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8/2/2019 1.01.Historical Developments
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HISTORICAL
DEVELOPMENTS INMANUFACTURING
(001)
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Introduction to Manufacturing
What is manufacturing?
Does manufacturing benefit
human kind?
Is manufacturing important
for the economy?
Manufacturing creates goods for
our existence. The products of
manufacturing are all around us.
Every thing we wear, we live in,
we travel on, even most of what
we eat, has gone through some
manufacturing process.
Manufacturing ------latin------
manus(hand) ;factus(made)
Manufacturing is the making of
goods and articles by hand or
especially by machinery, often on
large scale and with division of
labour.
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Introduction to Manufacturing
The history of manufacturing is marked by gradual developments ;the
cumulative effects have been of such substancial social consequences thatthey may be rightly regarded as revolutionary.
The First Industrial Revolution
At the end of 18th century, the development of steam engine made
power available in large quantities and many locations. This spurred
advances in manufacturing processes providing an abundance of goods ;The industrial revolution was characterized by the mechanical power
supplementing the physical power of the worker.
Toward the middle of 19th century, some functions of the worker were
taken over by machines in which mechanical components such as cams
and levers were ingeniously arranged to perform simple and repetitivetasks. Such hardautomation eliminated some jobs.
Around the turn of20th century, development was further aided by the
introduction of electric power.
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Introduction to Manufacturing
The Second Industrial Revolution
Beginning with the second half of the 20th century; Computers offerredthe undreamed of computational power
In the early 1970s the availability of microchip, with thousands of
electronic components crammed onto a tiny silicon wafer, made it
possible to perform computational, control, planning and management
tasks at high speeds Many dangerous, physically challenging and boring jobs(mind skills) are
performed by machines/robots controlled by computers.
The capability for gathering and processing information has dramatically
increased and it is commonly accepted that we have entered the
information age.
The belief is: we are in the process of developing into a post industrial
society, in which manufacturing will wither and the service sector based
on information processing will generate wealth.
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Introduction to Manufacturing
Do we really need manufacturing at all in the
information age?
The Economic Role of Manufacturing Engineering:
The factory was the alternative willingly chosen the
masses seeking to escape a rural existence burdened byfamine and disease.
Manufacturing as a Technical Activity:
Products coming out from high-tech industry face new
demands on safety and quality. Its manufacture too
demands the most advanced techniques.
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The Economic Role of Manufacturing Engineering
The GNP (sum of the value of all goods and services produced in a nationaleconomy) can be taken as a measure of material well being, though itexcludes the work performed in home, voluntary organisations, etc.
By analyzing the components of the GNP, it is evident that material wealthcomes from two substantial sources: material resource & knowledge andenergy that people apply in utilizing these resources.
Manufacturing claimed the largest single share until 1950s.
Since then much of the developments are in the service sector.
Increasing wealth is based on increasingly sophisticated manufacturingsector; this inturn creates the need for many increasingly sophisticatedsupporting activities ( research, design, finance, maintenence, distributon,field service, hospitality, travel industry, etc.)
For statistical purposes all these supporting activities are termed as
services
Yet, unless a nation is exceptionally well endowed with natural resources,strong service sector can exist only if there is a similarly strongmanufacturing sector.
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The Economic Role of Manufacturing Engineering
In the information age, knowledge is the most valuablecommodity.
Wealth is generated abundantly by producing tradable articlesin which knowledge is embodied (knowledge itself can bebought cheaply).
No nation exists in isolation any more, and international tradehas grown to a point where economies of all nations areinetrconnected. The flow of goods and services areincreasingly liberated from the earlier restrictions.
Manufacturing thus occupies a central position in theeconomies of all nations.
Many economic activities provide essential inputs tomanufacturing. Manufacturing creates all products needed forthe conversion of energy and raw materials: construction,transportation, communication, health care, entertainmentand leisure.
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Manufacturing as a Technical Activity
Example 1
The jet engine is the machine designed with most advanced
knowledge of thermal and fluid engineering principles, using
all available computer models for design and performance
evaluation. Its manufacture too demands the most advanced
techniques, as components are subjected to extremeconditions in operation.
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Manufacturing as a Technical Activity Example 1
First Stage : Compression
Second Stage : Combustion Third Stage : A large fan at the front of the engine increases thrust by
increasing the mass of the air displaced: in a high-bypass turbo fan engine, thebypass ratio is 6:1 or higher, which means that 6 times as much air passesaround the engine as passes through it.
Compression raises the temperature of the incoming air, and in recent
engines, the final-stage compressor blades are required to run red hot; weshall see throughout the text that new materials and technologies had to bedeveloped for making the compressor blades.
Developments in super alloys allowed a gradual increase in the operatingtemperature but a jump in performance came from cooling the blades bypassing the uncombusted compressor air through small holes in the airfoil.
Thus in addition to developing new processes for difficult ot manufacturealloys , techniques had to be found for very fine deep holes in very hardmaterials. Everybody recognizes jet engine is high-tech product.
