Lecture 22 41. New Technology in Manufacturing. MAE364 Manufacturing Processes Spring 2005. Instructor: T. Kesavadas (Prof. Kesh) Associate Professor, Mechanical and Aerospace Engineering, 1006 Furnas Hall. http://wings.buffalo.edu/courses/sp04/mae/364/
41. New Technology in Manufacturing
Instructor: T. Kesavadas (Prof. Kesh)
Mechanical and Aerospace Engineering,
1006 Furnas Hall.
Teaching Assistants (more details later):
Govindarajan Srimathveeravalli Sridhar Seshadri
Manu Factus : Latin for ‘made by hand’
A Well organized method of converting raw material to end product
End Product: Value and utility added to output.
Definition of product need, marketing information
Design analysis;codes/standards review; physical and analytical models
CAM and CAPP
Conceptual design and
evaluation Feasibility study
testing and evaluation
Inspection and quality
Production drawings; Instruction manuals
Packaging; marketing and
Material Specification; process
and equipment selection; safety review
Non metallic – plastic
Shape of clip
Life of clip
AISI 1010 welded tubing, assembly resistance welded and electrostatically painted
Aluminum alloy forging, polished and buffed
Forged aluminum tubing(alloy similar to 6063), polished and buffedManufacturing of a bicycle
AISI 1010,swaged and cadmium plated
AISI 1008,press formed resistance welded and painted
AISI 1020,forging and chromium plated
AISI 1010, luster finished coil stock,profile milled,resistance welded and chromium plated formed,welded and plated
AISI 1008, press formed,welded and plated
Cold drawn medium carbon steel,( similar to AISI 1035) bright zinc plated
AISI 1020 tubing, machine threaded and painted
AISI 1010,stamped and coined and chromium plated
Seamless AISI 1020 tubing swaged tube sections brazed into fork crown,painted
AISI 1010, stamped and chromium plated
Headed brass,nickel plated
AISI 1040 forging,carburized and chromium plated
Aluminum permanent mold casting,machined , polished and buffed
Case hardened forging quality steel parts, black oxide coating
Hardened high-carbon steel,thread rolled and chromium plated
AISI 1010,stamped and chromium plated
Forming and Shaping
Two methods of forming a dish shaped part from sheet metal electrostatically painted
Left: conventional hydraulic/mechanical press using male and female dies
Right: explosive forming using only one die.
Three methods of casting turbine blades electrostatically painted
A: conventional casting with ceramic mold
B: directional solidification
C: Method to produce single crystal blade
Automated Systems,Manual Systems etc
Machine Control Systems
Computer Numerical Control machines, Robots,Machines,Processes
Computer Integrated Technology
Enterprise elements to enhance understanding electrostatically painted
Applications of Technology
Aim of the Unit:-
To investigate the impact of modern
technology on the design and
manufacture of a range of products
You will learn how:-
You will investigate:-
In terms of its:-
Factories of the Future
& Next ICT CallsDr Erastos FilosFoF ICT Coordinator
Part of the Recovery Plan
To help manufacturing, in particular SMEs, across a broad range of sectors be competitive after the Crisis is over
Industry-driven R&D projects
4 annual co-ordinated calls until 2013 between the two relevant FP7 Themes, ICT and NMP
R&D stakeholders of European Technology Platforms ARTEMIS, ENIAC, EPOSS, EUROP, NESSI, PHOTONICS21, MANUFUTURE
Technology providers & industrial users (large & SME), academic researchers
Total FP7 budget (2010-2013):
245 M€ (ICT) + 400 M€ (NMP)
More than 25 sectors, 21 % of GDP (= € 6.5 trillion), 30+ million jobs
Crisis has reduced Europe’s production capacity
Export champions (but at risk) in machinery, automobiles, wind turbines, …
Largest global market share in automation & factory equipment
Under threat from low wage economies (eg mass-produced goods)
Chance to compete through high added-value products (eg quality, services, customisation, clean & energy efficient processes)
FoF ICT: Technology leaders to gain market share
Automation/industrial robotics & laser technology solutions for factory environments
Product/production design tools (eg software for modelling, simulation, visualisation)
Software for enterprise/supply-chain management
FoF ICT: European industrial end users to
Integrate latest technology into their production environments
Build on new competencies (knowledge, organisation, skills, business models)
Use technologies that enable energy-efficient and “waste-less” production
Smart Factories: electrostatically painted
Goal: More automation, better control & optimisation of factory processes
Means:Software, lasers & intelligent devices embedded in machines & factory infrastructure
Factories of the FutureICT Vision
Manufacture ofsustainable products
(a): Process automation& optimisation
(b): ICT & sensors for energy efficiency
(d): Laser applications
2010 FoF ICT Call - Virtual Factories electrostatically paintedWork Programme coverage
ICT-enabled intelligent manufacturing
Exploiting new materials through manufacturing
2012 2013 Policies
FP8 proposalend ’11
FP8 launchearly ’13
2012 FP7 Calls
9 July – 2 Dec 2010
Total ICT245 M€
July ’09 –Nov. ‘09
Obj. 7.1(40 M€)
Manuf. solutionsfor new ICTproducts
Obj. 7.2(20 M€)
Jul – Dec 2011
for Manufacturing electrostatically painted
Manufacturing ofThe double role of ICT
Smart FactoriesObj. 7.1
Virtual FactoriesObj. 7.3
Towards Future ICT Factories …
Digital FactoriesObj. 7.4
“ManufacturingSolutions fornew ICT“
Factories of theFuture
EU:Global leader in automation, industrial robotics & laser systems
Key industry players:ABB, Siemens, Festo, Schneider Electric, Acciona, Bosch, KUKA, COMAU, Trumpf, …
EU position:Increasingly threatened by Japan, USA, Korea, China
Lack of standardisation
Maintain & extend Europe’s 30% market share: «Factories» as products
Strong, export-oriented sector needs to maintain competitiveness
Tackle resource use efficiency of manufacturing (especially reduce 25% share of energy consumption)
Open new markets for innovative ICT devices & automation systems
Where do we stand?
