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MAE364 Manufacturing Processes Spring 2005

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MAE364 Manufacturing Processes Spring 2005

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  1. MAE364Manufacturing ProcessesSpring 2005 Instructor: T. Kesavadas (Prof. Kesh) Associate Professor, Mechanical and Aerospace Engineering, 1006 Furnas Hall. http://wings.buffalo.edu/courses/sp04/mae/364/ Teaching Assistants (more details later): Govindarajan Srimathveeravalli Sridhar Seshadri

  2. What is Manufacturing? (1) (2) (3) (4) (5)

  3. Manu Factus : Latin for ‘made by hand’ Definition: A Well organized method of converting raw material to end product End Product: Value and utility added to output.

  4. Manufacturing Process

  5. History of Manufacturing • Manufacturing started during 5000 – 4000 BC Wood work,ceramics,stone and metal work • Steel Production 600-800 AD • Industrial Revolution 1750 AD: Machine tools run by invention of steam engine • Mass Production and Interchangeable Parts • Computer Controlled Machines 1965 • CNC,FMS systems

  6. Historical development of materials - The Early Days

  7. Historical development of materials - The Industrial Revolution

  8. Historical development of materials - The Modern Age

  9. Req. for a good manufacturingsystem

  10. Requirements of a good manufacturing system • Product should meet design requirement • Economical Process • Quality should be built into the system • Should be flexible and responsive to new technology • High productivity: Best utilization of man, material, machine, capital and available resources.

  11. Steps in Modern Manufacturing Definition of product need, marketing information Design analysis;codes/standards review; physical and analytical models CAM and CAPP Production Conceptual design and evaluation Feasibility study Prototype production testing and evaluation Inspection and quality assurance CAD Production drawings; Instruction manuals Packaging; marketing and sales literature Material Specification; process and equipment selection; safety review Product Pilot Production

  12. Manufacturing of a Paper Clip • What is the function • How long does it last • How critical is the part • Material Metallic - what type Non metallic – plastic • Dimension Diameter of clip Shape of clip • Method of manufacturing Manual Automated • Function based design Stress, Strain Life of clip Stiffness • Style Appearance,Color,Finish Plating,painting

  13. 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 buffed Manufacturing 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

  14. Assignment 1 • Select a simple product of your choice • Try to analyze the different materials, processes, etc • Use library resources • We will discuss this in the class on Friday

  15. Selection of Process: Topic to be covered Casting • Sand/Expandable Mold,Permanent Mold Forming and Shaping • Rolling,forging,extrusion,powder metallurgy Machining • Turning,Boring,Drilling,Milling,Planing,Broaching,Grinding

  16. Selection of Process Unconventional Method • EDM,ECM,Ultrasound,High Energy Beam,machining Joining • Welding,Brazing,Soldering Finishing • Honing,Lapping,Polishing,Burnishing,Deburring

  17. Objectives of this course and what is expected of you • Manufacturing processes and fundamentals • Selection of appropriate process to meet design requirements • Effect of process parameters and variables on the quality of parts produced • Effect of material properties on a given process • Decision and methods for different product size and mix • Effect of design on manufacturability • Overview of computer aided methods in traditional manufacturing processes

  18. Two methods of forming a dish shaped part from sheet metal Left: conventional hydraulic/mechanical press using male and female dies Right: explosive forming using only one die. pressure Upper die Explosive water work piece Lower Die

  19. Three methods of casting turbine blades A: conventional casting with ceramic mold B: directional solidification C: Method to produce single crystal blade

  20. Selection of Process depends on • Dimensional and surface finish requirements • Operational Cost • Design and strength requirements • Consequences of various methods

  21. Design for Assembly • Design of the product to permit assembly • Possibility of multipurpose parts • Capability of manufacturing process to consistently produce parts which can be assembled without problem • Method or process of assembly Automated Systems,Manual Systems etc

  22. Design for Assembly

  23. Automation and Impact of Computers Machine Control Systems Computer Numerical Control machines, Robots,Machines,Processes Computer Integrated Technology • Responsive to market change • Better use of process,man,machining management etc • CAD/CAM: Computer Aided Design And Manufacturing • FMS: Flexible Manufacturing System • GT: Group Technology • VR: Virtual Reality