06 Manufacturing Hand Out (20 Mar-08)

8/14/2019 06 Manufacturing Hand Out (20 Mar-08)

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Manufacturing

Engineering MaterialMetals Ferrous / Non Ferrous

Non metals Polymer / Ceramic

CompositesMetal-Ceramic / Metal polymer / Ceramic Polymer

ProcessCasting

FormingMachining

Assembling & Material joining

Surface treatment

Manufacturing process

Manufacturing control

Quality control & Quality assurance systemMeasurement / Testing / InspectionQuality standard

Efficiency controlTQC

TPM


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Ceramic - polymer

Polymers

Metals

Ceramics

Metal - ceramiccomposites

Metal polymer

Engineering Materials

Metal Polymers Ceramic and

others

Composites

Ferrous Non

Ferrous

composites

composites

( Heavy Metals ) 4./.3 (NonferrousAlloy) (Cu), (Ni), (Pb), (Zn), (Sn), (Cr), (W),

(Ta), (Hg), (Au), (Ag), (Pt), (Mo), (Co), (Mn), (V), (Sb), (Cd)

(Light Metals) 4

./.3

(Al), (Mg), (Zr)


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(Ferrous Metals) (Wrought Irons) 1% (Steels)

60HB (C1010)131-170HB

1.(FE) 2. 2 - (Hardness) (Tensile Strength)

(Abrasive Resistance)(Hardening)-(Ductility)(Elongation)

(Machine ability)(Welding ability)3. (Alloying Elements)

4. (Addition Agents)


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2 (Carbon Steels Plain Carbon steels)

2.3

3 1. (Low Carbon Steels Mild Steels) 0.25% 90%

2) (Medium Carbon Steels) 0.2-0.5%

3. (High Carbon Steels) 0.5-1.5%


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1. 2.

3. (Shock Load) 4. 5. 6. 7. 8.

9. 10.


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2) (Alloy Steels) 2 1. (Low Alloy Steels) 8%

1-2%

(Machine Steels)

2. (High Alloy Steels) 8%

- (Stainless Steels)

2.4


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2.4

4075,0002.5Mo20.08121765316

4075,000-20.2132361309

4075,000-20.0891969304

4075,000-20.1581871302

4090,000-20.1571773301

Austenitic

Lb/in2OthersaMnCNiCrFe

Elongation,%Tensile StrengthChemical Analysis,%

Type


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- (Tool Steels) 5% 0.8-2.2% 200-218 HB

(HSS) ( HotHardness/Red Hardness) (End mill) (Tap) (Die) AISI 7

1.High speed Tool Steels 65 HRC 0.7-0.8%2. Hot working Tool Steels 55 HRC 0.4%

3. Cold-working Tool Steels 60HRC 1.0%4. Water-hardening Tool Steels 63 HRC 1.0%

5. Shock-resistant Tool Steels 50HRC b0.5%

6. Mold Steels 40HRC b 0.4%


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1) SAE(The Society of Automotive Engineers) AISI (The American Iron and Steel Institute)

AISI SAE1030Plain Carbon SteelsCarbon 0.30%

- 3.50% 1.55%

-

- 1.75%1.00%

- 1.25% 0.65%

- ( )

- 5.00%- 3.50%

( 1.75%)

31XX

32XX

33XX

3XXX

25XX

23XX

13XX

- Pain Carbon Steels ( )11XX

1XXX

10XX

2XXX

2.5 AISI-SAE


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2) DIN (Deutsche Industrial Norm)

(DIN) (Mid Steels/Low Carbon Steels) 2.7- 2.10

1 2 (DIN) - St 37.12 St 37 (Tensile Strength) 37 (370 MN/m2) 12

0.18%St 37 12

37 (DIN)

St

SIC

SIG/GS

Ge/GG

GH

Te/GT

GTW

GTS

GGG

GK

2.7 (DIN)

(DIN)

11 1611

(Plate)

(Sheet)

4.75

3 - 4.75

3

(Continuous butt-weldpipe)

2.8 2 (DIN)

12

13

16

21

22

23

26

1612

1613

1616

1621

1622

1623

1626

(DIN) St 37.12


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- 15 Cr 4 0.15% 1%

- 25 Cr Mo 44 0.25% 1% (4/4% = 1%) 0.4%(4/10% = 0.4%)

x

- X 210 Cr 12 2.1% 12%

- X 12Cr Ni 188

0.12%

18%

8%

3 C ()

4

10

100

P

S

C

Al

Cu

Mo

V

Cr

Mn

Ni

Si

W

Co3 2.11

2

1

2.11 1 2 315 Cr 4


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-(Cu) 8.9 ./.3 1,073 1,083 C (Corrosion Resistance)

45 100 HB

(Patina) 3

-(Pn)11.2 ./.3 327 C 2.19

- (Zn) 7.2 ./3 419 C

- (Ni) 8 - 8.9./3 1,453C

1.