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Schematic diagram illustrating the operation of a
low-bypass turbofan engine
http://upload.wikimedia.org/wikipedia/commons/7/77/Turbofan_operation_lbp.svghttp://upload.wikimedia.org/wikipedia/commons/7/77/Turbofan_operation_lbp.svg8/2/2019 1.01.Historical Developments
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A Pratt & Whitney F100 turbofan engine for the F-15 Eagle beingtested in the hush house at Florida Air National Guard base. Thetunnel behind the engine muffles noise and allows exhaust to escape
(www.en.wikipedia.org)
http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Turbofanhttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/Hush_househttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://www.en.wikipedia./http://upload.wikimedia.org/wikipedia/commons/6/69/F100_F-15_engine.JPGhttp://www.en.wikipedia./http://www.en.wikipedia./http://www.en.wikipedia./http://www.en.wikipedia./http://www.en.wikipedia./http://www.en.wikipedia./http://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Hush_househttp://en.wikipedia.org/wiki/Hush_househttp://en.wikipedia.org/wiki/Hush_househttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/Turbofanhttp://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F1008/2/2019 1.01.Historical Developments
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Manufacturing as a Technical Activity- Example 2
Many changes had to be made by the automobile
industry in the existing design of the automobiles, tosatisfy new demands regarding safety, pollution level,
gasoline consumption, durability, and quality of
product. These changes have affected the choice of
materials and manufacturing techniques.
Early automobile bodies had a steel frame to
which wooden panels were attached. Soon
wood was replaced with all steel body thatwas secured to a heavier chasis.
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First bits get assembled onto chassis 1200cc Herald on
Burlingtons new ladder chassis.
Frame at the back is where the petrol tank will go.
http://upload.wikimedia.org/wikipedia/commons/e/e5/Origin19.jpghttp://upload.wikimedia.org/wikipedia/commons/e/e5/Origin19.jpg8/2/2019 1.01.Historical Developments
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A bare chassis of the new Proton Exora MPV exhibited
at the Proton Technology Week.
The desire for weight reduction has led to uni-body construction
http://upload.wikimedia.org/wikipedia/commons/e/e5/Origin19.jpghttp://upload.wikimedia.org/wikipedia/commons/e/e5/Origin19.jpghttp://paultan.org/topics/proton-mpv-2009/http://upload.wikimedia.org/wikipedia/commons/5/5a/Proton-MPV-Chassis.jpghttp://paultan.org/topics/proton-mpv-2009/8/2/2019 1.01.Historical Developments
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Polski Fiat on its side
The all-welded frameless steel bodies were made of low
carbon steel which has desirable forming properties.
http://upload.wikimedia.org/wikipedia/commons/2/23/126p_Polski_Fiat_on_its_side.JPG8/2/2019 1.01.Historical Developments
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Aluminium chassis
Further interest in weight reduction and corrosion resistance led to the
introduction of galvanized steel , HSLA steel and Al alloys specially for
automotive applications. Much had to be learnt about the formingcapabilities of these materials so as to predict their formability to comlex
shapes.
http://upload.wikimedia.org/wikipedia/commons/7/7c/LotusEvorachassis.jpghttp://upload.wikimedia.org/wikipedia/commons/7/7c/LotusEvorachassis.jpg8/2/2019 1.01.Historical Developments
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Manufacturing as a Technical Activity- Example 2
Polymers have also been used first as fiber glass
reinforced epoxies and more recently as mass
produced body parts attached to a precision
machined drivable steel space frame. The car, in its entirety, has become a
sophisticated product, with several onboard
computers performing critical control functions.Auto production now has all the characteristics of
a high-tech industry.
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Manufacturing as a Technical Activity- Example 3
Bioengineering offers examples where manufacturing benefits humans
directly. One of the most frequently performed orthopaedic surgeries is the
replacement of arthritic hip joints with surgical implants.Materials had to
be found that could be implanted in to the body without adverse reactions
that could withstand the adverse dynamic loading (of millions of cycles per
year) by ever youger and active patients.
The shape of the spherical head is critical and techniques had to be
developed for high-precision machining.
Better ways of fastening the replacement in the bones also had to be
found since adhesive joints frequently fail after some years of service.
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Hip joint replacements are advanced
manufacturing products The Ti alloy stem is inserted into
the femur (thighbone) and thecup into the acetabulum (socketof the hip bone), with a wireresistant polymer lining providingthe sliding surface( Zimmer Inc,Warsaw, Indiana)
Pure Ti wire of 0.25mm diameteris sintered into a porous mass toprovide room for the ingrowth offresh tissue which fixes theimplant of the bone of anexperimental animal( Dr.W.Rostoker).
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Manufacturing as a Technical Activity- Example 4
Micro-electronics which is the heart of the second
industrial revolution could be exploited only byadapting old and creating new manufacturing
technologies, for new materials.
Advanced manufacturing processes have made it
possible to create millions of components on a single
silicon chip.
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Synthetic detail of an integrated circuit through four
layers of planarized copper interconnect, down to the
polysilicon (pink), wells (greyish), and substrate (green)
http://upload.wikimedia.org/wikipedia/commons/c/c6/Siliconchip_by_shapeshifter.png8/2/2019 1.01.Historical Developments
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Microchips (EPROM memory) with a transparent window,
showing the integrated circuit inside. Note the fine silver-colored
wires that connect the integrated circuit to the pins of the
package. The window allows the memory contents of the chip to
be erased, by exposure to strong ultraviolet light in an eraser
device
http://en.wikipedia.org/wiki/EPROMhttp://en.wikipedia.org/wiki/Ultraviolet_lighthttp://upload.wikimedia.org/wikipedia/commons/5/5c/Microchips.jpghttp://upload.wikimedia.org/wikipedia/commons/5/5c/Microchips.jpghttp://en.wikipedia.org/wiki/Ultraviolet_lighthttp://en.wikipedia.org/wiki/Ultraviolet_lighthttp://en.wikipedia.org/wiki/Ultraviolet_lighthttp://en.wikipedia.org/wiki/EPROM8/2/2019 1.01.Historical Developments
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References
Introduction to Manufacturing, John.A.Schey,
3rd Edition, Mc Graw Hill International
Editions, 2000.
(www.en.wikipedia.org)