Met 402 mod_1 (1)
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This document provides an overview of the key topics covered in Module 1 of an introduction to manufacturing course, including different manufacturing processes, design for manufacturing, material selection, production systems, product quality, and economics of manufacturing. It then goes on to describe various manufacturing processes like casting, forming, machining, and joining. It also discusses design for manufacturing guidelines, factors to consider when selecting materials and manufacturing processes, and methods for reducing manufacturing costs.
Met 402 mod_1 (1)
- 1. MODULE 1 COURSE OUTCOMES Different mfg processes Design for mfg Selection of materials for mfg processes Selection of mfg process Production systems Product quality Economics of mfging on mfg processes
- 2. Introduction to Mfg MFG : Converting raw material into finished product. • Some products are a single components (nail, bolt, fork, coat hanger, etc.) • Some products are assemblies of many components (ball point pens, automobiles, washing machines, etc.)
- 3. Manufacturing Processes: Casting Schematic illustration of various casting processes
- 4. Manufacturing Processes: Forming Schematic illustration of various bulk deformation processes
- 5. Manufacturing Processes: Forming Schematic illustration of various sheet metal forming processes
- 6. Manufacturing Processes: Forming Schematic illustration of various polymer processing methods
- 7. Manufacturing Processes: Machining Schematic illustrations of various machining and finishing processes.
- 8. Manufacturing Processes: Joining Schematic illustration of various joining processes
- 9. DFM Design for manufacturability (also known as design for manufacturing)- is the art of designing products in such a way that they are easy to manufacture. Each part or component of a product must be designed so that it not only meets design requirements & specifications but can also be mfged economically and with relative ease. This approach improves productivity and allows a manufacturer to remain competitive. DFM integrates product design process with materials, manufacturing methods, process planning, assembly, testing, and quality assurance.
- 10. What Internal Organization has the most Influence over Price, Quality, & Cycle Time? Manufacturing 20 - 30% Design 70 - 80%
- 11. Design for Mfg Guidelines 1. Minimize Total Number of Parts 2. Develop a Modular Design 3. Minimize Part Variations 4. Design Parts to be Multifunctional 5. Design Parts for Multiuse 6. Design Parts for Ease of Fabrication 7. Avoid Separate Fasteners
- 12. Design for Mfg Guidelines (Cont.) 8. Minimize Assembly Direction (Top Down Direction Preferred) 9. Maximize Compliance in Assembly 10. Minimize Handling in Assembly 11. Minimize complexity of Design 12. Maximize common Jigs and Fixtures 13. Optimize Work Position 14. Ease Access
- 13. Manufacturing a Product: General Considerations • Material Selection • Processing Methods • Final Shape and Appearance • Dimensional and Surface Finish • Economics of Tooling • Design Requirements • Safety and Environmental Concerns
- 14. Material Selection “Because without materials, there is no engineering.”
- 15. Selecting Materials for Products Selection of materials for products requires much experience, but several databases and expert systems are now available The following are the factors in selection of materials for products : 1. Material Substitution 2. Material Properties 3. Cost and Availability 4. Service Life and Recycling
- 16. Material substitution Majority of the design and mfging activities are concerned with improving existing products Reasons for substituting materials are: 1. Reduce the costs of materials and processing 2. Improve mfging, assembly, and installation 3. Improve the performance of the product 4. Increase stiffness-to-weight and strength-to-weight ratios 5. Reduce the need for maintenance and repair 6. Reduce vulnerability to the unreliability of the supply of materials 7. Improve compliance with legislation and regulations
- 17. Material Substitution Substitution of Materials in the Automobile Industry • Automobile industry is a major consumer of both metallic & nonmetallic materials • Constant competition among suppliers, particularly in steel, aluminum, and plastics • Efforts in investigating the advantages and limitations of principal materials
- 18. Material Substitution Substitution of Materials in the Aircraft and Aerospace Industries • Advanced materials are used in the Lockheed C-5A transport aircraft
- 19. Material Substitution Material Substitution in Common Products • Available products can be made by either set of materials: 1. Metal vs. wooden baseball bat 2. Metal vs. reinforced-plastic or wood handle for a hammer 3. Plastic vs. metal intake manifold 4. Cast-iron vs. aluminium lawn chair 5. Plastic vs. sheet-metal light-switch plate
- 20. Material Substitution Material Changes between C-5A and C-5B Military Cargo Aircraft • Table shows the changes made in materials for components of the two aircraft listed and the reasons for the changes
- 21. Properties of Materials Mechanical Properties: strength, toughness, ductility, hardness, elasticity, fatigue, creep. Behavior Under Loading: tension, compression, bending, torsion, shear. Physical Properties: density, specific heat, thermal expansion, thermal conductivity, melting point, electrical and magnetic properties. Chemical Properties: oxidation, corrosion, degradation, toxicity, flammability.
