1. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Manufacturing Processes Manufacturing Processes( 기계공작법 ) Introduction Introduction( 서론 ) Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical Engineering Gyeongsang National University

2. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU What is Manufacturing? Manufacturing( 제조 ) is the process of converting raw materials( 재료 ) into products( 제품 ). Nations with largest GDP growth concentrated on high value- added products, such as automobiles and machinery. Powder Bread Manufacturing?

3. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU What did we make? Paper  MaskPaper+Bamboo  KitePet bottle  Rocket Chopstick  GunPaper+Bamboo  Airplane Who to make it? Manufacturing Process

4. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Materials The types of materials( 재료 ) generally used in manufacturing: 1.Metals : Steels, Aluminium, copper 2.Plastics 3.Ceramics 4.Composite materials ( 복합재료 )

5. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Metals Iron (Fe): Cast iron, Steel, Carbon steel, High strength steel, Stainless steel, Tool steel POSCO: http://www.posco.com -> Products and Technologyhttp://www.posco.com Copper (Cu), Brass (Cu+Zn,Zinc), Bronze (Cu+Sn,Tin) Aluminum (Al), Duralumin (Al+Cu+Mg+Mn) Lead, Titanium, Nickel, (Zinc), Gold, Silver

6. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Polymer (Plastic) Thermoplastics: Nylon, Polyethylene, Polystyrene, Vinyl Thermosets: Epoxy, Phenolic, Polyester Elastomer: Rubber

7. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Composite Reinforced plastics, Concrete (Cement + Sand), Concrete- steel wire, Wood, Polywood, Polymer matrix FRP, Glass reinforced plastic, Carbon reinforced plastic

8. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Ceramics Clay, Glass (SiO 2 ), Diamond (C), Alumina (Al 2 O 3 ), Semiconductor (Si+P+B)

9. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Material property ~ Process Melting temperature ~ Casting Harness ~ Machining, Grinding Toughness (Ductile-Brittle) ~ Forming Electric property ~ EDM, Welding PropertiesMetalPlasticCeramic Melting temperature 1,000 ℃ 200 ℃ 3,000 ℃ Strength400MPa10MPa-300MPa, +50MPa ToughnessDuctile Brittle HardnessHighLowVery High T. E. conductivityHighLow Stiffness (=E)HighLowHigh Chemical stabilityMidHighVery high DensityHighLowHigh PriceHighLowHigh

10. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Melting temperature °CCeramicsMetalsPolymersComposites 4000 Graphite Tungsten 3400 3000SiC MgO Al 2 O 3 2052 2000SiliconPlatinumCermets Iron 1500, Ti Copper 1000Gold, Silver Al 660, Mg Zinc, LeadPE, PSFRP

11. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Material & Process MaterialsProcessProducts Metals Machining Forming Casting Axis Crank arm Engine housing PlasticsInjection moldingToy CeramicSinteringTerning insert Joining processes Welding Mechanical assembly Ship Car SiliconDeposition, EtchingMemory

12. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Manufacturing Process Market & Specification Conceptual Design Design for Manufacture Unit Manufacturing Assembly and Joining Machining Injection molding Casting Stamping Chemical vapor deposition Welding Bolting Bonding Soldering Product Sell

13. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Manufacturing Attributes for Decision Making 1.Cost( 비용 ) 2.Quality( 품질 ) 3.Rate( 생산성 ) 4.Flexibility( 유연성 )

14. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Casting ( 주조 ) 1.Cost: Expensive $100 - $10,000 2.Quality: Requires post finishing, 1mm 3.Flexibility: Very flexible, Good for large parts 4.Rate: Very slow 1 hour Engine housingCasting

15. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Forming ( 성형 ) 1.Cost: Cheap $0.1 - $100, Expensive equipment over $100,000 2.Quality: Reasonable 0.1mm 3.Flexibility: Shapes limited, Mass production 4.Rate: Fast (cycle time 5 sec) Side panel of automobilePress machine

16. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Plastics Injection ( 사출 ) 1.Cost: Cheap, $0.1, Expensive mold, over $10,000 2.Quality: Very high 0.05mm 3.Flexibility: Opening for ejection, Mass production 4.Rate: Very fast (5 sec) Injection mold & PlasticInjection machine

17. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Machining ( 절삭가공 ) 1.Cost: Expensive $100(Cylinder)-$10,000(Mold) 2.Quality: Very high, precise 0.01mm 3.Flexibility: Any shape cut by tool, Small production 4.Rate: Slow (1min-2day) Turning cylinderPress mold machining

18. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Welding ( 용접 ) 1.Cost: Cheap, but expensive labor 2.Quality: Wide range 3.Flexibility: Manual vs Robot 4.Rate: Slow in general Very Large Crude Carrier (VLCC)

19. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Thinfilm fabrication ( 반도체공정 ) 1.Cost: Very expensive equipments, $Millions 2.Quality: Very high, Nanometer pattern 3.Flexibility: Any shape in 2-D 4.Rate: Soso Lithography system, 110nm resolution

20. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Machine Parts Manufacturing Metal Parts Turn/Mill Cut/Drill Finishing Heat treat Grinding Cleaning

21. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Car Body Forming Joining Process Metal Parts Cutting Forming Surface Joining Painting

22. Introduction Manufacturing Processes © 2013 Su-Jin Kim GNU Reference Manufacturing Processes SME http://www.youtube.com/playlist?list=PL3AFB507B668A F162 http://www.youtube.com/playlist?list=PL3AFB507B668A F162 Plastic, Casting, Machining, Forming http://www.custompartnet.com http://www.custompartnet.com