1. ISAT 430 Introduction Spring 2001 Dr. Ken Lewis

2. Module 1 Spring 2001Dr. Ken Lewis ISAT 4302 Preliminary Stuff Professor – Dr. Ken Lewis Office – ISAT 125 Phone – 2753 Email – lewisgk Office hours – Whenever you want (assuming no other conflicts) Call me? – ANYTIME! Ask questions? -- ANYTIME!

3. Module 1 Spring 2001Dr. Ken Lewis ISAT 4303 Meeting Place and Times -- Syllabus is WRONG!!!! Lectures: MW 1010 – 1100 in room 148 Recitations: Tu 1100 – 12345 in room 1027

4. Module 1 Spring 2001Dr. Ken Lewis ISAT 4304 Preliminary Stuff -- Grading Hourly Exams (2)15% (30%) Project15% Quizzes15% Homework and class participation 10% Final exam30% 100%

5. Module 1 Spring 2001Dr. Ken Lewis ISAT 4305 Preliminary Stuff Units  If a problem uses units, be explicit and clear, and use units.  Units are your friend.

6. Module 1 Spring 2001Dr. Ken Lewis ISAT 4306

7. ISAT 430 Manufacturing Processes Spring 2001 Dr. Ken Lewis

8. Module 1 Spring 2001Dr. Ken Lewis ISAT 4308 What are we about? Material Manipulation conversion & forming, the molding and shaping of metals, glasses, ceramics, polymers and composites. From the earth to a part. removal, the machining, grinding, cutting, lithography and etching of materials. Getting rid of the excess stuff. joining, the welding, brazing, and soldering of materials. The sticking of things together. Assembly, mechanical assembly and electronics manufacturing. Putting together dissimilar materials.

9. Module 1 Spring 2001Dr. Ken Lewis ISAT 4309 We will delve into the sciences which are behind these processes.

10. Module 1 Spring 2001Dr. Ken Lewis ISAT 43010 Objectives of the Course We will look at the following:  How does stuff come from the Earth and become cool and useful?  What is the “process – structure – property – performance continuum”?  What are the material concerns that we have as we make a material selection to make a particular product?  What are the practical concerns that we have?

11. Module 1 Spring 2001Dr. Ken Lewis ISAT 43011 What will we look at first? The process – structure – property – product – performance continuum. An overview of the main methods of manufacturing.  The materials  The methods of change What factors affect the selection of manufacturing processes.

12. Module 1 Spring 2001Dr. Ken Lewis ISAT 43012 Process-Microstructure-Property-Product Performance Continuum Product Performance or Function Composition & Structure Synthesis/ Processing Properties/ Behavior Changes Dictate Changes Control Limit Affects Indicate

13. Module 1 Spring 2001Dr. Ken Lewis ISAT 43013 What are Manufacturing Processes???

14. Module 1 Spring 2001Dr. Ken Lewis ISAT 43014 Manufacturing Processes of Today Essentially, these are the ways that Man has found to take the characteristics of a material (mud, gold, a tree, a pile of ore, sea water….. ) and:  Make parts or things  Make things of greater value  Make things do something

15. Module 1 Spring 2001Dr. Ken Lewis ISAT 43015 Manufacturing Processes of Today 2 These processes change or alter the materials  State  Geometry  Properties  Microstructure  Appearance  ERGO “Value”

16. Module 1 Spring 2001Dr. Ken Lewis ISAT 43016 Primary Goals of a Manufacturing Process Produce components from selected materials  At the lowest possible cost  In the correct shape  Having optimum properties for its proposed use. Key Point – manufacturing adds value to the materials.

17. A Small History of Manufacturing

18. Module 1 Spring 2001Dr. Ken Lewis ISAT 43018 History First came the discovery of materials.  Wood tools  Fibers  Cloth  shelter  Clay  Pottery  Bricks  Metals  Copper  Bronze  iron Note that not only was the material discovered but processes which would change the materials form had to be Discovered.

19. Module 1 Spring 2001Dr. Ken Lewis ISAT 43019 History All that was available for millennia was simple hand crated materials.  One of a kind  Produced in a shop fashion.  Even when the Romans were churning out armor and weapons, it was just a shop multiplied many times. First step forward was the discovery of ‘division of labor’  Dividing the total process into a number of sub processes and making an individual worker and expert in just one or two sub processes.