What do we want to achieve & why?
Call FoF/2011 40 M€ IPs/STREPs
Primarily roll-to roll wet deposition, but also other processes, e.g.
Evaporation, hot-embossing, laser processing,other low-temperature processes
Tackle main roadblocks, e.g.
Patterning processes, resolution, registration accuracy, process stability, multilayer lamination, encapsulation, automation, in-line quality control, architectures to cut production costs
Standardisation issues as appropriate
Industry-driven, strong quality control, testing &validation elementsObjective 7.2Manufacturing solutions for new ICT products
Call FoF/2011 20 M€ IPs
C processes, e.g. HASE AQUILANO JACOBS
For Competitive Advantage
Tasks or operations
Examples: Giving an admission ticket to a customer, installing a engine in a car, etc.
Examples: How much change should be given to a customer, which wrench should be used, etc.
Storage areas or queues
Examples: Sheds, lines of people waiting for a service, etc.
Examples: Customers moving to the a seat, mechanic getting a tool, etc.
Flows of materials or customers
Go to school today?
Drive to school
Walk to class
Mechanical Properties: strength, toughness, ductility, hardness, elasticity, fatigue, creep.
Behavior Under Loading: tension, compression, bending, torsion, shear.
Physical Properties: density, specific heat, thermal expansion, thermal conductivity, melting point, electrical and magnetic properties.
Chemical Properties: oxidation, corrosion, degradation, toxicity, flammability.
Ferrous Metals: iron and steel.
Nonferrous Metals and Alloys: aluminum, magnesium, copper, nickel, titanium, superalloys, beryllium, zirconium, low-melting alloys, precious metals.
Plastics: thermoplastics, thermosets, elastomers.
Ceramics: glass, graphite, diamond.
Composite materials: reinforced plastics, metal-matrix and ceramic-matrix composites, honeycomb structures.
“The Process of Converting Raw Materials Into Products”
Use a Selection Chart
Introduction of molten metal into a mold cavity; upon solidification, metal conforms to the shape of the cavity.
Bulk deformation processes that induce shape changes by plastic deformation under forces applied by tools and dies.
Material removal from a work piece: cutting, grinding, nontraditional machining processes.
NC Machine Tool and Controller processes, e.g.
NC Punch Press Machine processes, e.g.
Injection Molding of Plastics processes, e.g.
Selective Laser Sintering System processes, e.g.
Courtesy of the University of Texas
“Unless you change the process, why would you expect the results to change”
AT&T Process processes, e.g.
Out-of-control processes, e.g.
TimeControl vs. Improvement
Traditional Approach processes, e.g.
Design the product
Make the product
Sell the product
Design the product
Make it with appropriate tests
Put it on the market
Conduct consumer research
Redesign with improvementsProduct Development Paradigms
loss processes, e.g.
Taguchi Loss Function Calculations processes, e.g.
L(x) = k(x - T)2
Example: Specification = .500 .020
Failure outside of the tolerance range costs $50
to repair. Thus, 50 = k(.020)2. Solving for k
yields k = 125,000. The loss function is:
L(x) = 125,000(x - .500)2
Expected loss = k(2 + D2) where D is the deviation
from the target.
Interrelationships processes, e.g.
evaluationHouse of Quality
technical processes, e.g.
quality planQuality Function Deployment
Customer contact and interaction processes, e.g.
CustomizationKey Service Dimensions
A well-controlled system is predictable
Traditional Industrial Engineering
New approaches from the total quality movement
The Process ManagementCategory examines the key aspects of an organization’s process management, including customer-focused design, product and service delivery, key business, and support processes. This Category encompasses all key processes and all work units.
6.1 Product and Service Processes
a. Design Processes
b. Production/Delivery Processes
6.2 Business Processes
6.3 Support Processes