1. C H A P T E R N I N E MANUFACTURING PROCESSES

2. 2 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. OBJECTIVES 1. Describe the role of computer-aided design in project development. 2. Define rapid prototyping and list four rapid prototyping technologies. 3. Describe the role of design in manufacture, assembly, disassembly, and service. 4. Define modeling for assembly. 5. Describe the role of material selection and material properties. 6. List the major manufacturing processes. 7. Look up accuracy and surface finishes for manufacturing processes. 8. Describe the role of measuring devices in production. 9. List factors that determine the cost of manufactured goods. 10.Define computer-integrated manufacturing.

3. 3 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. UNDERSTANDING MANUFACTURING Manufacturing is generally a complex activity involving a wide variety of resources and activities such as: Product design Product design Purchasing Purchasing Marketing Marketing Machinery and tooling Machinery and tooling Manufacturing Manufacturing Sales Sales Process planning Process planning Production control Production control Shipping Shipping Materials Materials Support services Support services Customer service Customer service

4. 4 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. The Design Process and Concurrent Engineering Sharing product design data among multiple users concurrently can shorten the time to product realization and result in a better product. Design and manufacturing activities have traditionally taken place sequentially rather than concurrently or simultaneously.

5. 5 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. COMPUTER-AIDED DESIGN AND PRODUCT DEVELOPMENT Computer-aided design (CAD) allows the designer to conceptualize objects more easily without having to make costly illustrations, models, or prototypes more easily without having to make costly illustrations, models, or prototypes. Computer-aided design (CAD) allows the designer to conceptualize objects more easily without having to make costly illustrations, models, or prototypes more easily without having to make costly illustrations, models, or prototypes. (Ford Motor Company/Dorling Kindersley.) These systems are now capable of rapidly and completely analyzing designs, from a simple bracket to complex structures.

6. 6 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. Computer-Aided Engineering Allows for Future Modification Computer-aided engineering (CAE) allows the performance of structures subjected to static or fluctuating loads and various temperatures to be simulated, analyzed, and tested efficiently, accurately, and more quickly than ever. The information developed can be stored, retrieved, displayed, printed, and transferred anywhere in the organization. Fiberglass Chassis for a Lotus Car Being Removed from the Mold. (Lotus Cars Ltd. /Dorling Kindersley.)

7. 7 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. Computer-Aided Engineering Links All Phases of Manufacturing Computer-aided manufacturing (CAM) involves all phases of manufacturing by utilizing and processing further the large amount of information on materials and processes collected and stored in the organization’s database. Computers now assist manufacturing engineers and others in organizing tasks such as programming numerical control of machines; programming robots for materials handling and assembly; designing tools, dies, and fixtures; and maintaining quality control. Car Frames Being Welded on a Robotic Assembly Line. (Courtesy of Adam Lubroth / Stone/Getty Images Inc.)

8. 8 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. RAPID PROTOTYPING SLA Rapid Prototyping System. (Courtesy of 3D Systems Corporation.) (Courtesy of Stratasys, Inc.) Rapid prototyping systems allow the engineer to develop a prototype directly from a CAD design within minutes or hours instead of the days or weeks it might otherwise take to create a prototype part.

9. 9 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. RAPID PROTOTYPING Translating the Model Today’s major rapid prototyping systems all work on a similar principle: they slice the CAD model into thin layers, then create the model, layer by layer, from a material that can be fused to the next layer until the entire part is realized. To send a CAD file to most rapid prototyping systems, often you export a file in the STL ( stereolithography) file format. Faceted Surface on a CAD Model Exported for Protoyping (Lockhart, D.; Johnson, Cindy M., Engineering Design Communication: Conveying Design Through Graphics, 1st, © 2000. Printed and electronically reproduced by permission of Pearson Education, Inc., Upper Saddle River, New Jersey.)

