Manufacturing Chapter 1

HABEEB HATTAB HABEEB

Office: BN-Block, Level-3, Room-088Email: [email protected]. No.: 7292H/P No.: 0126610058

Lecturer: HABEEB ALANI

University TENAGA National College Of Engineering Mechanical Department Academic Year - 2008Lecture Note


Introduction To Manufacturing and Manufacturing Systems


Japanese sword reworked for hard and soft metal parts


Space Shuttle


The Transistor


Everyday products


Manufacturing derived from:Manufacturing (derived from Latin)

= manus (hand) + factus (made) = made by hand


Manufacturing is an industrial activity that converts raw materials to useful products by the means of machines. Definition of Manufacturing:


Materials Development of Manufacturing depends on:Machine-ToolsComputer-aided Design (CAD)&Computer-aided mfg (CAM). RoboticsElectronics12345


Evolution of the Enterprise Evolution Steps:Hand Tool Animals Water Power Steam Engines Electrical Motors 123451-1


The MFG System:INPUT PROCESS OUTPUT


Customer Demand Material Money Energy HR Education R & D INPUT


PROCESS Design Production Management


OUTPUT Consumer Goods Capital Goods Quality Cost Effectiveness


`Money - Working Capital (Money for employee) Fixed Capital (For machine tools and buildings) INPUT


Energy - Electricity To run the machines - Compressed air To run the pneumatic systems and clean machines and products - Steam To run the turbines and utilized in produce of polystyrene (Expansion OP.) - Gas To use it in Furness, welding operations and boilers. INPUT


- Creating plans for new productsLowering the product cost at maintained high qualityDesignPROCESS


- Designated at the design stage- Machine tools typesPROCESS Production- Machining processes- People are selected at the design stage


Goods- Customers goods: People use them (Food, Cars, .)OUTPUT Products- Capital goods: Products used to make other consumer goods (Machine tools, Plant, .)


The Classification of basic Manufacturing Mass production1-2ModerateJob-lotabc


Mass Production Features: - Goods are produced at a high volume for considerable period of time ( >100.000 parts per year). - Machine are not flexible (They are not able to produce other types of products). - Products of this type of mfg are the cheapest.a


Moderate production Features: - Variable products (depends on the sale order and the market demand) (2,500-100,000 parts per year). - Multipurpose machine tools and CNC machine tools are usually used in this type of mfg.- Product Ex.: Tools, Moulds, Radio transmitters.b


Job-lot production Features: - The plant does not any specific type of products but it is able to produce any type of product that the market is in need of.- Products move in lots between mfg processes (10-500 parts per lot).- Machine are more flexible and universal.c- Product Ex: Airplanes, Automobile parts, and Plastic products .


Organization for Manufacturing -A plant needs an affective organizing method for manufacturing in order to manage its resources /

Employees Money Power

Materials Machines .

*A good mfg strategy is needed.

See table 1.1 (Evolution of strategy mfg sys.. 14235


Concurrent Engineering CE It is a philosophy that promotes interactive design and manufacturing efforts to develop product and processes simultaneously. CE is not an engineering discipline.

- CE Objective: Optimizing the use of companyresources and reducing time to market cycle.


General CE phases for a new project: Technology and concept development: Definition of customer requirement implementation. Assessment of primary alternatives processes. Development of required resources. Preparation of product plan.abcdPh.-1


Product and Process Development and Prototype validation -CE Function: Product improvement for assembly and mfg Development the mfg and assembly processes Establish baseline process technology Establish program goals and risk-reduction plans freezing abcdPh.-2This is the phase in which the CE team will


Cont

Generally other project elements are addressed I this phase , such as financial business plans, product concept demonstration, freezing of engineering content, and final project approval.Note:Ph.-2Ph.-2


Process Validation and Product Design Confirmation : The Production process and methods are finalized Simulation and pilot runs are conducted to test critical steps Machine and equipment are validated for production readiness, quality and performanceabcPh.-3This is the execution phase where


Production and continuous improvement :- This face is the Acceleration of production floor into Full rated capacity. This means: Attaining high product quality at the lowest costs.Ph.-4


Design, Material and Production 1-3According to the existing machine tools and the designed product we choose the raw materials.