- (Sn) 7.3 ./3 232 C


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- (W) 19.3./3 3,370C

(Refractory Metals)

- (Mo)10.2 ./3 2,622 C (Stiffness) (Refractory Metals) (Jet)

- (V) 5.7./3 1,715 C (Ferro-vanadium)

-(Co) 8.6 ./3 1,490 C

- (Mn) 7.4 ./3 1,250 C

- (Cr) 6.8./3 1,900C


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3). - (Brass) (Copper Zinc Alloys) 50% 70% (Tombak)CuZn 37 63% 37%

37-42% 15% (Machining)

- (Bronze) (Copper Tin Alloys) 80-98%

- (Aluminum Alloys) 2.14 (Age hardening)


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2.14

2526038000H36

718026000O0.31.210.70.396.53004

2248570000T3

1818527000O

0.50.61.50.54.493.52024

2016524000H18

109013000O0.3--0.6-99.o1100

4015923000H18

77611000O

0.3--0.4-99.51050

%MpaIb/in2SIMnMgFeCuAl

ElongationTensile StrengthTemper

Typical Composition,%code


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Casting Various Mold (cavity for molten metal)

Molding Molding machine Mold (cavity for not polymer)

Rolling Rolling mill Roll (reduce work thickness)

Forging Forge hammer Die (squeeze work to shape)

Extrusion Press Extrusion die (reduce cross section)

Stamping Press Die (shearing, forming sheet metal)

Machining Machine tool Cutting tool (material removal)

Fixture (hold work part)

Jig (hold part and guide tool)

Grinding Grinding machine Grinding wheel (material removal)

Welding Welding machine Electrode (fusion of work metal)

Fixture (hold parts during welding)

Process Equipment Special tooling (function)


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0 0.9982 (20C)

-38.9 13.56 (20)

232 5.52 (232)

327 10.56 (440)

420 6.21 (420)

660 2.35 (760)

1,083 7.84 (1,200)

1,537 7.13 (1,600)

1,170 6.9 (1,300)

1. 2% 1. 2%

2. 2.

3.

3.

4. 4.

5. 1,150 C-1,1250 C 5. ~ 1,536 C

6. 6.

7. 7. 8. 8.

9. 9.

10.10.

Casting ()

Cast iron Carbon Steel


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1,500 1,550C

(Moisture Test) 50 100-110C2

% (FreeMoisture) (Permeability Testing)

( )50. 2,000 CM3

. (Strength Test)

. (Distribution Test)


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(Forming Process) (Roll Forming)

Bloom (150 x 150 m.m)

Billet (40 x 40 m.m) , , Flab () ,

1.1 Flat Rolling1.2 Shape Rolling

1.3 Other Rolling (Ring, Treat, Seamless Tubing, Pipe) (Forging)

2.1 Open-Die Forging

2.2 Closed-Die Forging Hot / Semi-hot / Cold Forging

2.3 Flash Less Forging (Coining)

2.4 Other Forging (Heading, Swaging, Roll Forging, Hobbing)


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5.1

(Stress)

(Plastic) 5.1

1. (Bloom)

150 x 150 .

2. (Billet) 40 x 40.

