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Manufacturing Processes

Manufacturing Processes. An Introduction By: Sunil Kumar Ojha. Do you ever heard Manufacturing ? Which is the leading Manufacturing Country in the world? How Manufacturing affect economy of acommon man and for a country ? Curiosity How parts are made ????????.

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Manufacturing Processes

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  1. Manufacturing Processes An Introduction By: Sunil Kumar Ojha

  2. Do you ever heard Manufacturing ? • Which is the leading Manufacturing Country in the world? • How Manufacturing affect economy of acommon man and for a country ? • Curiosity How parts are made ????????

  3. Introduction • Take a few moments and inspect some of the objects around you

  4. Introduction

  5. Introduction • What do they all have in common • They have all been transformed from raw materials • Components of various size and shape • Assembled into the products you see now

  6. What is Manufacturing • Derived from 2 latin words • Manus – hand • Factus – make • Made by hand • The process of converting raw materials into useful products.

  7. What is Manufacturing • Technologically • Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given material to make parts or products • Includes assembly of multiple parts to make products • Typically carried out as a sequence of operations

  8. What is Manufacturing • Economically • Manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations • Adds value

  9. What is Manufacturing • A nation’s level of manufacturing activity is related directly to its economic health • Generally, the higher the level of manufacturing activity in a country, the higher the standard of living of its people • In the US, the manufacturing industries account for about 20% of the Gross National Product (GNP), 32 % in China and app. 15 % in India.

  10. A Brief History of Manufacturing • Many manufacturing processes have been around for thousands of years • Can you name some ancient examples of the following: • Grinding • Forging / Smithy Work • Casting • Others

  11. A Brief History of Manufacturing • Industrial Revolution (1760-1830) • Change from agriculture/handicraft economy to one based on industry and manufacturing • Watt’s steam engine • Machine tools • Power spinning loom • Factory system organization • Interchangeable parts

  12. A Brief History of Manufacturing • Interchangeable parts • Pre-requisite for mass production • Eli Whitney Contract to produce 10,000 muskets for US government

  13. A Brief History of Manufacturing • Second Industrial Revolution (late 1800s, early 1900s) • Mass production • Scientific management movement • Assembly lines • Henry Ford • Electrification of factories • 1881 – first power generator in New York • 1920 – electricity overtakes steam in factories

  14. Why Study Manufacturing? • The costs of a product are substantially determined in the product design phase • As such, designers/engineering determine up to 70% of the manufacturing costs • Designers may make poor decisions about materials, tolerances, shapes, size, and product function • All of these have tremendous impact on the processes used in the manufacturing of a product

  15. Why Study Manufacturing? • A thorough knowledge of manufacturing processes is necessary for those who designandmake the parts • If better decisions can be made in the early phases of product design • Better products for customers • Greater profits for manufacturing companies

  16. Manufacturing Example • You have been asked to design & produce paper clips • (Developed by a Norwegian) • (US Patent in 1901) • Let’s discuss important factors involved in the design and manufacture of paper clips

  17. Manufacturing Example • What type of material would you choose to make this product? • Should it be metallic or nonmetallic? • If metal, what type of metal? • If “wire” shape, what diameter? • Should it be round or other cross-section? • What should be the surface finish?

  18. Manufacturing Example • How would you shape the wire into a paper clip? • By hand on a simple fixture? • If not, what kind of machine would you design to make the paper clips? • How would you produce 10,000 clips? • How about millions of clips?

  19. Manufacturing Example • Clip must meet basic functional requirements • Hold paper with sufficient clamping force • Proper design – shape, size, feel, appearance • Stiffness and strength of material

  20. Manufacturing Example • Too stiff • Inconvenient for users • Not stiff enough • Won’t hold papers • Yield stress too low • Permanent deformation during normal use

  21. Manufacturing Example • Can the wire undergo bending during manufacturing without cracking or breaking? • Is the wire corrosion resistant? • Can the wire be easily cut without causing excessive wear on the tooling? • Will the cutting process produce a smooth edge on end of wire? • What’s the most economical method of manufacturing the clip in the needed quantities?