- 23. Engineering Materials Materials Metals Plastics Ferrous Non-ferrous Thermoplastics Thermosets Elastomers Steel Aluminum Acrylic Phenolic Rubber Stainless steel Copper Nylon Polymide Polyurethane Die & tool steel Zinc ABS Epoxies Silicone Cast iron Titanium Polyethylene Polyester Tungsten Polycarbonate PVC
- 24. Engineering Materials Materials Ceramics Metals Plastics Glass Composites Carbides Reinforced plastics Nitrides Metal-Matrix Graphite Ceramic-Matrix Diamond Laminates Glasses Glass ceramics
- 25. The Choice ……… In many cases metals and non metals are viewed as competing materials The selection is being based on how well each is capable of providing the required properties When both perform adequately total cost often becomes the deciding factor 1. The cost of material 2. Plus the cost of fabricating the desired component
- 26. Ferrous Metals: Applications • Structural: building structures, concrete reinforcement • Automotive: chassis, engine parts, drive train, body parts • Marine: ship hulls, structure, engines • Defense: tanks, weapons • Consumer Products: appliances, recreational vehicles, toys, utensils and tools
- 27. Nonferrous Metals: Applications • Architectural: aluminum windows and doors • Automotive: aluminum engine blocks, copper wiring, mag wheels • Marine: brass/bronze fittings, bearings, propellers • Defense: brass shell casings • Consumer Products: electrical wiring, utensils, jewelry, electronics
- 28. Plastics (Polymers) • Compared to metals, plastics have lower density, strength, elastic modulus, and thermal and electrical conductivity, and a higher coefficient of thermal expansion • The design of plastic parts should include considerations of their low strength and stiffness, and high thermal expansion and low resistance to temperature.
- 29. Plastics: Applications • Architectural: electrical and thermal insulation, weather seals, carpets, wall coverings, paint • Aerospace: electrical and thermal insulation, instrument panels, seals • Automotive: body panels, instrument panels, upholstery, electrical and thermal insulation, seals, hoses, tires • Consumer Products: toys, sporting goods, appliances, tools, utensils, clothing, shoes, packaging
- 30. Cost and Availability Cost and availably of raw matl/processed matls are major concern in mfg. If raw/ processed materials are not commercially available in the desired shape, dimensions, tolerance, & quantities substitutes or additional processing may be required; which will increase production cost.
- 31. Service Life and Recycling Wear, fatigue ,creep and dimensional stability are important considerations. Recycling or proper method of disposal of the components The proper treatment and disposal of toxic wastes
- 32. Selecting Manufacturing Processes Processing methods for materials can be listed as follows: 1. Casting 2. Forming and shaping 3. Machining 4. Joining 5. Micro manufacturing and nanomanufacturing 6. Finishing
- 33. Selecting Manufacturing Process A wide range of mfg process are used to produce a variety of parts, shapes and sizes. There is usually more than one method of mfg a part from a given material. Part shape, size, and thickness, dimensional tolerances, and surface-finish requirements greatly influence the selection of a process Quantity of parts and production rates determine the processes that are used and the economics of production.
- 34. Function dictates the Shape restricts choice of material and the choice of shape. Function material and process. Material Shape Process is Process interacts Process influenced by with shape. material Material selection and process cannot be separated from the shape and the function of the product, two way interaction.
- 35. Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.
- 36. Manufacturing a Sheet-metal Part by Different Methods • Two methods of making a dish-shaped sheet metal part: (a) press working (b) explosive forming
- 37. Shapes and some common methods of production.
