Manufacturing Processes An Introduction By: Sunil Kumar Ojha

Do you ever heard Manufacturing ? Which is the leading Manufacturing Country in the world? How Manufacturing affect economy of acommon man and for a country ? Curiosity How parts are made ????????

Introduction Take a few moments and inspect some of the objects around you

Introduction

What do they all have in common They have all been transformed from raw materials Components of various size and shape Assembled into the products you see now

What is Manufacturing Derived from 2 latin words Manus – hand Factus – make Made by hand The process of converting raw materials into useful products.

What is Manufacturing Technologically Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given material to make parts or products Includes assembly of multiple parts to make products Typically carried out as a sequence of operations

What is Manufacturing Economically Manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations Adds value

What is Manufacturing A nation’s level of manufacturing activity is related directly to its economic health Generally, the higher the level of manufacturing activity in a country, the higher the standard of living of its people In the US, the manufacturing industries account for about 20% of the Gross National Product (GNP), 32 % in China and app. 15 % in India.

A Brief History of Manufacturing Many manufacturing processes have been around for thousands of years Can you name some ancient examples of the following: Grinding Forging / Smithy Work Casting Others

A Brief History of Manufacturing Industrial Revolution ( ) Change from agriculture/handicraft economy to one based on industry and manufacturing Watt’s steam engine Machine tools Power spinning loom Factory system organization Interchangeable parts

A Brief History of Manufacturing Interchangeable parts Pre-requisite for mass production Eli Whitney Contract to produce 10,000 muskets for US government

A Brief History of Manufacturing Second Industrial Revolution (late 1800s, early 1900s) Mass production Scientific management movement Assembly lines Henry Ford Electrification of factories 1881 – first power generator in New York 1920 – electricity overtakes steam in factories

Why Study Manufacturing? The costs of a product are substantially determined in the product design phase As such, designers/engineering determine up to 70% of the manufacturing costs Designers may make poor decisions about materials, tolerances, shapes, size, and product function All of these have tremendous impact on the processes used in the manufacturing of a product

Why Study Manufacturing? A thorough knowledge of manufacturing processes is necessary for those who design and make the parts If better decisions can be made in the early phases of product design Better products for customers Greater profits for manufacturing companies

Manufacturing Example You have been asked to design & produce paper clips (Developed by a Norwegian) (US Patent in 1901) Let’s discuss important factors involved in the design and manufacture of paper clips

Manufacturing Example What type of material would you choose to make this product? Should it be metallic or nonmetallic? If metal, what type of metal? If “wire” shape, what diameter? Should it be round or other cross-section? What should be the surface finish?

Manufacturing Example How would you shape the wire into a paper clip? By hand on a simple fixture? If not, what kind of machine would you design to make the paper clips? How would you produce 10,000 clips? How about millions of clips?

Manufacturing Example Clip must meet basic functional requirements Hold paper with sufficient clamping force Proper design – shape, size, feel, appearance Stiffness and strength of material

Manufacturing Example Too stiff Inconvenient for users Not stiff enough Won’t hold papers Yield stress too low Permanent deformation during normal use

Manufacturing Example Can the wire undergo bending during manufacturing without cracking or breaking? Is the wire corrosion resistant? Can the wire be easily cut without causing excessive wear on the tooling? Will the cutting process produce a smooth edge on end of wire? What’s the most economical method of manufacturing the clip in the needed quantities?