On the other hands, according to the existing materials and required quality we choose the machine tools.


In order to attain a high production rate with a low labor cost, Automatic features have been built gradually in different machine tools. Nowadays we deal with fully automatic machine tools and computer aided design and manufacturing (CAD/CAM). But the problem is that maintenance of such automatic machines is very expensive.- Efficiency of production :


The quality and accuracy must be maintained for the whole mfg processes so at the output we produce parts that can be quickly assembled (interchangeable). Cont.. Efficiency of production


- Economical production is determined by: A functional simple design that has appropriate quality (no more or less). 1 A material choice that represents the best compromise among physical properties, cost, and machinability. 2 The selection of mfg processes that provide the plant with required quality and accuracy (no more accuracy than necessary) at the lowest possible cost. 3


MaterialsEngineering MaterialsMetallic Non-Metallic Ferrous Non-Ferrous OrganicNon- Organic


Materials Application ChainProcessingStructurePropertiesPerformanceSelectionField Application* SELECTION is the Critical Step for Technologists.


Stress & StrainDislocations & DeformationElasticity & PlasticityElastic ConstantsMechanical Properties


Mechanical TestingMechanical PropertiesStrengthening MechanismsFailure Analysis

Tests


Resistivity & ConductivityElectronic-Band StructureSemiconductivityRefraction & ReflectionTransmissionElectrical PropertiesElectrical Properties


The Evolution of Materials


Classes of MaterialsBasicMetalsCeramicsPolymersAdvancedCompositesSemiconductorsBiomaterials


Materials that are normally combinations of "metallic elements".

Metals usually are good conductors of heat and electricity. Metals are quite strong but malleable and tend to have a lustrous look when polishedMetals


Ceramic materials developed for gas turbine rotors are used in aircraft and diesel engine parts.

CeramicsCeramics are generally compounds between Metallic and NONmetallic elements and include such compounds as: -Oxides -Nitrides -Carbides

Typically they are insulating and resistant to high temperatures and harsh environments.


Using advanced polymer materials, organic light emitting diode (OLEDs) displays produce bright, high-contrast display panels with a wide viewing angle. OLED panels are emissive, eliminating the need for the backlight required in display technologies such as liquid crystal displays (LCDs). PlasticsPlastics (or polymers) are generally compounds based upon carbon and hydrogen (Organic Compounds). They are very large molecular structures. Usually they are low density and are not stable at high temperatures.


SemiconductorsSEMIconductors have electrical properties intermediate between Metallic conductors and Ceramic insulators. Also, the electrical properties are strongly dependent upon small amounts of Impurities.


CompositesComposites consist of more than one material type. Fiberglass, a combination of glass and a polymer, is an example. Concrete and plywood are other familiar composites. Many new combinations include ceramic fibers in a metal or polymer matrix.


Composites


CompositesGraphite Matrix Composite ShaftLiquid Metal FacePlateGolf ClubsHand bagGhost airplane


BioMaterialsMaterials compatible with an organism (e.g. Humans) that can be used to make implants, prostheses, and surgical instruments. Designed not to provoke rejection by our bodies (skin, blood, bone, etc.), they can be natural (collagen, cellulose, etc.) or synthetic (metallic, alloy, ceramic, plastic, and others). Dental crowns and contact-lenses use biomaterials.


StructuredinformationUnstructuredinformationData Organization of Materials


mountMetallography: to see microstructuresmetalSteel (Fe-C)Nickel Alloy 242


The goal of design:To create products that perform their function effectively, safely, at acceptable costWhat do we need to know about materials to do this? More than just test data.Stat/MathanalysisDesign dataSelection ofmaterial and processPotential applications Materials Information for Design


Next Lecture:Nature And Properties of Materials


THANK YOU


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Manufacturing Chapter 1