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Introduction to Manufacturing Processes
Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Introduction to Manufacturing Processes Project Lead The Way, Inc. Copyright 2010
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AIM: How can we identify the various processes used in the creation of a product? Focus questions What important roles do manufacturing processes play in the production of consumer products? How are raw materials converted into finished products? What is meant by a product’s life cycle?
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Products and Manufacturing
Introduction to Manufacturing Processes Products and Manufacturing Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Product Creation Cycle Design → Material Selection → Process Selection → Manufacture → Inspection → Feedback Typical product cost breakdown Project Lead The Way, Inc. Copyright 2009
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Material processing – Process of converting raw materials to finished products Primary _- crushing stone, preparing materials from oil industry for plastics Secondary – converting primary materials to finished products
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Some processing methods
Casting – sand investment or lost wax shell moulding Centrifugal Die casting Metal forming – changing shape by applying pressure and heat
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Metal forging – shaping through plastic deformation e
Metal forging – shaping through plastic deformation e.g to make jewelry, coins Metal extrusion – drawing or forcing material through or around a die by stretching, compressing, bending (used to create components with uniform cross-section) Machining – sawing, bending, turning, reaming, tapping, threading, drilling
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Processing plastics Blow moulding (injection moulding) Thermo forming
Extrusion
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Manufacturing Process
Introduction to Manufacturing Processes Manufacturing Process Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties A sequence of operations and processes designed to create a specific product The process of turning materials into a product ©iStockphoto.com ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Engineers in Manufacturing
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Manufacturing Engineer Select and coordinate specific processes and equipment Industrial Engineer Responsible for the manufacturing system design Materials Engineer Develop and select materials based on desired material properties and manufacturing processes Project Lead The Way, Inc. Copyright 2009
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Manufacturing System Designs
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Job Shop Small quantities of products Large variety of products Products move through the shop to various machines General-purpose machines ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Manufacturing System Designs
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Flow Shop Larger quantities of products Production line Special purpose machines ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Manufacturing System Designs
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Linked-Cell Shop Manufacturing and subassembly cells connected to final assembly Lean production system One piece flow system ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Manufacturing System Designs
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Project Shop Product being manufactured cannot be easily moved during production Production processes are brought to the product Examples: Bridges, ships, large airplanes, locomotives, large machinery ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Manufacturing System Designs
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Continuous Process Large plants Utilized in the manufacture of liquids, oils, gases, and powders ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Manufacturing System Designs
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Lean Manufacturing 100% “good” units flow from process to process Integrated quality control (IQC) All employees are inspectors ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Basic Manufacturing Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Casting and Foundry Forming or Metalworking Machining Joining and Assembly Rapid Prototyping Other Project Lead The Way, Inc. Copyright 2009
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Casting and Foundry Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties In one step raw materials are transformed into a desirable shape Parts require finishing processes Excess material is recyclable Society of Manufacturing Engineers (Producer). (2010). Casting. Available from the Society of Manufacturing Engineers, One SME Drive: Dearborn, Michigan ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Basic Casting Process Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties A mold is created – A cavity that holds the molten material in a desired shape until it is solidified Multiple-use mold Single-use molds Material is heated to a specified temperature Molten material is poured into a mold cavity Molten material solidifies into the shape of the cavity Casting or mold is removed Casting is cleaned, finished, and inspected Project Lead The Way, Inc. Copyright 2009
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Forming and Metalworking Processes
Introduction to Manufacturing Processes Forming and Metalworking Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Utilizes material that has been cast Modify the shape, size, and physical properties of the material Hot and cold forming ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Forming and Metalworking Processes
Introduction to Manufacturing Processes Forming and Metalworking Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Rolling – Material passes through a series of rollers, reducing its thickness with each pass Forging – Material is shaped by the controlled application of force (blacksmith) Project Lead The Way, Inc. Copyright 2009
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Forming and Metalworking Processes
Introduction to Manufacturing Processes Forming and Metalworking Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Extrusion – Material is compressed and forced through a die to produce a uniformed cross section Wire, rod, and tube drawing – Material is pulled through a die to produce a uniformed cross section ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Forming and Metalworking Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Cold forming and forging – Slugs of material are squeezed into dies Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Machining Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Controlled removal of material from a part to create a specific shape or surface finish Cutting element is used Movement must exist between the part and cutting element ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Machining Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Turning Processes Operations that create cylindrical parts Work piece rotates as cutting tool is fed into the work ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Machining Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Turning Processes Lathes and turning centers Processes include: Straight, taper, contour turning, facing, forming, necking, parting, boring, threading, and knurling ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Machining Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Milling Processes Operations that create flat or curved surfaces by progressively removing material Cutting tools rotate as the work piece is secured and fed into the tool Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Machining Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Milling Processes Mills – Vertical and horizontal Processes include: Surfacing, shaping, forming, slotting, T-slotting, angle, straddle, dovetailing, and slab milling Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Machining Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Drilling Processes Operations that create holes Cutting tools rotate and are fed into nonmoving secured work pieces Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Machining Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Drilling Processes Drilling and boring machines Processes include: Drilling, counter drilling, step drilling, boring, counter boring, countersinking, reaming, spot facing, and tapping Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Machining Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Shearing Processes Operations that break unwanted material away from the part A material is placed between a stationary and movable surface. The movable surface (blade, die, or punch) applies a force to the part that shears away the unwanted material. Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Machining Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Shearing Processes Automated hole punch, squaring shear, and rotary cutter Processes include: Shearing, blanking, cutoff, and parting; punching, perforating, and slotting; notching, lacing, and trimming Project Lead The Way, Inc. Copyright 2009