3. (Slab)


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(Extrusion) (Drawing Process)

3.1 Heat Extrusion , (Ram)

3.2 Import Extrusion

3.3 Drawing Process

(Sheet-Metal Forming)4.1 Shearing Cutting Blanking, Piercing, Cut off,Notching (),

Lancing, Slitting ()

4.2 Bending

4.3 Deep Drawing

4.4 Rubber Forming

4.5 Other Spinning, Explosive, Electro Hydraulic Forming, ElectromagneticForming

(Forming Process) ()


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(Methods of Powder Production) 0.1 1,000

(Sintering)

(Atomization)

5.1 (Mixing) - Lubricants

5.2.1 (Compaction) -

5.2.2 (Power Rolling)

5.2.3 (Power Extrusion)

5.2.4 (Power Forging)

5.2.5 Power Injection - 50% - 80%

5.3 (Sintering Process)

- (Binder)


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(C ) ()

, , 760 900

10 45

1,000 1,150 8 - 45

1,000 1,150 30 - 45 1,100 1,290 30 - 60

Alnico ( Fe, Ni, Al Co) 1,200 1,300 120 150

1,200 1,500 10 - 600

1,430 1,500 20 - 30

2,050 120

2,350 480

2,400 480

:


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Machining ()

- Cutting Tool and Materials Tool Steel (Carbon Steels, Low/Medium alloy

steel) , High Speed (HSS), Cemented Carbides, Cermets ( Binder)

Ceramics ( Al2 O3 , Si3 N4)

- Cutting Process

:- (Turning, (Boring)

(Drilling), (Threading / Tapping) , (Facing), (Shaping/ Planning) , (Broaching), (Sawing),/ (Grinding / Lapping)

:- Ultrasonic Machining , , Electrochemical Machining (ECM) , ECD, ECG, Electric Discharge Machine(EDM : ) , Wire Cut

( ldi )


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(Welding)(Fusion Welding Processes)

1) (Shielded Metal Arc Welding : SMAW)

5000 C

(Slag)

2 (AlternatingCurrent ;AC) (Direct Current ; DC)


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2.0. 2.5 . 3.2 . 4.0 . 5.0 . 6 . 20-550 Amp 3-38 .

2). (Metal Inert Gas Welding : MIG)(Consumable Electrode) (Spool) (Contact Tip)

(Active Gas) Metal Active Gas : MAG CO2 Welding ProcessesMIG MAG AWS. Gas Metal Arc

Welding: MAW (MIG)

3) (Fl C d A W ldi


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3) (Flux-Cored Arc Welding :FCAW) 0.5-4.0 . FCAW

SMAW GMAW 2 - Self-Shielded Flux-Cored Arc Welding

- Gas-Shielded Flux-Cored Arc Welding

FCAW

( )


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Surface Hardening - Induction hardening / Nitro carburizing /

Carburizing / Nitriding

Surface Coating - Painting / Electroplating / Physical and Chemical

vapor deposit / Evaporation coating / Hot dipping /

Phosphate coating / Anodizing

Chemical power - Alkaline Cleaning

- Solvent Cleaning

- Acid Cleaning

Physical power

- Blast Finishing

- Barrel Finishing

- Vibratory Finishing

- Polishing Finishing

- Ultrasonic Cleaning

Chemical & Physical Power - Electro Chemical Cleaning

Surface Engineering ()

(S f C i )


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(Surface Coating)

- - - - -

- 1. (Electroplating)

Electrolyte

0.05 . Hard Chromium Plating 70HRC

2 (H t Di i )


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2. (Hot Dipping)

(Zn) (A) (Pb) 0.04-0.09 . 450 C 3.(Phosphate Coating)

0.0025-0.05 . 4. (Chromate Conversion Coating)

Sodium Potassiumchromate Hydrofluoric acid (Complexchromium compound) Phosphate Coating5. (Anodizing)


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Introduction to Manufacturing

Manufacturing Enterprise=

Inputs Outputs

/


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Organizing for Manufacturing

E x a m p l e o f M a n u f a c t u r i n g O r g a n i z a t i o n C h a r t

H u m a n R e s o u r c e s

Q u a l i t y A s s u r a n c e

P l a n n i n g

M e l t i n g

F o r m i n g

P a c k i n g

P r o d u c t i o n

M a i n t e n a n c e

M o u ld & D e s i g n

T e c h n i c a l I m p r o v e m e n t

E n g i n e e r i n g

F i n i s h e d g o o d s

S u p p l i e s & S p a r e p a r t s

R a w M a t e r ia l s

W a r e h o u s e & S t o r e

F a c t o r y M a n a g e r

M a r k e t i n g

S a l e s

M a r k e t i n g M a n a g e r

F i n a n c e & A c c o u n t i n g

P u r c h a s i n g

F i n a n c e & A d m i n . M a n a g e r

M a n a g i n g D i r e c t o r


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Design, material, and production