- 38. ADVANTAGES OF CASTING PROCESS The most intricate of shapes, both external and internal, may be cast. As a result, many other operations, such as machining, forging, and welding, can be minimized or eliminated. Because of their physical properties, some metals can only be cast to shape since they cannot be hot-worked into bars, rods, plates, or other shapes. Objects may be cast in a single piece. Metal casting is a process highly adaptable to the requirements of mass production.
- 39. Large numbers of a given casting may be produced very rapidly. For example, in the automotive industry hundreds of thousands of cast engine blocks and transmission cases are produced each year. Extremely large, heavy metal objects may be cast when they would be difficult or economically impossible to produce otherwise. Large pump housing, valves, and hydroelectric plant parts weighing up to 200 tons illustrate this advantage of the casting process.
- 40. Some engineering properties are obtained more favorably in cast metals. Examples are :: More uniform properties from a directional standpoint; i.e., cast metals exhibit the same properties regardless of which direction is selected for the test piece relative to the original casting. Strength and lightness in certain light metal alloys, which can be produced only as castings. Good bearing qualities are obtained in casting metals.
- 41. Disadvantages of Casting: Though casting is cheapest for MASS Production, it becomes non economical in case of JOB production. Sand casting leaves rough surface which needs machining in most of cases. It adds up the cost in production. Again in sand casting, poor dimensional accuracy is achieved. Cast products are superior for compressive loads but they are very poor in tensile or shock loads.(They are brittle).
- 42. Advantages of Forging The forgings are consistent in shape and do not have any voids, porosity, inclusions, or defects. Parts that are produced by this method have high strength to weight ratio and therefore used in the design of the aircraft frames. It offers low cost for moderate to long runs. • High speed of production. DISADVANTAGES High tool cost. High tool maintenance. Limitation in size and shape.
- 43. Production Methods • Job Production – One-off production - each item might have particular specifications • Mass Production – suitable for mass market products that are identical • Batch Production – each stage of the production process has an operation completed on it before moving on to the next stage – allows modifications to be made to products that otherwise are the same
- 44. Manufacturing Costs and Cost Reduction • The total cost of a product consists of material costs, tooling costs, fixed costs, variable costs, direct-labor costs, and indirect-labor costs • Depending on the particular company and the type of products made, different methods of cost accounting may be used • Costs are also attributed directly to product liability
- 45. Manufacturing Costs and Cost Reduction Materials Costs • Costs depend on the type of material, processing history, size, shape, and surface characteristics Tooling Costs • Costs are involved in making the tools, dies, molds, patterns, and special jigs and fixtures required for manufacturing a product • Greatly influenced by the production process selected
- 46. Manufacturing Costs and Cost Reduction Fixed Costs • These costs include electric power, fuel, taxes on real estate, rent, insurance, and capital Capital Costs • Represent machinery, tooling, equipment, and investment in buildings and land
- 47. Manufacturing Costs and Cost Reduction Direct-labor Costs • Costs for labor that is directly involved in manufacturing products • Time required for producing a part depends on its size, shape, dimensional accuracy and surface finish • Labor costs in manufacturing and assembly vary greatly from country to country • Manufacturers consider moving production to countries with a lower labor rate known as outsourcing
- 48. Manufacturing Costs and Cost Reduction Indirect-labor Costs • Consist of costs for supervision, maintenance, quality control, repair, engineering, research, and sales and cost of office staff Manufacturing Costs and Production Quantity • Large production require the use of mass- production special machinery (dedicated machinery) • Small-batch production involves general-purpose machines
- 49. Manufacturing Costs and Cost Reduction Cost Reduction • Cost reduction use relative costs as a parameter • Some products require complex and expensive production steps to process • Design phase has the largest influence on the quality and success of a product in the marketplace • Cost–benefit analysis requires reliable input data, technical and human factors
- 50. Manufacturing Costs & Global Competitiveness • Cost of a product is taking into consideration the product’s marketability and customer satisfaction. • Major impact on manufacturing includes: 1. Global competition 2. Market conditions fluctuated widely 3. Customers demand 4. Product complexity