KCEP 2113 Basic Manufacturing g Process

Dr. Ahmed Aly Diaa Sarhan Room L8-14 Phone: 4593 Email: ah_sarhan@um.edu,my

Contents

Introduction Casting Processes Machining Processes Deformation Processes Joining Processes Surface Treatments Industrial Measurements

Labs

Recommended Reading
1-Kalpakjian and Schmid (2001): Manufacturing Engineering and Technology. Prentice Hall (recommend for purchase: will be relevant at other times in this course). 2- Kalpakjian and Schmid (2003): Manufacturing Processes for Engineering Materials. Prentice Hall. 3-Ashby and Jones (1980): Engineering Materials. Pergamon Press.

Casting Process Electroplating Shearing and bending Milling Turning Grinding g Welding Sandblasting Precision Measurement Visit( if possible might be limited) Injection Mold Stamping St i Industrial Casting

Why Manufacturing?

Why study Manufacture?

80% of Malaysias foreign direct investment (FDI) goes to manufacturing sector Main contributor to national income (50%) Largest employment sector Contributes to the wealth and growth to the country Electronics industry is the main sector in manufacturing Improves p society y economically, y, socially y and technologically

Manufacturing core to economic activity! As a designer: understand the limitations available

Tolerances Production rates Economic issues

In general: develop analytic skills, specifically for process oriented tasks

What is Manufacturing?

Brief History y of Manufacture (BCE)

Manufacture is derived from two Latin words manus (hand) and factus(make); the combination means made by hand M d b Made by h hand d accurately t l d described ib d th the manual l methods used when the English word manufacture was first coined around 1567 A.D. AD Most modern manufacturing is accomplished by automated and computer-controlled p machinery y that is manually supervised

< 4000 BC: Casting, g hammering, g stone tools 4000-3000 BC: casting with lost wax, stamping, sta p g, soldering so de g 3000-2000 BC: Bronze, wire drawing, sheet formation riveting formation, riveting, brazing 2000-1 BC: Cast iron, Steel, coins, welding

Brief History of Manufacture (CE)

Brief History of Manufacture (1900s)

1-1500: blast furnaces, forging armour and steel swords swords, 1500-1700: cast iron cannon, water power for metalworking 1700-1800: Extrusion (pipes), rolling iron bars lathe bars, 1800-1900: steam hammer, continuous rolling, lli vitrified it ifi d grinding i di machine hi

1900-1920: oxyacetylene welding, high speed machining 1920-1940: die casting, tungsten carbide tools, mass production, plastics 1940 1950 hi 1940-1950: high h precision i i l lost t wax, steel t l extrusion, t i powder metals 1950 1960: chemical machining 1950-1960: machining, automatic control 1960-1970: single crystal turbine blades, numerical control 1970-2000: vacuum casting, rapid solidification, rapid prototyping, etc!

Manufacturing
Fundamental of Engineering Science

What is Manufacturing Processes?

Raw Material

M t i lT Material Transformation f ti Process

Assembly

Product

Manufacturing g is the application pp of p physical y and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products; Manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations Manufacturing adds value to the material by changing its shape or properties, or by combining it with other materials that have been similarly altered

Machine and Automation

Materials in Manufacturing

Materials in Manufacturing

Most engineering materials can be classified into one of three basic categories: 1. Metals- ferrous and non ferrous/ alloys 2. Ceramics 3. Polymers Their chemistries are different, different their mechanical and physical properties are dissimilar, these differences affect the manufacturing processes that can be used to produce products from them. In addition to the three basic categories, there are: 4. Composites nong mixtures of the other homogeneous three basic types rather than a unique category

Various new materials are available today in the forms of alloys alloys, having different characteristics and advantages. Materials selection is critical in manufacturing for it contributes to the performance, cost and manufacturability of the component to be p produce.

Material Selection

Manufacturing Processes
Two basic types of process operations: 1. Processing operations - transform a work material from one state of completion to a more advanced state state. Operations that change the geometry, properties, or appearance of the starting material 2 Assembly operations - join two or more components in order to 2. create a new entity Types of Assembly operations a. a Joining processes welding, welding brazing brazing, soldering soldering, and adhesive bonding b. Mechanical assembly fastening by mechanical methods: use of screws, bolts, nuts, other threaded fasteners, press fitting, expansion fits

Properties Processes compatibility Manufacturing issues ( cost, lead time etc) Dimensions and complexity Availability Finishing and appearance

Processing Operations
Shaping operations
Three categories of processing operations: 1. S Shaping ap g ope operations at o s - a alter te t the e geo geometry et y of o the t e starting sta t g work material 2. Property-enhancing operations improve physical properties ti of f the th material t i l without ith t changing h i its it shape, h e.g.. Heat treatment of metals and glasses; sintering of powdered metals and ceramics 3. Surface processing operations - performed to clean, treat, coat, or deposit material onto the exterior surface of f the th work. k (e.g. ( Cleaning; Cl i surface f t treatments t t like lik sand d blasting; coating and thin film deposition

How do you change/alter the shape/dimension of a material?

Shaping Operations four categories

1.

Material Removal
Material removal processes - starting material is a solid (ductile or brittle), from which material is removed so resulting part has desired geometry Excess material removed from the starting workpiece so geometry. what remains is the desired geometry. Examples: machining such as turning, drilling, and milling; also grinding and nontraditional processes

2.

3.

4.

Material removal processes - starting material is a solid (ductile or brittle), from which material is removed so resulting part has desired geometry Deformation eo a o p processes ocesses - s starting a g material a e a is sa ductile solid (commonly metal) that is deformed Particulate processing - starting material is a powder, and the powders are formed into desired g geometry y and then sintered to harden Solidification processes - starting material is a heated liquid or semi-fluid that solidifies to form part geometry

Cutting and Machining (illus)

Deformation

Deformation processes - starting material is a ductile solid (commonly metal) that is deformed. Starting work part is shaped by application of forces that exceed the yield strength of the material Examples: (a) forging, (b) extrusion

Rolling (illustration)

Forging (illustrations)

Particulate Shaping

Solidification

Particulate processing - starting material is a powder, and the powders are formed into desired geometry and then sintered to harden. Starting materials are powders of metals or ceramics ceramics. Usually involves pressing and sintering, in which powders are first squeezed in a die cavity and then heated to bond the individual particles ti l

Solidification processes - starting material is a heated liquid or semi-fluid that solidifies to form part geometry. Starting material is heated sufficiently to transform it into a liquid or highly plastic state Examples: Casting for metals, molding for plastics

Sand Casting (illustration)

Important aspects:

Fluid flows Cooling rates M ld d Mould design i

Property enhancement

Surface Modification

Annealing Hardening Heat treatment

Surface S rface preparation preparation- deburring deb rring Surface coatingSurface texturing

Metal Finishing (illustration)

Assembly Processes/Joining method

All previous processes have been for single parts Most products contain several parts

Need to join these parts Welding Adhesive bonding Mechanical fastening

Three j joining g methods will be considered:

Joining (illustrations)

Course Outcomes
Determine the suitability of manufacturing process in order to fit the requirement of the product/process itself. Understand the basic manufacturing process for metals, non-metals, polymers and composites. polymers, composites Understand the casting process and able to design a mould for this process. Use measurement equipments in regards with suitability of the product requirement and able to determine fits and tolerances of the product. product Understand surface treatment process. Understand conventional machining and able to determine cutting tool wear and tool life. Understand various type of joining process, which commonly used in the industry industry. Understand method in polymer and composite processing.

E d End