Product Design Product design is a critical activity It has been estimated that 70-80% of the cost of product development and manufacture is determined by decisions made in the initial design stages The design of a product first request a thorough understanding of the functions and performance expected of the product

Product Design Traditionally design and manufacturing activities have taken place sequentially This practice has proven to be inefficient Concurrent engineering was developed to find more effective ways to bring products to the market quicker Products early to market enjoy higher profits and greater longevity

Product Design Concurrent engineering integrates the design and manufacture of products, optimizing all elements involved in the product life cycle Consists of several deliberate iterations All disciplines involved early in the design stages so that the iterations Benefits to one automotive company 30% reduction in # of components 25% decrease in weight 50% decrease in manufacturing time

Design for Manufacturing Design and manufacturing should never be viewed as separate activities Components must be designed so that they meet design requirements AND can be manufactured economically

Design for Manufacturing DFM is a comprehensive approach to the production of goods It integrates the design process with materials, manufacturing methods, process planning, assembly, testing, and quality assurance Requires designers have a fundamental understanding of the characteristics, capabilities, and limitations of materials, manufacturing processes, and equipment

Design for Manufacturing Designers need to understand variability in: Machine performance Dimensional accuracy Surface finish Processing time Effect of processing method on quality

Manufacturing Processes Over 300 individual manufacturing processes have been identified in the industrial environment Grouped into several families of processes sharing common characteristics

Manufacturing Processes Broad categories of processing methods for materials include: Casting Forming and shaping Machining Joining Finishing Nanofabrication

Manufacturing Processes Casting Expendable and permanent molds Forming and Shaping Rolling, forging, extrusion, sheet forming, powder metallurgy Machining Turning, boring, drilling, milling, planing, shaping, broaching, grinding Chemical and electrical maching High-energy beam machining

Manufacturing Processes Joining Welding, brazing, soldering, diffusion bonding, adhesive bonding, mechanical joining Finishing Honing, lapping, polishing, deburring, surface treating, coating, plating Nanofabrication Nano = 1/billion Etching techniques, electron-beams, laser-beams

Casting Starting material is heated sufficiently to transform it into a liquid or highly plastic state Casting process at left and casting product

Forming or Shaping Starting workpart is shaped by application of forces that mareial plastically flow and get desired shape Examples: (a) forging and (b) extrusion

Machining Process Excess material removed in the form of chips with the help of cutting tool from the starting piece so what remains is the desired geometry Examples: (a) turning, (b) drilling, and (c) milling

Joining Process Two or more parts assembled together to make single part. Two types:- Permanent : like welding, brazing, adhesive bonding Non Permanent joining: Nut Bolt, Screw etc

Finishing  L apping,  Polishing  Deburring  Surface treating  Coating  Plating

Nanofabrication Nano = 1/billion Etching techniques, electron-beams, laser-beams

Manufacturing Processes Each manufacturing process has its own advantages and limitations Selection of a particular manufacturing process depends not only on the shape to be produced but on factors related to material properties For example, brittle materials cannot easily be shaped or formed, but can be cast, machined or ground

Current Trends Today engineering and manufacturing firms rely heavily on the use of CAD, CAE, and CAM techniques CAD – Computer Aided Design CAE – Computer Aided Engineering CAM – Computer Aided Manufacturing

Current Trends CAD Visualization in Engineering Design CAE Numerical Methods CAE Modeling & Digital Simulation Finite Element Analysis CAM Manufacturing Processes CNC

Current Trends CIM – Computer Integrated Manufacturing In simple terms, methodology where applicable engineering and manufacturing data is available to the entire business enterprise Common CIM Technologies CNC – Computer Numerical Control Adaptive Control Industrial robots Automated handling of materials Automated and robotic assembly systems JIT – Just-in-Time production FMS – Flexible manufacturing systems Artificial intelligence

Current Trends Benefits Better use of materials, equipment & personnel Better control of production and management of the total manufacturing operation Greatly reduced duplicated information Responsiveness to rapid changes in market High quality products at a lot cost

Quality Product quality is one of the most important aspects of manufacturing Directly influences marketability of a product – customer satisfaction Formerly – inspect products after they were made Currently – build quality in from the design stage and subsequent to it Control of processes is a critical factor in product quality – SPC (Statistical Process Control) Control the process, not the products Major goal is to prevent defects from occurring rather than discover them after the fact

Quality TQM – Total quality management Quality assurance must be the responsibility of everyone involved in design & manufacturing of a product Pioneers in quality control 6 sigma % Defects reduced to 3 per million