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Abrasive Machining Processes
Introduction to Manufacturing Processes Machining Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Abrasive Machining Processes Operations in which small particles of materials (abrasives) remove small chips of material upon contact Drum, disc, and belt sanders; surface, vertical and horizontal spindle; disc grinders; media blaster; tumblers Project Lead The Way, Inc. Copyright 2009
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Thermal and Chemical Processes
Introduction to Manufacturing Processes Machining Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Thermal and Chemical Processes Operations that cut and shape materials through chemical means No mechanical force is used Electrical discharge, electrochemical, chemical, laser, electron beam, flame cutting, and plasma-arc cutting Processes include: Grinding, sawing, cutting, machining, milling, blanking, and etching Project Lead The Way, Inc. Copyright 2009
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Heat Treating Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Controlled heating and cooling of a material to alter its properties while maintaining its shape Properties include: Strength, toughness, machinability, wear resistance, and corrosion resistance 90% of heat treating is preformed on steel and other ferrous metals Project Lead The Way, Inc. Copyright 2009
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Heat Treating Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties To aid in the manufacturing process, materials can be treated to be weak and ductile and then can be re-treated to provide high strength. Can also occur incidentally during the manufacturing process Project Lead The Way, Inc. Copyright 2009
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Joining and Assembly Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Can you think of a product with only one part? Most products consist of multiple parts that are assembled to form a finished product. Typical assembly processes include: Mechanical fastening; soldering and brazing, welding; adhesive bonding Project Lead The Way, Inc. Copyright 2009
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Joining and Assembly Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Mechanical Fastening Use physical force to hold parts together Mechanical fasteners or part design Screws, bolts, nails, rivets, cotter pins, retaining clips, and edge design ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Joining and Assembly Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Welding Operations that use heat, pressure, or both to permanently join parts Gas, arc, stud, spot, forge, roll laminating, resistance, and induction welding ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Joining and Assembly Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Adhesive bonding Bonding of adjoining surfaces by filling the gap between each surface with a bonding material Glue, cement, thermoplastic, thermosetting, and elastomers ©iStockphoto.com ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Joining and Assembly Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Soldering and Brazing Operation in which metal surfaces are bonded together by an alloy Heated molten alloy flows between the adjoining surfaces When the heat is removed, the molten metal solidifies and the metal surfaces are bonded ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Rapid Prototyping Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Additive process Parts are produced directly from software applications Common rapid prototyping systems include: stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), laminated object manufacturing (LOM), digital light processing (DLP) Project Lead The Way, Inc. Copyright 2009
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Introduction to Manufacturing Processes
Rapid Prototyping Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Finished parts can be field tested depending upon building material Created parts can be used to create a mold Modifications to design can be implemented quickly Project Lead The Way, Inc. Copyright 2009
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Other Manufacturing Processes
Introduction to Manufacturing Processes Other Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Testing Transportation Material handling Packaging ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Material-Specific Manufacturing Processes
Introduction to Manufacturing Processes Material-Specific Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Plastic Processes Ceramic Processes ©iStockphoto.com Project Lead The Way, Inc. Copyright 2009
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Plastics Manufacturing Processes
Introduction to Manufacturing Processes Plastics Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Extrusion A rotating screw forces plastic through a heating chamber and then through a heated die Produces long plastic parts with uniform cross sections Project Lead The Way, Inc. Copyright 2009
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Plastics Manufacturing Processes
Introduction to Manufacturing Processes Plastics Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Injection Molding Heated plastic is forced by a movable plunger through a nozzle and then into a mold. The material fills the mold and then is cooled. Most widely used high-volume production process Project Lead The Way, Inc. Copyright 2009
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Plastics Manufacturing Processes
Introduction to Manufacturing Processes Plastics Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Casting Plastic is melted and poured into a mold – No pressure or fillers are required. Rotational Molding A closed mold is filled with a predetermined amount of plastic. The mold is heated, rotated, and then cooled to create a hollow plastic object with uniform wall thickness. Project Lead The Way, Inc. Copyright 2009
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Plastics Manufacturing Processes
Introduction to Manufacturing Processes Plastics Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Blow Molding A solid bottom hollow tube is placed between two mold halves and heated. The heated tube is then expanded into the sides of the mold with compressed air. Project Lead The Way, Inc. Copyright 2009
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Plastics Manufacturing Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Thermoforming Plastic sheets are heated over an open mold to a working temperature. Once workable, a vacuum is applied to the mold, forcing the plastic sheet to take the shape of the mold. Reaction Molding Liquid reactants are mixed and then pressurized into a mold. No heat is needed. Curing time is typically less than 1 minute. Project Lead The Way, Inc. Copyright 2009
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Ceramic Manufacturing Processes
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Two distinct classes of materials and processes exist. Glass is heated to a molten state, shaped by viscous flow, and then cooled to produce a solid. Crystalline Ceramics Material is shaped and then heated to produce a permanent solid. Project Lead The Way, Inc. Copyright 2009
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Manufacturing Importance
Introduction to Manufacturing Processes Principles Of EngineeringTM Unit 3 – Lesson 3.2 Material Properties Typical product cost breakdown Project Lead The Way, Inc. Copyright 2009
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DO NOW PRODUCT ANALYSIS
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DESIGN MANUFACTURE MARKET USE DISPOSE PRODUCT LIFE CYCLE
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