Introduction to Manufacturing Processes · 2015. 11. 18. · Plastics Manufacturing Processes Liquid reactants are mixed and then pressurized into a mold. No heat is needed. Curing

Introduction to Manufacturing

Processes

Product Creation Cycle Design → Material Selection → Process

Selection → Manufacture → Inspection →

Feedback

Typical product

cost breakdown

Products and Manufacturing

Manufacturing Process

A sequence of operations and processes

designed to create a specific product.

The process of turning materials into a

product.

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Engineers in Manufacturing

Manufacturing Engineer Select and coordinate specific processes and equipment.

Industrial Engineer Responsible for the manufacturing system design.

Materials Engineer Develop and select materials based on desired material properties and manufacturing processes.

Manufacturing System Designs

Small quantities of products.

Large variety of products.

Products move through the shop to various machines.

General-purpose machines.

Job Shop

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Flow Shop

Larger quantities of products.

Production line.

Special purpose machines.



Linked-Cell Shop

Manufacturing and subassembly cells

connected to final assembly.

Lean production system.

One piece flow system.



Project Shop

Product being manufactured cannot be easily moved during production.

Production processes are brought to the product.

Examples: Bridges, ships, large airplanes, locomotives, large machinery.



Continuous Process

Large plants.

Utilized in the manufacture of liquids, oils, gases, and powders.



Lean Manufacturing

100% “good” units flow from process

to process.

Integrated quality control (IQC).

All employees are inspectors.


Basic Manufacturing Processes

Casting and Foundry

Forming or Metalworking

Machining

Joining and Assembly

Rapid Prototyping

Other

Casting and Foundry Processes

In one step, raw materials are transformed

into a desirable shape.

Parts require finishing processes.

Excess material is recyclable.

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Basic Casting Process

A mold is created – A cavity that holds the molten

material in a desired shape until it is solidified.

• Multiple-use mold

• Single-use molds

Material is heated to a specified temperature.

Molten material is poured into a mold cavity.

Molten material solidifies into the shape of the cavity.

Casting or mold is removed.

Casting is cleaned, finished, and inspected.

Utilizes material that has been cast.

Modify the shape, size, and physical

properties of the material.

Hot and cold forming.

Forming and Metalworking Processes



Rolling – Material passes through a series of

rollers, reducing its thickness with each pass.

Forging – Material is shaped by the controlled

application of force (blacksmith).

Wire, rod, and tube drawing – Material is pulled

through a die to produce a uniformed cross section.

Extrusion – Material is compressed and forced

through a die to produce a uniformed cross section.


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Cold forming and forging – Slugs of material

are squeezed into dies.


Machining Processes

Controlled removal of material from a part to

create a specific shape or surface finish.

Cutting element is used.

Movement must exist between the part and

cutting element.

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Turning Processes

Operations that create cylindrical parts.

Work piece rotates as cutting tool is fed into

the work.

Machining Processes

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Turning Processes

Lathes and turning centers.

Processes include: Straight, taper, contour

turning, facing, forming, necking, parting,

boring, threading, and knurling.

Machining Processes


Milling Processes

Operations that create flat or curved

surfaces by progressively removing

material.

Cutting tools rotate as the work piece is

secured and fed into the tool.

Machining Processes

Milling Processes

Mills – Vertical and horizontal.

Processes include: Surfacing, shaping,

forming, slotting, T-slotting, angle, straddle,

dovetailing, and slab milling.

Machining Processes

Drilling Processes

Operations that create holes.

Cutting tools rotate and are fed into

nonmoving secured work pieces.

Machining Processes

Drilling Processes

Drilling and boring machines.

Processes include: Drilling, counter drilling,

step drilling, boring, counter boring,

countersinking, reaming, spot facing, and

tapping.

Machining Processes

Shearing Processes Operations that break unwanted material away

from the part.

A material is placed between a stationary and

movable surface. The movable surface (blade,

die, or punch) applies a force to the part that

shears away the unwanted material.

Machining Processes

Automated hole punch, squaring shear, and

rotary cutter.

Processes include: Shearing, blanking, cutoff,

and parting; punching, perforating, and slotting;

notching, lacing, and trimming.

Shearing Processes

Machining Processes

Abrasive Machining Processes Operations in which small particles of materials

(abrasives) remove small chips of material upon

contact.

Drum, disc, and belt sanders; surface, vertical

and horizontal spindle; disc grinders; media

blaster; tumblers.

Machining Processes

Thermal and Chemical Processes

Operations that cut and shape materials

through chemical means.

No mechanical force is used.

Machining Processes

Electrical discharge, electrochemical,

chemical, laser, electron beam, flame

cutting, and plasma-arc cutting.

Processes include: Grinding, sawing,

cutting, machining, milling, blanking, and

etching.

Heat Treating Processes

Controlled heating and cooling of a material

to alter its properties while maintaining its

shape.

Properties include: Strength, toughness,

machinability, wear resistance, and corrosion

resistance.

90% of heat treating is performed on steel and

other ferrous metals.

Heat Treating Processes

To aid in the manufacturing process, materials

can be treated to be weak and ductile and

then can be re-treated to provide high

strength.

Can also occur incidentally during the

manufacturing process.

Joining and Assembly Processes

Can you think of a product with only one

part?

Most products consist of multiple parts that

are assembled to form a finished product.

Typical assembly processes include:

Mechanical fastening; soldering and

brazing, welding; adhesive bonding.

Joining and Assembly Processes Mechanical Fastening

Use physical force to hold parts together.

Mechanical fasteners or part design.

Screws, bolts, nails, rivets, cotter pins,

retaining clips, and edge design.


Joining and Assembly Processes Welding

Operations that use heat, pressure, or

both to permanently join parts.

Gas, arc, stud, spot, forge, roll laminating,

resistance, and induction welding.


Joining and Assembly Processes Adhesive bonding

Bonding of adjoining surfaces by filling the

gap between each surface with a bonding

material.

Glue, cement, thermoplastic, thermosetting,

and elastomers.


Joining and Assembly Processes Soldering and Brazing

Operation in which metal surfaces are

bonded together by an alloy.

Heated molten alloy flows between the

adjoining surfaces.

When the heat is removed, the molten

metal solidifies and the metal surfaces are

bonded.

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Rapid Prototyping

Additive process.

Parts are produced directly from software

applications.

Common rapid prototyping systems include:

stereolithography (SLA), selective laser

sintering (SLS), fused deposition modeling

(FDM), laminated object manufacturing

(LOM), digital light processing (DLP).

Rapid Prototyping

Finished parts can be field tested depending

upon building material.

Created parts can be used to create a mold.

Modifications to design can be implemented

quickly.

Other Manufacturing Processes

Testing

Transportation

Material handling

Packaging

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Material-Specific Manufacturing Processes

Plastic Processes

Ceramic Processes

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Plastics Manufacturing Processes

A rotating screw forces plastic through a

heating chamber and then through a

heated die.

Produces long plastic parts with uniform

cross sections.

Extrusion

Heated plastic is forced by a movable plunger

through a nozzle and then into a mold. The material

fills the mold and then is cooled.

Most widely used high-volume production process.

Plastics Manufacturing Processes Injection Molding

Plastic is melted and poured into a mold –

No pressure or fillers are required.

Plastics Manufacturing Processes Casting

A closed mold is filled with a

predetermined amount of plastic. The

mold is heated, rotated, and then cooled

to create a hollow plastic object with

uniform wall thickness.

Rotational Molding


A solid bottom hollow tube is placed

between two mold halves and heated.

The heated tube is then expanded into

the sides of the mold with compressed

air.

Blow Molding


Liquid reactants are mixed and then

pressurized into a mold.

No heat is needed. Curing time is typically

less than 1 minute.

Reaction Molding

Plastic sheets are heated over an open

mold to a working temperature. Once

workable, a vacuum is applied to the mold,

forcing the plastic sheet to take the shape

of the mold.

Thermoforming

Ceramic Manufacturing Processes

Two distinct classes of materials and

processes exist.

Glass is heated to a molten state, shaped

by viscous flow, and then cooled to

produce a solid.

Crystalline Ceramics

Material is shaped and then heated

to produce a permanent solid.

Manufacturing Importance

Typical product

cost breakdown

Documents

Introduction to Manufacturing Processes · 2015. 11. 18. · Plastics Manufacturing Processes Liquid reactants are mixed and then pressurized into a mold. No heat is needed. Curing