1. Manufacturing technology Introduction
Technology II – Jan Tomíček

2. Manufacturing
Important part of World economy. Allmost all products are manufactured.
Demands are increasing
New issues – energy efficiency, waste, etical issues

3. Changes in the world of goods manufacturing
World wide competetion
New materials
Advanced technologies
New manufacturing systems
Enviromental issues

4. 1. World Wide Competetion
Global business
Market = Whole world
Everybody can make business –
knowledge vs. capital
customization vs. mass production
Product placement vs. variability

5. 2. New materials Demands from customers
Smooth surface on plastic parts
Transparency of plastic
Shiny metal look etc.
New developed materials with better properties
Heat resistant materials
High strength materials
Special materials

6. 3. Advanced technologies
Complex products
Combined principles
Mechanical principles
Electrical
Electronical
Combination
Water, steam, electricity,

7. 4. New manufacturing systems
Manufacturing strategies
Management

8. 5. Enviromental issue Low energy and material consumption
Utilization of human labor, heavy work
Healt and security issues
Ethical problems

9. Product Life Cycle Design Construction Manufacturing Sale
Service and recycling

10. TIME Cost Per unit SATURATION Annual sales per model START-UP
RAPID GROWTH
MATURATION
COMODITY or DECLINE
Product variety
Great variety, product innovation
Increasing standartization
Emergence of a dominant stadart design
High standardization
„comodity“ characteristics
Industry structure
Small competetiors
Fallout and Consolidation
Few large companies
„Survivors“ become comodities
Form of competetion
Product characteristics
Product Quality, Cost and availability
Price and Quality and Reliability
Price with consistent quality

11. Price of the product? What is the best price of the product?
Smallest, affordable, highest, psychologically friendly, discounted??
Production costs!

13. Manufacturing costs Methods:
Casting, foundry, moulding
Forming of metalforming
Machining(material removal)
Surface treatments(finishing)
Heat treatment
Joining and assembling
Machining is approx 40% of manufacturing costs
TECHNOLOGY II

14. Machining
Chip removal process – Material is removed in form of chips from a piece of raw material to archive the desired shape.
Material(chips) are removed by a tool from the blank
This process is called „Chip forming“

15. DISADVANTAGES ADVANTAGES variety of work materials
variety of part shapes and geometric features
dimensional accuracy
good surface finishes
DISADVANTAGES
wasteful of material
time consuming

16. Material utilization

17. A CUTTING TOOL
single-point tool (a)
multiple cutting edge tool (b)

18. Chip forming principle
Continuous vs. discontinuous chip
Force stresswork hardeningsaturation(fully hardened material)shearconinuous chip

19. CHIP FORMATION (orthogonal cutting schema)
the tool is forced into the material
plastic deformation → hardening of the material
shear deformation – shear plane (angle φ)

20. CHIP FORMATION

21. Secondary deformation zone

22. Chip breakers Preventing the built-up edge
Groove type - premanufactured
Obstruction type

23. Chip and Tool geometry
Tool – rake & face angle

24. Chip thickness
Chip thickness ratio

25. CUTTING CONDITIONS cutting speed vc [m.s-1]; [m.min-1]
feed f [mm.rev-1]; [m.min-1]
depth of cut d = ap [mm]

26. Chip types

27. Chip breaking diagramme

28. Chip breaking diagramme

29. Chip volume ratio
Calculation W =
Value 3-400
Large volume of chips

30. Chips removal Chips must be removed
From the cut – gravity, liquid, air etc.
From the machine – liquid, automatic, manually
From the workshop – conveyors, carriages
From factory –
recycling

31. What to think about?
Next time – resistance of material, cutting forces, heat and temperature