  22. Product Design • Product design is a critical activity • It has been estimated that 70-80% of the cost of product development and manufacture is determined by decisions made in the initial design stages • The design of a product first request a thorough understanding of the functions and performance expected of the product

  23. Product Design • Traditionally design and manufacturing activities have taken place sequentially • This practice has proven to be inefficient • Concurrent engineering was developed to find more effective ways to bring products to the market quicker • Products early to market enjoy higher profits and greater longevity

  24. Product Design • Concurrent engineering integrates the design and manufacture of products, optimizing all elements involved in the product life cycle • Consists of several deliberate iterations • All disciplines involved early in the design stages so that the iterations • Benefits to one automotive company • 30% reduction in # of components • 25% decrease in weight • 50% decrease in manufacturing time

  25. Design for Manufacturing • Design and manufacturing should never be viewed as separate activities • Components must be designed so that they meet design requirements AND can be manufactured economically

  26. Design for Manufacturing • DFM is a comprehensive approach to the production of goods • It integrates the design process with materials, manufacturing methods, process planning, assembly, testing, and quality assurance • Requires designers have a fundamental understanding of the characteristics, capabilities, and limitations of materials, manufacturing processes, and equipment

  27. Design for Manufacturing • Designers need to understand variability in: • Machine performance • Dimensional accuracy • Surface finish • Processing time • Effect of processing method on quality

  28. Manufacturing Processes • Over 300 individual manufacturing processes have been identified in the industrial environment • Grouped into several families of processes sharing common characteristics

  29. Manufacturing Processes • Broad categories of processing methods for materials include: • Casting • Forming and shaping • Machining • Joining • Finishing • Nanofabrication

  30. Manufacturing Processes • Casting • Expendable and permanent molds • Forming and Shaping • Rolling, forging, extrusion, sheet forming, powder metallurgy • Machining • Turning, boring, drilling, milling, planing, shaping, broaching, grinding • Chemical and electrical maching • High-energy beam machining

  31. Manufacturing Processes • Joining • Welding, brazing, soldering, diffusion bonding, adhesive bonding, mechanical joining • Finishing • Honing, lapping, polishing, deburring, surface treating, coating, plating • Nanofabrication • Nano = 1/billion • Etching techniques, electron-beams, laser-beams

  32. Casting • Starting material is heated sufficiently to transform it into a liquid or highly plastic state • Casting process at left and casting product

  33. Forming or Shaping • Starting workpart is shaped by application of forces that mareial plastically flow and get desired shape • Examples: (a) forging and (b) extrusion

  34. Machining Process • Excess material removed in the form of chips with the help of cutting tool from the starting piece so what remains is the desired geometry • Examples: (a) turning, (b) drilling, and (c) milling

  35. Joining Process • Two or more parts assembled together to make single part. • Two types:- • Permanent : like welding, brazing, adhesive bonding • Non Permanent joining: Nut Bolt, Screw etc

  36. Finishing • Lapping, • Polishing • Deburring • Surface treating • Coating • Plating

  37. Nanofabrication • Nano = 1/billion • Etching techniques, • electron-beams, • laser-beams

  38. Manufacturing Processes • Each manufacturing process has its own advantages and limitations • Selection of a particular manufacturing process depends not only on the shape to be produced but on factors related to material properties • For example, brittle materials cannot easily be shaped or formed, but can be cast, machined or ground

  39. Current Trends • Today engineering and manufacturing firms rely heavily on the use of CAD, CAE, and CAM techniques • CAD – Computer Aided Design • CAE – Computer Aided Engineering • CAM – Computer Aided Manufacturing

  40. Current Trends • CAD • Visualization in Engineering Design • CAE • Numerical Methods • CAE Modeling & Digital Simulation • Finite Element Analysis • CAM • Manufacturing Processes CNC

  41. Current Trends • CIM – Computer Integrated Manufacturing • In simple terms, methodology where applicable engineering and manufacturing data is available to the entire business enterprise • Common CIM Technologies • CNC – Computer Numerical Control • Adaptive Control • Industrial robots • Automated handling of materials • Automated and robotic assembly systems • JIT – Just-in-Time production • FMS – Flexible manufacturing systems • Artificial intelligence

  42. Current Trends • Benefits • Better use of materials, equipment & personnel • Better control of production and management of the total manufacturing operation • Greatly reduced duplicated information • Responsiveness to rapid changes in market • High quality products at a lot cost

  43. Quality • Product quality is one of the most important aspects of manufacturing • Directly influences marketability of a product – customer satisfaction • Formerly – inspect products after they were made • Currently – build quality in from the design stage and subsequent to it • Control of processes is a critical factor in product quality – SPC (Statistical Process Control) • Control the process, not the products • Major goal is to prevent defects from occurring rather than discover them after the fact

  44. Quality • TQM – Total quality management • Quality assurance must be the responsibility of everyone involved in design & manufacturing of a product • Pioneers in quality control • 6 sigma - 99.999997% • Defects reduced to 3 per million

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