10. 10 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. TYPES OF RAPID PROTOTYPING SYSTEMS Stereolithography Apparatus (SLA) Solid Ground Curing (SGC) Selective Laser Sintering (SLS) Fused Deposition Modeling (FDM) Laminated Object Manufacturing (LOM) Topographic Shell Fabrication (TSF) 3D Printing Rapid Tooling Direct Shell Production Casting (DSPC) 3D Printer Model. (Courtesy of Z Corporation.)

11. 11 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. DESIGN FOR MANUFACTURE, ASSEMBLY, DISASSEMBLY, AND SERVICE This area is termed design for manufacture (DFM). DFM is a comprehensive approach to producing goods and integrating the design process with materials, manufacturing methods, process planning, assembly, testing, and quality assurance. (Courtesy of the New York Times.)

12. 12 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. MATERIAL SELECTION Standard shapes are often used in materials testing to make it easier to compare results. (Courtesy of Clive Streeter © Dorling Kindersley.) Ferrous metals: carbon, alloy, stainless, and tool and die steels. Nonferrous metals: aluminum, magnesium, copper, nickel, titanium, superalloys, refractory metals, beryllium, zirconium, low-melting alloys, and precious metals. Plastics: thermoplastics, thermosets, and elastomers. Ceramics: glass ceramics, glasses, graphite, diamond, and diamond-like materials. Composite materials: reinforced plastics, metal- matrix and ceramic-matrix composites. These are also known as engineered materials. Nanomaterials: shape-memory alloys, amorphous alloys, superconductors, and various other materials with unique properties. The following are the general types of materials used in manufacturing today, either individually or in combination:

13. 13 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. COST AND AVAILABILITY OF MATERIALS APPEARANCE, SERVICE LIFE, AND RECYCLING Cost and availability of raw and processed materials and manufactured components are major concerns in manufacturing. Competitively, the economic aspects of material selection are as important as the technological considerations of properties and characteristics of materials. The appearance of materials after they have been manufactured into products influences their appeal to the consumer. Time- and service- dependent phenomena such as wear, fatigue, creep, and dimensional stability are important. Recycling or proper disposal of materials at the end of their useful service lives has become increasingly important in an age when we are more conscious of preserving resources and maintaining a clean and healthy environment.

14. 14 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. DOS AND DON’TS OF PRACTICAL DESIGN

15. 15 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. DOS AND DON’TS OF PRACTICAL DESIGN Continued…

16. 16 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. Practical Considerations

17. 17 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. Practical Considerations Continued…

18. 18 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. DIMENSIONAL ACCURACY AND SURFACE FINISH Ultraprecision manufacturing techniques and machinery are now being developed and are coming into more common use. For machining mirrorlike surfaces, for example, the cutting tool is a very sharp diamond tip, and the equipment has very high stiffness and must be operated in a room where the temperature is controlled within 1°C. Highly sophisticated techniques such as molecular-beam epitaxy and scanningtunneling microscopy are being implemented to obtain accuracies on the order of the atomic lattice 0.1 nm.

19. 19 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. MEASURING DEVICES USED IN MANUFACTURING Although the machinist uses various measuring devices depending on the kind of dimensions (fractional, decimal, or metric) shown on the drawing, to dimension correctly, the engineering designer must have a working knowledge of common measuring tools. Most measuring devices in manufacturing are adjustable so they can be used for a range of measurements, but some measuring devices are designed to be used for only one particular dimension.

20. 20 Technical Drawing with Engineering Graphics, 14/e Giesecke, Hill, Spencer, Dygdon, Novak, Lockhart, Goodman © 2012, 2009, 2003, Pearson Higher Education, Upper Saddle River, NJ 07458. All Rights Reserved. OPERATIONAL AND MANUFACTURING COSTS The design and cost of tooling, the lead time required to begin production, and the effect of workpiece material on tool and die life are major considerations. Depending on its size, shape, and expected life, the cost of tooling can be substantial. For example, a set of steel dies for stamping sheet metal fenders for automobiles may cost about $2 million. scrap rate quantity of parts Availability of machines and equipment safety