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Introduction to Manufacturing Processes
Pt. 1 Principles Of Engineering © 2012 Project Lead The Way, Inc.
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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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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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