7 manufacturing
TRANSCRIPT
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INTRODUCTION AND
OVERVIEW OF MANUFACTURING
1.What is Manufacturing?2.Materials in Manufacturing
3.Manufacturing Processes4.Production Systems
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Manufacturing is Important
Technologically
Economically
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Manufacturing - Technologically
Important
Technology - the application of science toprovide society and its members with thosethings that are needed or desired
Technology provides the products that help our
society and its members live better
What do these products have in common?
They are all manufactured Manufacturing is the essential factor that makes
technology possible
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Manufacturing - Economically Important
Manufacturing isone way by which
nations creatematerial wealth
U.S. economy:
Sector% of
GNP
Manufacturing 20%
Agriculture, minerals, etc. 5%
Construction & utilities 5%
Service sectorretail,
transportation, banking,
communication, education, and
government
70%
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Manufacturing - Technologically
Manufacturing
as a technical
Process:
Application of physical and chemical processesto alter the geometry, properties, and/orappearance of a starting material to make parts or
products
Manufacturing also includes assembly
Almost always carried out as a sequence of
operations
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Manufacturing - Economically
Manufacturing
as an economic
process
Transformation of materials into items of greatervalue by means of one or more processing and/orassembly operations
Manufacturing adds valueto the material by
changing its shape or properties, or by combiningit with other materials
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Manufacturing Industries
Industry consists of enterprises andorganizations that produce or supplygoods and services
Industries can be classified as:
1.Primary industries - those that cultivate andexploit natural resources, e.g., farming,
mining
2.Secondary industries - take the outputs ofprimary industries and convert them intoconsumer and capital goods -
manufacturing is the principal activity
3.Tertiary industries - service sector
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Manufacturing Industries - continued Secondary industries include
manufacturing, construction, and electric
power generation
Manufacturing includes several industries
whose products are not covered in this
book; e.g., apparel, beverages,
chemicals, and food processing
For our purposes, manufacturing means
production of hardware
Nuts and bolts, forgings, cars, airplanes, digitalcomputers, plastic parts, and ceramic products
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Methods of Manufacture
FIGURE 1.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or
upsetting, (c) extrusion, (d) machining, (e) joining two pieces.
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Manufacturing Processes
Two basic types:1. Processing operations - transform a work
material from one state of completion to a
more advanced state
Operations that change the geometry, properties, orappearance of the starting material
2.Assembly operations - join two or morecomponents to create a new entity
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Figure 1.4 Classification of manufacturing processes
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Processing Operations
Alters a materials shape, physicalproperties, or appearance in order to addvalue
Three categories of processing operations:
1. Shaping operations - alter the geometry of thestarting work material
2. Property-enhancing operations - improve physicalproperties without changing shape
3. Surface processing operations - to clean, treat,coat, or deposit material on exterior surface of the
work
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Shaping ProcessesFour Categories
1. Solidification processes - starting material isa heated liquid or semifluid2. Deformation processes - starting material is
a ductile solid (commonly metal)3. Particulate processing - starting material
consists of powders
4. Material removal processes - startingmaterial is a ductile or brittle solid
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Solidification Processes - Casting
Starting material is heated sufficiently totransform it into a liquid or highly plastic
state
Examples:metalcasting, plastic molding
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Open Molds and Closed Molds
Figure 10.2 Two forms of mold: (a) open mold, simply acontainer in the shape of the desired part; and (b) closed
mold, in which the mold geometry is more complex and
requires a gating system (passageway) leading into the
cavity.
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Figure 11.1 A large sand casting weighing over 680 kg (1500 lb)
for an air compressor frame (photo courtesy of Elkhart Foundry).
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Shell MoldingCasting process in which the mold is a thin shell of sand
held together by thermosetting resin binder
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Expanded Polystyrene Process
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Investment Casting
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Permanent Mold Casting
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Die Casting
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Centrifugal Casting
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Forming Processes: Deformation
Starting workpart is shaped by application offorces that exceed the yield strength of the
material
Examples: (a) forging, (b) extrusion
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Forming Processes: Deformation
Bulk Deformation
Sheet Metal Forming
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Bulk Deformation Processes
Rolling
ExtrusionDrawing
Forging
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Figure 19.2 Some of the steel products made in a rolling mill.
Rolled Products Made of Steel
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Cutting
Deep
Drawing
Sheet Metal Forming Processes
V-Bending
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Presses
Figure Schematic representation of the
various types of press drive mechanisms.
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Types of Press Frame
Figure 17-61(Right) A 200-ton
(1800-kN) straight-sided press.
(Courtesy of Rousselle
Corporation, West Chicago,
IL.)
Figure 17-60(Left) Inclinable
gap-frame press with sliding
bolster to accommodate two
die sets for rapid change of
tooling. (Courtesy of Niagara
Machine & Tool Works, Buffalo,
NY.)
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Figure 19.20 Diagram showing details of a drop hammer
for impression-die forging.
Drop Hammer Details
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Figure 20.32 Components of a typical mechanical drive stamping press
Stamping Press
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Forming: Particulate Processing
Starting materials are powders of metals orceramics
Usually involves pressing and sintering, in
which powders are first compressed and
then heated to bond the individual particles
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Forming: Material Removal Processes
-Machining
Excess material removed from thestarting piece so what remains is the
desired geometry
Examples: machining such asturning, drilling, and milling; also
grinding and nontraditional
processes
Turning: Machining
of cylindrical partsDrilling Milling
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Forming: Material Removal Processes
-Machining
Turning examples
Standard Turning Facing
Threading:
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Figure 21.3 Two forms of milling: (a) peripheral milling, and (b)
face milling.
Two Forms of Milling
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Turning Machine:
Lathe
Milli M hi
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Milling Machine:
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Figure 31.1 Basic configuration of an arc welding process.
Joining Processes:
Welding, a Permanent Joining Process
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A pool of molten metal is formed near electrode tip,and as electrode is moved along joint, molten
weld pool solidifies in its wake
Figure 31.1 Basic configuration of an arc welding process.
Arc Welding
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31.4 Gas metal arc welding (GMAW).
Gas Metal Arc Welding
R i t S t W ldi
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Resistance welding,
showing the components inspot welding, the main
process in the RW group.
Resistance Spot Welding
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Figure 31.21 A typical oxyacetylene welding operation (OAW).
Oxyacetylene Welding
Brazing - Soldering: Permanent
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Figure 32.4 Several techniques for applying filler metal in brazing:(a) torch and filler rod. Sequence: (1) before, and (2) after.
Brazing - Soldering: Permanent
Joining ProcessesWeak Bonding,
Lower Temperatures
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Figure 32.10 Types of stresses that must be
considered in adhesive bonded joints: (a) tension, (b)
shear, (c) cleavage, and (d) peeling.
Joining Process: Adhesive Bonding