment.

• Surface processing operations: performed to clean, treat, coat or deposit material onto the exterior surface of the work. Examples for coating are plating and painting.

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Manufacturing Processes

• Shaping processes: change the geometry of a work material by application of heat or mechanical force or a combination of both. It can be classified into four categories:

• Solidification processes: the starting material is a heated liquid or semifluid that cools or solidifies to form the part geometry.

• Particulate processing: the starting material is a powder, and the powders are formed and heated into the desired geometry.

• Deformation processes: the starting material is a ductile solid that is deformed to shape the part.

• Material removal processes: the starting material is a solid, from which material is removed so that the resulting part has the desired geometry.

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Solidification process: material is heated sufficiently to transform it to the liquid state.

the material (metals, plastics and ceramic glasses) in the liquid state,

poured into a mold cavity and allowed to solidify ,

taking a solid shape that is the same as the cavity.

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Particulate processing:

Particulate processing. (1) Starting material (2) Pressing (3) Sintering.

• Starting materials are powders of metals or ceramics.

• pressed and sintered.

• squeezed into a die cavity under a high pressure

• heated to bond the individual particles together.

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Deformation processes:

the starting workpart is shaped

application of forces that exceed the yield strength of the material

material must be ductile enough (accomplished by means of heating)

this process includes extrusion and forging.

Deformation processes (a) forging (b) extrusion

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Material removal processes

remove excess material from the starting workpart

to get the desired geometry.

include machining and grinding. includes turning, drilling and milling.

nontraditional processes: lasers, electron beams, electric discharge, etc.

Material removal processes. (a) turning (b) drilling (c) milling.

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Surface processing

1. Cleaning: includes both chemical and mechanical processes to remove dirt, oil and other contaminants from the surface.

2. Surface treatments: includes mechanical working such as sand blasting and physical processes such as diffusion and ion implantation.

3. Coating and thin film deposition: apply a coating of material to the exterior surface of the workpart, examples are painting (organic coating) and electroplating. Thin film deposition in the other hand include physical and chemical vapor deposition to form extremely thin coatings of various substances.

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Assembly operations

• in which two parts or more are joined permanently or semipermanentlyto form a new entity.

• Permanent joining includes welding, soldering, adhesive bonding, etc.

• Mechanical assembly fastens parts in a joint that can be conveniently disassembled (using threaded fasteners such as bolts, rivets, nuts, etc).

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welding

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