Advanced Manufacturing ME 10405/10505 Professor Jim Waterman For Today – Objectives of the Course – Who am I? – My approach to the course – Outline for the semester – What is Manufacturing – intro to the course

Advanced Manufacturing ME 10405/10505 Professor Jim Waterman For Today Objectives of the Course Who am I? My approach to the course Outline for the semester What is Manufacturing – intro to the course

Advanced Manufacturing ME 10405/ Course Objectives – Provide an overview of modern manufacturing processes – Enable students to select and design processes to make things – Provide insights as to what is state of the art now, and what is coming

Advanced Manufacturing ME 10405/ My Approach – Bring some relevance to the subject What is happening in industry today – Bring you into the discussion I want your questions, and your knowledge We'll learn together – Get you ready to design for manufacture, or design the processes of the future

Advanced Manufacturing ME 10405/10505 Course Outline – First Half Intro and Overview of Manufacturing Engineering Materials Properties of Engineering Materials Dimensions Tolerancing and Surfaces Metal Casting Glassworking Shaping processes for Plastics Shaping processes for Rubber/Polymer Composites Powder Metallurgy Ceramics Metal Forming Metal working (roll/forge/extrude) Sheet Metal Metal Machining(including tool life) Principles Machine Tools Cutting tools tech Mid Term Oct 15

Advanced Manufacturing ME 10405/10505 Course Outline – Second Half Grinding/abrasive processes Non-traditional Processes Mechanical Energy processes Ultrasonic, Water Jet, Electrochemical machining EDM,Electron Beam/Laser Beam Machining Chem Machining Heat Treatment of Metals Surface Processing Cleaning,Diffusion/ion implant,Plating/electroforming Conversion coatings, Vapor deposition Organic coatings Welding :Fundimentals/Joints/physics Processes: Arc, Oxy/fuel, Acetalyene, Fusion Solid state Braze/Solder/Adhesive bond Mechanical Assembly Rapid Prototype processes Survey of Additive Manufacturing processes SLA, Fused Deposition, Powder based Ink/liquid based Others are developed Micro/Nano fabrication technologies

Advanced Manufacturing ME 10405/10505 Course Outline – Second Half Production Systems/process planning Survey of Automation/Manufacturing Systems CNC Cells and work flow/part families 'Flexible Machine Cells' Lean 'CIM' Discussion of life cycle data driven mfg/standards. Quality Process Capability Statistical Process Control Futures Extrapolating today to tomorrow (incorporate through the semester?) Supply Chain considerations – global issues Final Exam

What is Manufacturing?  The word manufacture is derived from two Latin words, manus (hand) and factus (make)  Taken together the combination means made by hand, which is how things were made in 1567 when the word first entered the English language  Today manufacturing can be defined two ways:  Technologically  Economically ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Technological Definition of Manufacturing  The application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products  It also includes assembly of multiple parts to make products ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Economic Definition of Manufacturing  The transformation of materials into items of greater value by means of one or more processing and/or assembly operations  Manufacturing adds value ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing Industries Industries can be classified as:  Primary industries: – Cultivate and exploit natural resources (e.g., agriculture and mining)  Secondary industries: – Take the output of the primary industries and convert them into consumer and capital goods (e.g., manufacturing, construction, power utilities)  Tertiary industries: – Service sector (e.g., retail, financial, education, transportation, government) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufactured Products Final products made by the manufacturing industries can be divided into two major classes:  Consumer goods – products purchased directly by consumers (e.g., cars, personal computers, TVs, tires,, and tennis rackets)  Capital goods – products purchased by companies to produce goods and/or provide services (e.g., aircraft, trucks and buses, machine tools, construction equipment) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing and Gross Domestic Product (GDP)  In the U.S:  Manufacturing accounts for about 12% of GDP – And the service sector accounts for more than 75% of GDP  BUT! Manufactured capital goods purchased by the service sector are the enablers of that sector  Without these manufactured products, the service industries could not function ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Production Quantity and Product Variety  Production quantity = the number of units produced annually of a given product type  Three ranges:  Low production (1 to 100 units per year)  Medium production ( 100 to 10,000 units)  High production (10,000 to millions of units)  Product variety refers to the number of different types of products made ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Production Quantity and Product Variety  Manufacturing plants tend to specialize in a combination of production quantity and product variety that lies inside the diagonal band shown below ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes How would you 'break' the curve?

