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Environmentally Conscious Design & Manufacturing

Environmentally Conscious Design & Manufacturing. Class 5: Manufacturing. Prof. S. M. Pandit. Manufacturing. Agenda What is a Manufacturing Enterprise? Systems View - Manufacturing Manufacturing Processes Modeling. Manufacturing Enterprise. Marketing. Product Design.

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Environmentally Conscious Design & Manufacturing

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  1. Environmentally Conscious Design & Manufacturing Class5: Manufacturing Prof. S. M. Pandit

  2. Manufacturing Agenda • What is a Manufacturing Enterprise? • Systems View - Manufacturing • Manufacturing Processes • Modeling

  3. Manufacturing Enterprise Marketing Product Design Manufacturing Enterprise Finance Manufacturing Management Technology

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

  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. Manufacturing Enterprise - Manufacturing Manufacturing Traditional • Machining Single and multi-point cutting • Joining, Forming, Casting .. • Metrology Non-Traditional • Laser Cutting • Abrasive jet machining • Electrochemical machining • Explosive deformation and joining • Hydroforming Laser Cutting http://www.servicemetal.com

  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. Manufacturing Enterprise - Manufacturing CNC information flow http://www.ab.com/cnc

  9. Systems View Finite-Element Analysis Computational Fluid Dynamics Kinematic / Dynamic Analysis Design Visualization and Animation Drafting CAM

  10. Manufacturing Processes • Solidification • Forming Processes • Particulate Processing • Material Removal • Joining

  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. Manufacturing Processes - Solidification 1 Sand Casting Sand Core Sprue Riser Parting Line

  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, T0 , and the ambienttemperature, T . ‘h’, As , r, V, and Cp are the convective heat transfer coefficient, Surface area, density, Volume, and specific heat capacity, respectively.

  14. Manufacturing Processes - Forming • Polymer processing • Cost advantages • Rheological properties and temperature dependent properties • Temperature & pressure Molding Injection Blow Extrusion Rolling Forging • Influence on grain structure • Diffusion processes • Directional properties Reference: Physical Metallurgy by Dieter

  15. Manufacturing Processes - Powder Metallurgy 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. Powder production Blending Compaction Sintering

  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. Machining - 2

  18. Machining - 3

  19. Machining - 4 Radial drilling machine

  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. Machining - 6 Electro-chemical machining of blades

  22. Machining - 7 Abrasive jet machining - schematic

  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. Machining - 9 • Electron - beam machining: • Intense energy densities • Non - contact • Clean http://www.llnl.gov/IPandC/op96/09/9c-com.html

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