1 / 36

ISAT 430

ISAT 430. Introduction. Dr. Ken Lewis. Spring 2001. Preliminary Stuff. Professor – Dr. Ken Lewis Office – ISAT 125 Phone – 2753 Email – lewisgk Office hours – Whenever you want (assuming no other conflicts) Call me? – ANYTIME! Ask questions? -- ANYTIME!.

phelan-christensen
Download Presentation

ISAT 430

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. ISAT 430 Introduction Dr. Ken Lewis Spring 2001

  2. Preliminary Stuff • Professor – Dr. Ken Lewis • Office – ISAT 125 • Phone – 2753 • Email – lewisgk • Office hours – Whenever you want (assuming no other conflicts) • Call me? – ANYTIME! • Ask questions? -- ANYTIME! Dr. Ken Lewis ISAT 430

  3. Meeting Place and Times -- Syllabus is WRONG!!!! • Lectures: MW 1010 – 1100 in room 148 • Recitations: Tu 1100 – 12345 in room 1027 Dr. Ken Lewis ISAT 430

  4. Preliminary Stuff -- Grading Dr. Ken Lewis ISAT 430

  5. Preliminary Stuff • Units • If a problem uses units, be explicit and clear, and use units. • Units are your friend. Dr. Ken Lewis ISAT 430

  6. Dr. Ken Lewis ISAT 430

  7. ISAT 430 Manufacturing Processes Dr. Ken Lewis Spring 2001

  8. What are we about? Material Manipulation • conversion & forming, the molding and shaping of metals, glasses, ceramics, polymers and composites. From the earth to a part. • removal, the machining, grinding, cutting, lithography and etching of materials. Getting rid of the excess stuff. • joining, the welding, brazing, and soldering of materials. The sticking of things together. • Assembly, mechanical assembly and electronics manufacturing. Putting together dissimilar materials. Dr. Ken Lewis ISAT 430

  9. We will delve into the sciences which are behind these processes. Dr. Ken Lewis ISAT 430

  10. Objectives of the Course • We will look at the following: • How does stuff come from the Earth and become cool and useful? • What is the “process – structure – property – performance continuum”? • What are the material concerns that we have as we make a material selection to make a particular product? • What are the practical concerns that we have? Dr. Ken Lewis ISAT 430

  11. What will we look at first? • The process – structure – property – product – performance continuum. • An overview of the main methods of manufacturing. • The materials • The methods of change • What factors affect the selection of manufacturing processes. Dr. Ken Lewis ISAT 430

  12. Process-Microstructure-Property-Product Performance Continuum Product Performance or Function Limit Composition & Structure Indicate Affects Changes Control Dictate Changes Properties/ Behavior Synthesis/ Processing Dictate Dr. Ken Lewis ISAT 430

  13. What are Manufacturing Processes??? Dr. Ken Lewis ISAT 430

  14. Manufacturing Processes of Today • Essentially, these are the ways that Man has found to take the characteristics of a material (mud, gold, a tree, a pile of ore, sea water….. ) and: • Make parts or things • Make things of greater value • Make things do something Dr. Ken Lewis ISAT 430

  15. Manufacturing Processes of Today2 • These processes change or alter the materials • State • Geometry • Properties • Microstructure • Appearance • ERGO “Value” Dr. Ken Lewis ISAT 430

  16. Primary Goals of a Manufacturing Process • Produce components from selected materials • At the lowest possible cost • In the correct shape • Having optimum properties for its proposed use. • Key Point – manufacturing adds value to the materials. Dr. Ken Lewis ISAT 430

  17. A Small History of Manufacturing

  18. History • First came the discovery of materials. • Wood tools • Fibers • Cloth • shelter • Clay • Pottery • Bricks • Metals • Copper • Bronze • iron Note that not only was the material discovered but processes which would change the materials form had to be Discovered. Dr. Ken Lewis ISAT 430

  19. History • All that was available for millennia was simple hand crated materials. • One of a kind • Produced in a shop fashion. • Even when the Romans were churning out armor and weapons, it was just a shop multiplied many times. • First step forward was the discovery of ‘division of labor’ • Dividing the total process into a number of sub processes and making an individual worker and expert in just one or two sub processes. Dr. Ken Lewis ISAT 430

  20. The Industrial Revolution (1760 – 1845) • Four things changed production forever. • The steam engine • Machine tools • Textile machinery • The factory system Dr. Ken Lewis ISAT 430