20. Module 1 Spring 2001Dr. Ken Lewis ISAT 43020 The Industrial Revolution (1760 – 1845) Four things changed production forever.  The steam engine  Machine tools  Textile machinery  The factory system

21. Module 1 Spring 2001Dr. Ken Lewis ISAT 43021 History 3 – The Industrial Revolution All was what are called “cottage industries”. The Industrial Revolution  Change was driven by the discovery of a new source of power “STEAM”!  John Watt invented the steam engine.  Steam power quickly replace the traditional water wheels, animal wheels, and windmills.  Developed in England  England tried to keep the new technologies to give themselves an economic edge Didn’t work.

22. Module 1 Spring 2001Dr. Ken Lewis ISAT 43022 History 4 – The Industrial Revolution 2 Possible only because of machine tools...  John Wilkinson invented the boring machine in 1775.  Allowed Watts to make the steam engine  Henry Maudsley developed the screw cutting lathe in 1800  Allowed turning with much greater precision and speed. The textile industry was vastly changed  The spinning jenny  Power loom  Jacquard loom

23. Module 1 Spring 2001Dr. Ken Lewis ISAT 43023 History 5 – The Industrial Revolution 3 The factory system  Division of labor  Several fold increase in labor efficiency

24. Module 1 Spring 2001Dr. Ken Lewis ISAT 43024 History 6 Other forces  Eli Whitney in the US developed the concept of interchangeable parts.  Precursor to mass production and assembly lines.  Henry Ford introduced the assembly in Detroit in 1913

25. Module 1 Spring 2001Dr. Ken Lewis ISAT 43025 Classification of Manufacturing Processes Conversion Processes Manufacturing Processes Processing OperationsAssembly Operations Extraction Casting Particulate processing Forming processes Material removal Permanent joining processes Brazing & soldering Adhesive bonding Shaping processes Property enhancing processes Heat treatment Surface cleaning Coating/ depositn. Mechanical fastening Welding Surface processing operations Threaded fasteners Permanent fastening methods

26. Module 1 Spring 2001Dr. Ken Lewis ISAT 43026 Manufacturing Processes Conversion  Transform materials from their raw or natural state to a more useful semi-finished form Processing Operations  Transform a material in transit from one state of completion to a state closer to the desired product. Assembly Operations  Unit separate parts to from a new entity

27. Module 1 Spring 2001Dr. Ken Lewis ISAT 43027 Conversion Processes Extraction  Conversion of metals from their natural ores by mining, separation and reduction to the metallic state. Casting  shaping by the transformation of the liquid to the solid state;  exploits the fluidity of a liquid as it takes shape and solidifies in a mold.

28. Module 1 Spring 2001Dr. Ken Lewis ISAT 43028 Processing Operations Add value by:  Changing the geometry  Properties  Appearance Achieved by the controlled application of thermal, mechanical, electrical or chemical energy to accomplish the above

29. Module 1 Spring 2001Dr. Ken Lewis ISAT 43029 Processing Operations 2 Can be divided into three divisions  Shaping Operations  Property Enhancing Operations  Surface Processing Operations

30. Module 1 Spring 2001Dr. Ken Lewis ISAT 43030 Shaping Operations Processes that alter the geometry and maybe the physical and mechanical properties. Examples  Casting (of metals)  Molding of plastics  Deformation processes – sheet forming, forging, extrusion, drawing, etc.,  Particulate processing – powder metallurgy  Material removal processing – machining, cutting and grinding

31. Module 1 Spring 2001Dr. Ken Lewis ISAT 43031 Property Enhancing Operations Operations that manipulate or enhance both the physical and mechanical properties of the starting solid semi-finished material or product. Control of properties of a part during manufacture  Allow properties to be matched to the application  Especially when the magnitude or directionality of the mechanical properties is important

32. Module 1 Spring 2001Dr. Ken Lewis ISAT 43032 Property Enhancing Operations 2 Examples  Heat treatment  Organic composite cure schedules  Deformation processes

33. Module 1 Spring 2001Dr. Ken Lewis ISAT 43033 Surface Processing Operations Operations performed to clean, treat, coat, or deposit material onto the exterior surface of the part Examples  Electroplating – anodizing  Nit riding  Case hardening  Grinding  painting

34. Module 1 Spring 2001Dr. Ken Lewis ISAT 43034 Assembly Operations Joining Processes Mechanical Assembly

35. Module 1 Spring 2001Dr. Ken Lewis ISAT 43035 Joining Processes Uniting individual workpieces  Permanently  Semi-permanently Melting, using adhesive bonding materials Usually results in added weight Examples  Welding  Brazing & soldering  Adhesive bonding  Solid state bonding.

36. Module 1 Spring 2001Dr. Ken Lewis ISAT 43036 Mechanical assembly Units sub assemblies without melting Examples  Semi-permanent  Nuts  Bolts  Screws  Threaded fasteners  Permanent  Press-fitting  Expansion fits.