Engineering MaterialProcess

Quality assurance

Efficiency control


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Major contents of Manufacturing

-Product design

-Process design-Selecting material

-Selecting Manufacturing Process

-Computer Integrated Manufacturing

-QA & TQM

-Product Liability

-Manufacturing Cost

-Lean Production

C t I t t d M f t i (CIM)


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Computer-Integrated Manufacturing (CIM)Major goals of automation in manufacturing facilitiesMajor goals of automation in manufacturing facilities

-Integrating various operation to improve productivity

-Increase product quality and uniformity

-Minimize cycle times-Reduce labor costs

Effectiveness of CIMEffectiveness of CIM

1.Responsiveness to rapid changes in market demand and product modification

2.Better use of materials machinery and personal, and reduction in inventory

3.Better control of production and management of the total manufacturing operation

4.Manufacturing of high-quality product at low cost

Recent utilization of Computer in manufacturing applicationRecent utilization of Computer in manufacturing application

-Control and optimization of processes

-Material handling

-Assembly

-Automated inspection and testing of products

-Inventory control and etc.


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Out line of CIM major applications1.Computer numerical control (CNC)

2.Adaptive control (AC)

3.Industrial robots

4.Automated handling

5.Automated and robotic assembly systems

6.Computer-aided process planning (CAPP)

7.Group technology (GT)

8.Just-in-time production

9.Cellular manufacturing

10.Flexible manufacturing systems (FMS)11.Expert systems

12.Artificial intelligence (AI)

CIM


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CIM Inventory CIM

1. CNC Movement (Machine component) (Code)

NumericalNumerical control 1950 Automation Advance

2. Adaptive Control

- Parameter() Manufacturing process Adjust Optimize production rateProduct Quality minimize cost

3. Industrial Robot- Process / , - Human error, Variability, Quality, Productivity- Welding, Assembling

4. Automated Handling

Computer work in process

- Store - Machine Machine- - Shipment

5. Automated and Robotic assembly system

- - Robot

6. Computer Aided Process Planning- ProductivityProcess


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1. 2. (Tooling) Tooling

3. Engineering changerequirement

4. - - - - (Motion and Time Study)-

- - 5.

Quality


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Quality /

Quality Control

Quality Assurance


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Quality Assurance

/


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Highlight of Quality Management1. (TQC) n 4

1.1 no PDCA n Cycle of Administration1.2 o- action o (Fact &Data) no o n 1.3o-o Standard n 1.4 o (Kaizen) n - n

2.

TQC o n

2.1Business Management Activities o n Daily Administration Policy Management nn

2.2Activities at the Worksite o n QC Circle Activities Suggestion System Other small group activities


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3. o n Quality Control } in Top Management Front line employee

n Companywide Quality Control.4. o nKaizen Small Continuous Improvement n

5. o - -o BottomUp n QC Circle, 5 - , Safety

Suggestion n o n n n - o Morale n d - o o n Skill o{

6. o - - Creative Suggestion o- n

o one o Implement n 90% n o n } o-


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7. promote Project PDCA

Project 8. Production System

9. 3 M Muda (Waste), Mura(Unevenness)

Muri (Overburden)10. 2 Production System Just In Time Jidoka10.1Just In Time 10.2Jidoka


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TQC TPM

( )

TQC TPM

(SOFTWARE)

QC Technique)

PART PER MILLION (PPM)

(HARDWARE)

(Zero loss)


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TPM

TPM T Total

Total participation

Total system (PM, CM, MP)

Total efficiency

P Productive

Perfect or Production

M Maintenance

Including Management

TPM

( Zero Failure )

( Zero Breakdown )

( Zero Defect )

( Zero Accident )

( High Moral )

(Self Maintenance)


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(Self Maintenance) TPM

TPM1.

1.1

1.2 2. -

-

-


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-

-

0

123

45

-

-

67

1

-

- ( )

Bottom up


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3. 1) 2

- -

2 -

2)

-

-

3)


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)

- ( ) ( ) ( )

( )

- ( 5 )

-

4)


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) - -

- - -

- -

ISO 9001:2000


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1. 2. 3.

4. 5. 6. 7. 8.

ISO 9001:2000

, 1 JD

2 QMR ()

3

,

,


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1) IQA2) Feedback

3) KPI4)5)6)7)

Documents

06 Manufacturing Hand Out (20 Mar-08)