  21. History3 – The Industrial Revolution • All was what are called “cottage industries”. • The Industrial Revolution • Change was driven by the discovery of a new source of power “STEAM”! • John Watt invented the steam engine. • Steam power quickly replace the traditional water wheels, animal wheels, and windmills. • Developed in England • England tried to keep the new technologies to give themselves an economic edge • Didn’t work. Dr. Ken Lewis ISAT 430

  22. History4 – The Industrial Revolution2 • Possible only because of machine tools... • John Wilkinson invented the boring machine in 1775. • Allowed Watts to make the steam engine • Henry Maudsley developed the screw cutting lathe in 1800 • Allowed turning with much greater precision and speed. • The textile industry was vastly changed • The spinning jenny • Power loom • Jacquard loom Dr. Ken Lewis ISAT 430

  23. History5 – The Industrial Revolution3 • The factory system • Division of labor • Several fold increase in labor efficiency Dr. Ken Lewis ISAT 430

  24. History6 • Other forces • Eli Whitney in the US developed the concept of interchangeable parts. • Precursor to mass production and assembly lines. • Henry Ford introduced the assembly in Detroit in 1913 Dr. Ken Lewis ISAT 430

  25. Classification of Manufacturing Processes Manufacturing Processes Conversion Processes Processing Operations Assembly Operations Permanent joining processes Property enhancing processes Surface processing operations Extraction Mechanical fastening Shaping processes Heat treatment Surface cleaning Coating/ depositn. Threaded fasteners Particulate processing Forming processes Material removal Permanent fastening methods Casting Adhesive bonding Brazing & soldering Welding Dr. Ken Lewis ISAT 430

  26. Manufacturing Processes • Conversion • Transform materials from their raw or natural state to a more useful semi-finished form • Processing Operations • Transform a material in transit from one state of completion to a state closer to the desired product. • Assembly Operations • Unit separate parts to from a new entity Dr. Ken Lewis ISAT 430

  27. Conversion Processes • Extraction • Conversion of metals from their natural ores by mining, separation and reduction to the metallic state. • Casting • shaping by the transformation of the liquid to the solid state; • exploits the fluidity of a liquid as it takes shape and solidifies in a mold. Dr. Ken Lewis ISAT 430

  28. Processing Operations • Add value by: • Changing the geometry • Properties • Appearance • Achieved by the controlled application of thermal, mechanical, electrical or chemical energy to accomplish the above Dr. Ken Lewis ISAT 430

  29. Processing Operations2 • Can be divided into three divisions • Shaping Operations • Property Enhancing Operations • Surface Processing Operations Dr. Ken Lewis ISAT 430

  30. Shaping Operations • Processes that alter the geometry and maybe the physical and mechanical properties. • Examples • Casting (of metals) • Molding of plastics • Deformation processes – sheet forming, forging, extrusion, drawing, etc., • Particulate processing – powder metallurgy • Material removal processing – machining, cutting and grinding Dr. Ken Lewis ISAT 430

  31. Property Enhancing Operations • Operations that manipulate or enhance both the physical and mechanical properties of the starting solid semi-finished material or product. • Control of properties of a part during manufacture • Allow properties to be matched to the application • Especially when the magnitude or directionality of the mechanical properties is important Dr. Ken Lewis ISAT 430

  32. Property Enhancing Operations2 • Examples • Heat treatment • Organic composite cure schedules • Deformation processes Dr. Ken Lewis ISAT 430

  33. Surface Processing Operations • Operations performed to clean, treat, coat, or deposit material onto the exterior surface of the part • Examples • Electroplating – anodizing • Nit riding • Case hardening • Grinding • painting Dr. Ken Lewis ISAT 430

  34. Assembly Operations • Joining Processes • Mechanical Assembly Dr. Ken Lewis ISAT 430

  35. Joining Processes • Uniting individual workpieces • Permanently • Semi-permanently • Melting, using adhesive bonding materials • Usually results in added weight • Examples • Welding • Brazing & soldering • Adhesive bonding • Solid state bonding. Dr. Ken Lewis ISAT 430

  36. Mechanical assembly • Units sub assemblies without melting • Examples • Semi-permanent • Nuts • Bolts • Screws • Threaded fasteners • Permanent • Press-fitting • Expansion fits. Dr. Ken Lewis ISAT 430

More Related