1. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:1 Environmentally Conscious Design & Manufacturing Class 5: Manufacturing Prof. S. M. Pandit

2. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:2 Manufacturing Agenda l What is a Manufacturing Enterprise? l Systems View - Manufacturing l Manufacturing Processes l Modeling

3. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:3 Manufacturing Enterprise Product DesignMarketing Finance Manufacturing TechnologyManagement

4. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:4 Manufacturing Enterprise - Product Design Product Design Traditional l Functional Requirements l Cost, Time & Material constraints l Design tools for CAE (Integrated CAD - CAM +.. Research Areas l Computer Aided Design Tools l Environmentally-Friendly Product Design and Packaging l Human Machine Interface l Rapid Prototyping Stereolithography: http://www.nitc.qub.ac.uk/divs/pddc.htm

5. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:5 Manufacturing Enterprise - Product Design CAD Drafting function Divide into elements Optimize storage and processing Finite element / Finite difference analysis 2D.. 2.5D.. 3D Solid Stress / Thermal / Fluid Flow Material Properties -- Isotropic Anisotropic

6. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:6 Manufacturing Enterprise - Manufacturing Manufacturing Traditional l Machining Single and multi-point cutting l Joining, Forming, Casting.. l Metrology Non-Traditional l Laser Cutting l Abrasive jet machining l Electrochemical machining l Explosive deformation and joining l Hydroforming http://www.servicemetal.com Laser Cutting

7. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:7 Manufacturing Enterprise - Manufacturing CAM - Data transfer (integrated CAD - CAM) - Machine tool controller (language) - Program entry / debugging / dry run -Tool wear / breakage -Dimensional accuracy -Temperature effects -Elastic deformation

8. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:8 Manufacturing Enterprise - Manufacturing http://www.ab.com/cnc CNC information flow

9. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:9 Systems View Finite-Element Analysis Computational Fluid Dynamics Kinematic / Dynamic Analysis Design Visualization and Animation Drafting CAM

10. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:10 Manufacturing Processes Solidification Forming Processes Particulate Processing Material Removal Joining

11. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:11 Manufacturing Processes Solidification Processes Melting Furnace (Metals: 800 C to 3000 C) - Alloying - Phase stability - Inclusions and impurities (chemical metallurgy) - Stirring and agitation - Buoyancy and surface tension driven flow - Bubbles in the melt {Chemical and Physical Metallurgy}

12. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:12 Manufacturing Processes - Solidification 1 Sand Casting Sprue Riser Sand Core Parting Line

13. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:13 Manufacturing Processes - Solidification 2 Solidification Time - temperature - composition Quenching (conduction heat transfer) - Simple analysis: Lumped parameter transient temperature profiles ‘T’ is a function of time, , the initial temperature, T 0, and the ambient temperature, T . ‘ h’, A s, r, V, and C p are the convective heat transfer coefficient, Surface area, density, Volume, and specific heat capacity, respectively.

14. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:14 Manufacturing Processes - Forming Molding Injection Blow Extrusion Rolling Forging Polymer processing Cost advantages Rheological properties and temperature dependent properties Temperature & pressure Influence on grain structure Diffusion processes Directional properties Reference: Physical Metallurgy by Dieter

15. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:15 Manufacturing Processes - Powder Metallurgy Powder production Blending Compaction Sintering Creating a “die compaction tool” 1) Develop a user-friendly software simulation model 2) Develop the required material models and incorporate them into the software, 3) Determine the material properties necessary to verify and implement the model, 4) Verify model output through experimental techniques, and 5) Demonstrate the applicability of the process model.

16. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:16 Machining - 1 Metal removal Turning, Milling, Drilling: Primary Inputs: Electrical Energy Cutting fluid Primary Outputs:Finished products Spent cutting fluid Others: Lubricants, oils, machined chips, tool debris, heat

17. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:17 Machining - 2

18. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:18 Machining - 3

19. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:19 Machining - 4 Radial drilling machine

20. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:20 Machining - 5 Metal removal Electro discharge / Electro-chemical / Primary Inputs: Electrical Energy Cutting fluid / Electrolytes Primary Outputs:Finished products Spent cutting fluid / Electrolyte Others: Lubricants, oils, work-piece debris, tool debris, heat, Metal vapor, Metallic compounds,...

21. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:21 Machining - 6 Electro- chemical machining of blades

22. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:22 Machining - 7 Abrasive jet machining - schematic

23. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:23 Machining - 8 Metal removal - no ‘tooling’ Electron beam, Laser, Abrasive jet, Water jet Primary Inputs: Electrical Energy Fluids & abrasives Primary Outputs:Finished products Spent fluid & abrasives Others: Heat, Metal vapor, Metallic compounds,...

24. Environmentally Conscious Design & Manufacturing (ME592) Date: March 15, 2000 Slide:24 Machining - 9 http://www.llnl.gov/IPandC/op96/09/9c-com.html Electron - beam machining: Intense energy densities Non - contact Clean