Advanced Manufacturing ME 10405/10505 Professor Jim Waterman For Today Objectives of the Course Who am I? My approach to the course Grading, Homework, PBWorks Outline for the semester What is Manufacturing – intro to the course

Advanced Manufacturing ME 10405/10505 Course Objectives Provide an overview of modern manufacturing processes Enable students to select and design efficient and cost effective processes to make things Provide insights as to what is state of the art now, and what is coming And leave each of you with a dissatisfaction for the ways things are made today!

Advanced Manufacturing ME 10405/10505 Syllabus Obtain a broad understanding of how things are made: Taxonomy of manufacturing processes and an examination of current state of the art manufacturing Emphasis on trends and directions in manufacturing, the relationship of digital data to design and production, and the impact of supply chain on production decisions. Objectives: Provide Students with knowledge of modern manufacturing processes, future directions of manufacturing, to include additive (3D printing) techniques, the use of digital data across the entire design/build/support product life cycle. Students will be able to identify appropriate manufacturing processes for given problems Students will understand the key factors affecting product quality, productivity and economic production

Advanced Manufacturing ME 10405/10505 My Approach Bring some relevance to the subject What is happening in industry today Bring you into the discussion I want your questions, and your knowledge We'll learn together Get you ready to design for manufacture, or design the processes of the future

Graded Course Components Homework 20% - mostly assigned from the text Will be assigned about once weekly. Due in one week from assignment To be submitted in PDF ONLY – to waterman@rowan.edu Mid Term Exam 20% Semester Project 30% A project will be assigned, focusing on expanding your understanding of advanced manufacturing technologies and their application to important uses in today's world. Grad student projects will likely require the manufacture of a physical product in addition to the research and design aspects involved in product and process design. Final Exam 30%

Advanced Manufacturing ME 10405/10505 Course Outline – First Half Text: Introduction to Manufacturing -Mikell P. Groover First Edition ISBN-13: 978-0470632284 ISBN-10: 0470632283 Intro and Overview of Manufacturing Engineering Materials Properties of Engineering Materials Dimensions Tolerancing and Surfaces Metal Casting Glassworking Plastics Rubber/Polymer Composites Powder Metallurgy Ceramics Metal Forming and metal working (roll/forge/extrude) Sheet Metal Metal Machining(including tool life) Principles Machine Tools Cutting tools tech Mid Term – Monday, Oct 19

Advanced Manufacturing ME 10405/10505 Course Outline – Second Half Grinding/abrasive processes Non-traditional Processes Mechanical Energy processes Ultrasonic, Water Jet, Electrochemical machining EDM,Electron Beam/Laser Beam Machining Chem Machining Heat Treatment of Metals Surface Processing - Cleaning,Diffusion/ion implant,Plating/electroforming Conversion coatings, Vapor deposition Organic coatings Welding :Fundimentals/Joints/physics Processes: Arc, Oxy/fuel, Acetalyene, Fusion, Solid state Braze/Solder/Adhesive bond Mechanical Assembly Rapid Prototype processes Survey of Additive Manufacturing processes SLA, Fused Deposition, Powder based Ink/liquid based What folks are doing to make additive as fast as current processes! Micro/Nano fabrication technologies

Advanced Manufacturing ME 10405/10505 Course Outline – Second Half Production Systems and process planning Automation/Manufacturing Systems CNC Cells and work flow/part families/'Flexible Machine Cells' Lean Manufacturing Model based design and life cycle data driven mfg/standards. Quality Process Capability and Statistical Process Control Futures Extrapolating today to tomorrow - we'll do this throughout the semester Supply Chain considerations – global issues Final Exam – Weds, December 16

