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IntroductionManufacturing Processes© Su-Jin Kim GNU
Manufacturing Processes(기계공작법)
Introduction(서론)
Associate Professor Su-Jin Kim
School of Mechanical EngineeringGyeongsang National University
IntroductionManufacturing Processes© Su-Jin Kim GNU
What is Manufacturing?
• Manufacturing(제조) is the process of converting raw materials(재료) into products(제품).
• Nations with largest GDP growth concentrated on high value‐added products, such as automobiles and machinery.
Powder BreadManufacturing?
IntroductionManufacturing Processes© Su-Jin Kim GNU
What did we make?
Paper Mask Paper+Bamboo Kite Pet bottle Rocket
Chopstick Gun Paper+Bamboo Airplane
Who to make it?
Manufacturing Process
IntroductionManufacturing Processes© Su-Jin Kim GNU
Materials
The types of materials(재료) generally used in manufacturing:
1. Metals : Steels, Aluminium, copper2. Plastics3. Ceramics4. Composite materials (복합재료)
IntroductionManufacturing Processes© Su-Jin Kim GNU
Metals
• Iron (Fe): Cast iron, Steel, Carbon steel, High strength steel, Stainless steel, Tool steel
• POSCO: http://www.posco.com ‐> Products and Technology
• Copper (Cu), Brass (Cu+Zn,Zinc), Bronze (Cu+Sn,Tin)• Aluminum (Al), Duralumin (Al+Cu+Mg+Mn)• Lead, Titanium, Nickel, (Zinc), Gold, Silver
IntroductionManufacturing Processes© Su-Jin Kim GNU
Polymer (Plastic)
• Thermoplastics: Nylon, Polyethylene, Polystyrene, Vinyl• Thermosets: Epoxy, Phenolic, Polyester• Elastomer: Rubber• LG Chemical: http://www.lgchem.com product
IntroductionManufacturing Processes© Su-Jin Kim GNU
Ceramics
• Clay, Glass (SiO2), Diamond (C), Alumina (Al2O3), Semiconductor (Si+P+B)
IntroductionManufacturing Processes© Su-Jin Kim GNU
Composite
• Reinforced plastics, Concrete (Cement + Sand), Concrete‐steel wire, Wood, Polywood, Polymer matrix
• FRP, Glass reinforced plastic, Carbon reinforced plastic• Hankuk fiber: http://fiber‐x.com
IntroductionManufacturing Processes© Su-Jin Kim GNU
Material property ~ Process
• Melting temperature ~ Casting• Harness ~ Machining, Grinding• Toughness (Ductile‐Brittle) ~ Forming• Electric property ~ EDM, Welding
Properties Metal Plastic Ceramic
Melting temperature 1,000℃ 200℃ 3,000℃Strength 400MPa 10MPa -300MPa, +50MPaToughness Ductile Ductile BrittleHardness High Low Very HighT. E. conductivity High Low LowStiffness (=E) High Low HighChemical stability Mid High Very highDensity High Low HighPrice High Low High
IntroductionManufacturing Processes© Su-Jin Kim GNU
Melting temperature°C Ceramics Metals Polymers Composites
4000
Graphite
Tungsten 3400
3000 SiC
MgO
Al2O3 2052
2000 Silicon Platinum Cermets
Iron 1500, Ti
Copper
1000 Gold, Silver
Al 660, Mg
Zinc, Lead PE, PS FRP
IntroductionManufacturing Processes© Su-Jin Kim GNU
Material & ProcessMaterials Process Products
MetalsMachiningFormingCasting
AxisCrank armEngine housing
Plastics Injection molding Toy
Ceramic Sintering Cutting tools
Joining processesWeldingMechanical assembly
ShipCar
Silicon Deposition, Etching Memory
IntroductionManufacturing Processes© Su-Jin Kim GNU
Manufacturing Process
Market &Specification
ConceptualDesign
Design forManufacture
Unit Manufacturing
Assembly andJoining
•Machining•Injection molding•Casting•Stamping•Chemical vapor deposition
•Welding•Bolting•Bonding•Soldering
ProductSell
IntroductionManufacturing Processes© Su-Jin Kim GNU
Manufacturing Attributes forDecision Making1. Cost(비용)2. Quality(품질)3. Rate(생산성)4. Flexibility(유연성)
IntroductionManufacturing Processes© Su-Jin Kim GNU
Casting (주조)
1. Cost: Expensive $100 ‐ $10,0002. Quality: Low quality, 1mm3. Flexibility: Very flexible, Good for large parts4. Rate: Very slow 1 hour
Engine housingCasting
IntroductionManufacturing Processes© Su-Jin Kim GNU
Plastics Injection (사출)
1. Cost: Cheap, $0.1 , Expensive mold, over $10,0002. Quality: Very high 0.05mm3. Flexibility: Opening for ejection , Mass production4. Rate: Very fast (5 sec)
Injection mold & PlasticInjection machine
IntroductionManufacturing Processes© Su-Jin Kim GNU
Forming (성형)
1. Cost: Cheap $0.1 ‐ $100, Expensive equipment over $100,000
2. Quality: Reasonable 0.1mm3. Flexibility: Shapes limited, Mass production4. Rate: Fast (cycle time 5 sec)
Side panel of automobilePress machine
IntroductionManufacturing Processes© Su-Jin Kim GNU
Machining (절삭가공)
1. Cost: Expensive $100(Cylinder)‐$10,000(Mold)2. Quality: Very high, precise 0.01mm3. Flexibility: Any shape cut by tool, Small production4. Rate: Slow (1min‐2day)
Turning cylinderPress mold machining
IntroductionManufacturing Processes© Su-Jin Kim GNU
Welding (용접)
1. Cost: Cheap, but expensive labor2. Quality: Wide range3. Flexibility: Manual vs Robot4. Rate: Slow in general
Very Large Crude Carrier (VLCC)
IntroductionManufacturing Processes© Su-Jin Kim GNU
Thinfilm fabrication (반도체공정)
1. Cost: Very expensive equipments, $Millions2. Quality: Very high, Nanometer pattern3. Flexibility: Any shape in 2‐D4. Rate: Soso
Lithography system, 110nm resolution
IntroductionManufacturing Processes© Su-Jin Kim GNU
Reference
• Manufacturing Processes SME http://www.youtube.com/playlist?list=PL3AFB507B668AF162
• Plastic, Casting, Machining, Forming http://www.custompartnet.com