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