Manufacturing Capability  Refers to the technical and physical limitations of a manufacturing firm and its individual plants  Three dimensions of manufacturing capability: 1. Technological processing capability – available set of manufacturing processes 2. Physical product limitations – size and weight of the products that can be made 3. Production capacity – production quantity that can be produced in a given time period ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Materials in Manufacturing Most engineering materials fall into one of 3 basic categories: Metals: Ferrous (e.g., steel and cast iron) Nonferrous (e.g., aluminum, copper, nickel) Ceramics Crystalline ceramics (e.g., clay, alumina) Glass Polymers Thermoplastics (e.g., polyethylene) Thermosets (e.g., epoxies) Elastomers (e.g., rubber) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing Processes  A manufacturing process is a designed procedure that results in physical and/or chemical changes to a starting work material with the intention of increasing the value of that material  Usually carried out as a unit operation, which is a single step in the sequence of steps required to transform the material into as final product ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Two Basic Types of Manufacturing Operations 1. Processing operations – transforms a work material from one state of completion to a more advanced state that is closer to the final desired product  Usually performed on discrete workparts 2. Assembly operations – joins two or more components to create a new entity, called an assembly, subassembly, or other term (e.g., weldment) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing Taxonomy

Processing Operations  General types: 1. Shaping operations – alter the geometry of the starting work material 2. Property-enhancing operations – improve the physical properties of the material without changing its shape 3. Surface processing operations – performed to clean, treat, coat, or deposit material onto the surface of the work ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Shaping Processes  Four categories based on the state of the starting material: 1. Solidification processes 2. Particulate processes 3. Deformation processes 4. Material removal processes ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Solidification Processes  Starting material is a heated liquid or semifluid that cools and solidifies to form the part geometry ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Particulate Processes  Starting material is a powder, and the powders are formed to create geometry and heated to strengthen ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Deformation Processes  Starting material is a ductile solid (commonly metal) that is deformed to shape the part Forging Extrusion ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Material Removal Processes  Starting material is a solid (ductile or brittle), from which material is removed so that what remains has the desired geometry Turning Drilling Milling ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Property-Enhancing Processes  Involves heat treatments, which include:  Annealing and strengthening processes performed on metals and glasses  Sintering of powdered metals and crystalline ceramics ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Surface Processing Operations:  Cleaning – chemical and mechanical processes to remove dirt, oil, and other contaminants  Surface treatments – mechanical working (e.g., sand blasting) and physical processes (e.g., diffusion)  Coating and thin-film deposition – apply a coating to the exterior surface of the work (e.g., electroplating, painting, physical vapor deposition) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Assembly Operations  Permanent Joining processes  Welding  Brazing  Soldering  Adhesive bonding  Mechanical Fastening  Joints can be disassembled (e.g., threaded fasteners)  Joints are permanent (e.g., rivets) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Production Machines  Machine tools – power-driven machines used to operate cutting tools  Other production machines developed subsequently:  Presses for stamping operations  Forge hammers  Rolling mills  Welding machines  Insertion machines for assembly ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Categories of Production Equipment  General-purpose machines  More flexible and adaptable to a variety of jobs  Commercially available for any manufacturing company to invest in  Special-purpose machines  Usually designed to produce a specific part or product in very large quantities  Achieve high efficiencies and short cycle times ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Tooling  Production machines usually require tooling that customizes the equipment for a particular part or product  In many cases, the tooling must be designed specifically for the part or product (e.g., a mold)  When used with general-purpose equipment, the tooling can be exchanged at the end of a production run ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Production Equipment and Tooling for Various Processes ProcessEquipmentSpecial tooling Casting(various types)Mold MoldingMolding machineMold ForgingForge hammerForging die ExtrusionExtrusion pressExtrusion die StampingStamping pressStamping die MachiningMachine toolCutting tool GrindingGrinding machineGrinding wheel ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Some Resources (outside of the book) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes I. The Library of Manufacturing: good companion resource to book for process information – II. Industry Week website – news, white papers –