What is Manufacturing? Pg. 1-14 of Text The word manufacture is derived from two Latin words, manus (hand) and factus (make) Today manufacturing can be defined two ways: Technologically Economically ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Technological Definition of Manufacturing Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products It also includes assembly of multiple parts to make products ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Economic Definition of Manufacturing The transformation of materials into items of greater value by means of one or more processing and/or assembly operations Manufacturing adds value ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing Industries Industries can be classified as: Primary industries: Cultivate and exploit natural resources (e.g., agriculture and mining) Secondary industries: Take the output of the primary industries and convert them into consumer and capital goods (e.g., manufacturing, construction, power utilities) Tertiary industries: Service sector (e.g., retail, financial, education, transportation, government) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufactured Products Final products made by the manufacturing industries can be divided into two major classes: Consumer goods – products purchased directly by consumers (e.g., cars, personal computers, TVs, tires,, and tennis rackets) Capital goods – products purchased by companies to produce goods and/or provide services (e.g., aircraft, trucks and buses, machine tools, construction equipment) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing and Gross Domestic Product (GDP) In the U.S: Manufacturing accounts for about 12% of GDP And the service sector accounts for more than 75% of GDP BUT! Manufactured capital goods purchased by the service sector are the enablers of that sector Without these manufactured products, many service industries could not function ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Production Quantity and Product Variety Production quantity = the number of units produced annually of a given product type Three ranges: Low production (1 to 100 units per year) Medium production ( 100 to 10,000 units) High production (10,000 to millions of units) Product variety refers to the number of different types of products made ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Production Quantity and Product Variety Manufacturing plants tend to specialize in a combination of production quantity and product variety that lies inside the diagonal band shown below How can you increase product variety at higher rates of production? ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing Capability Refers to the technical and physical limitations of a manufacturing firm and its individual plants Three dimensions of manufacturing capability: Processing capability – available set of manufacturing processes Physical product limitations – size and weight of the products that can be made Production capacity – production quantity that can be produced in a given time period ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Materials in Manufacturing Most engineering materials fall into one of 3 basic categories: Metals: Ferrous (e.g., steel and cast iron) Nonferrous (e.g., aluminum, copper, nickel) Ceramics Crystalline ceramics (e.g., clay, alumina) Glass Polymers Thermoplastics (e.g., polyethylene) Thermosets (e.g., epoxies) Elastomers (e.g., rubber) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing Processes A manufacturing process is a procedure that results in physical and/or chemical changes to material to increase the value of that material Usually carried out as a unit operation, which is a single step in the sequence of steps required to transform the material into as final product ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Two Basic Types of Manufacturing Operations Processing operations – transforms a work material from one state of completion to a more advanced state that is closer to the final desired product Usually performed on discrete workparts Assembly operations – joins two or more components to create a new entity, called an assembly, subassembly, or other term (e.g., weldment) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing Taxonomy You will see this again! ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Processing Operations – where we'll get started General types: Shaping operations – alter the geometry of the starting work material Property-enhancing operations – improve the physical properties of the material without changing its shape Surface processing operations – performed to clean, treat, coat, or deposit material onto the surface of the work ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Shaping Processes Four categories based on the state of the starting material: Solidification processes Particulate processes Deformation processes Material removal processes ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Solidification Processes Starting material is a heated liquid or semifluid that cools and solidifies to form the part geometry ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Particulate Processes Starting material is a powder, and the powders are formed to create geometry and heated to strengthen ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Deformation Processes Starting material is a ductile solid (commonly metal) that is deformed to shape the part Forging Extrusion ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Material Removal Processes Starting material is a solid (ductile or brittle), from which material is removed so that what remains has the desired geometry Turning Drilling Milling ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Property-Enhancing Processes Involves heat treatments, which include: Annealing and strengthening processes performed on metals and glasses Sintering of powdered metals and crystalline ceramics ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Surface Processing Operations: Cleaning – chemical and mechanical processes to remove dirt, oil, and other contaminants Surface treatments – mechanical working (e.g., sand blasting) and physical processes (e.g., diffusion) Coating and thin-film deposition – apply a coating to the exterior surface of the work (e.g., electroplating, painting, physical vapor deposition) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Assembly Operations Permanent Joining processes Welding Brazing Soldering Adhesive bonding Mechanical Fastening Joints can be disassembled (e.g., threaded fasteners) Joints are permanent (e.g., rivets) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Production Machines Machine tools – power-driven machines used to operate cutting tools Other production machines developed subsequently: Presses for stamping operations Forge hammers Rolling mills Welding machines Insertion machines for assembly ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Categories of Production Equipment General-purpose machines More flexible and adaptable to a variety of jobs Commercially available for any manufacturing company to invest in Special-purpose machines Usually designed to produce a specific part or product in very large quantities Achieve high efficiencies and short cycle times ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Tooling Production machines usually require tooling that customizes the equipment for a particular part or product In many cases, the tooling must be designed specifically for the part or product (e.g., a mold) When used with general-purpose equipment, the tooling can be exchanged at the end of a production run ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Production Equipment and Tooling for Various Processes Process Equipment Special tooling Casting (various types) Mold Molding Molding machine Mold Forging Forge hammer Forging die Extrusion Extrusion press Extrusion die Stamping Stamping press Stamping die Machining Machine tool Cutting tool Grinding Grinding machine Grinding wheel ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Some Resources (outside of the book) The Library of Manufacturing: good companion resource to book for process information http://thelibraryofmanufacturing.com/index.html Industry Week website – news, white papers http://www.industryweek.com/ PBWorks site http://me10405.pbworks.com/w/page/84451462/FrontPage Most of you should have an invite already – it will contain assignments, class materials, etc. ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

For Next Class Read Textbook Intro to Mfg Overview – pg 1-14 Engineering Materials/Properties of Materials – pg 15-76 ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes