Manufacturing Processes

Context: Prototype vs. Product

ME72 Device Prototype Quantity Mfg. cost Variability 1

Toy RC car Product 5,000

Automobile Product 10,000 $10,000+ Very little

$200 in parts $5-10 + your effort Can be a lot Little

Prototype -> Product

Prototypes are one-offs Products are to be manufactured What if someone wanted you to make 1,000 of your device for $50 each?
What would you change?

How do you make it to meet scale, cost, and repeatability?

Better, faster, cheaper Manufacturing Processes
What processes should you use?

Design for manufacturability

How do you design so it is easily made/assembled?

MACHINING PROCESSES SINGLE POINT MACHINING TURNING BORING FACING FORMING SHAPING,PLANNING MULTIPOINT MACHINING DRILLING MILLING SAWING, FILING BROACHING, THREAD CUTTING, GRINDING SURFACE GRINDING CYLINDRICAL GRINDING CENTERLESS GRINDING INTERNAL GRINDING FORM GRINDING ABRASIVE WIRE CUTTING HONING LAPPING ULTRASONIC MACHINING BUFFING, POLISHING BURNISHING TUMBLING GRIT BLASTING CHEMICAL MACHINING ENGRAVING CHEMICAL MILLING CHEMICAL BLANKING ELECTROCHEMICAL MACHINING ELECTRICAL DISCHARGE MACHINING LASTER MACHINING ELECTRON BEAM MACHINING PLASMA-ARC CUTTING FLAME CUTTING, WATER JET CUTTING

DEFORMATION PROCESSES OPEN-DIE FORGING IMPRESSION-DIE FORGING CLOSED-DIE FORGING PRECISION OR FLASHLESS FORGING COINING HEADING, PIERCING, HUBBING, COGGING, FULLERING, EDGING, ROLL FORGING, SKEW ROLLING ROLLING FLAT, RING, THREAD, GEAR, PIERCING EXTRUSION DIRECT, INDIRECT HYDROSTATIC, IMPACT, BACKWARD DRAWING ROD & WIRE, FLAT STRIP, TUBES SWAGING SHEARING BENDING PRESS-BRAKE FORMING, ROLL FORMING TUBE FORMING BEADING, FLANGING, HEMMING, SEAMING STRECH FORMING BULGING DEEP DRAWING PRESS FORMING RUBBER FORMING SPINNING EXPLOSIVE FORMING ELECTROHYDRAULIC FORMING MAGNETIC-PULSE FORMING SUPERPLASTIC FORMING

METAL CASTING AND POWDER PROCESSES CASTING CASTING OF INGOTS CONTINUOUS CASTING SAND CASTING SHELL MOLDING SLURRY MOLDING INVESTMENT CASTING (LOW-WAX PROCESS) EVAPORATIVE CASTING DIE CASTING (GRAVITY-FEED, PRESSURIZED) CENTRIFUGAL CASTING SQUEEZE CASTING RHEOCASTING CRYSTAL GROWING CRYSTAL-PULLING ZONE MELTING Electro forming Plasma Spraying POWDER METALLURGY PRESSING ISOSTATIC PRESSING SINTERING JOINING PROCESSES MECHANICAL JOINING BOLTS, SCREWS, RIVETS SOLID-STATE WELDING DIFFUSION, FORGING, FRICTION, DEFORMATION LIQUID STATE WELDING RESISTANCE WELDING ARC WELDING THERMAL WELDING HIGH-ENERGY BEAM WELDING ELECTRONIC BEAM, LASER LIQUID-SOLID STATE BONDING BRAZING SOLDERING ADHESIVE BONDING PLASTICS AND COMPOSITES JOINING (MECHANICAL, HEATING, SOLVENTS, ULTRASONICS)

Source: Gutowski

Manufacturing process (page 1)

POLYMER PROCESSES EXTRUSION FIBER SPINNING CALANDERING FILM BLOWING COATING (MELTS, SOLUTION, PLASMA, ELECTROSTATIC, PLASTISOL, UV CURABLE) BLOW MOLDING INJECTION MOLDING REACTION INJECTION MOLDING (RIM) COMPRESSION MOLDING TRANSFER MOLDING CASTING THERMOFORMING ROTATIONAL MOLDING SOLID STATE FORMING MACHINING ETCHING SOLVENT PROCESSING FOAMING BONDING IMPREGNATING PAINTING

COMPOSITES PROCESSES (POLYMER COMPOSITES) PULTRUSION FILAMENT WINDING PULL FORMING BRAIDING AUTOCLAVE MOLDING COMPRESSION MOLDING (SMC) RESIN TRANSFER MOLDING AUTOCOMP MOLDING HAND LAY-UP SPRAY-UP AUTOMATIC TAPE LAY-UP STAMPING DIAPHGRAM FORMING INJECTION MOLDING (FILLED THERMOPLASTICS, BMC) REINFORCED REACTION INJECTION MOLDING (RRIM) (METAL MATRIX COMPOSITES) HOT PRESSURE BONDING HOT ISOSTATIC PRESSING LIQUID METAL INFILTRATION ELECTRODEPOSITION PLASMA SPRAY DEPOSITION CERAMICS PROCESSES POWER PROCESSES CONSOLIDATION SINTERING MELT PROCESSES CRYSTALLINE MATERIALS (SILICON) GLASSES DRAWING, CASTING, BLOWING, TEMPERING (OPTICAL & STRUCTURAL FILTERS) COATING SOL-GEL CERAMICS PROCESSING

MICROELECTRONICS PROCESSING CRYSTAL GROWTH CZOCHRALSKI CRYSTAL GROWTH FLOAT-ZONE CRYSTAL GROWTH WAFER PROCESSING SLICING, ETCHING, POLISHINNG SURFACE PROCESSES CHEMICAL VAPOR DEPOSITION (CVD) EPITAXIAL FILM GROWTH POLY CRYSTALLINE FILM GROWTH S102 FILMS OTHER (DIELECTRICS, METALS) OXIDATION ION IMPLANTATION PHYSICAL VAPOR DEPOSITION SPUTTERING EVAPORATION LITHOGRAPHY PHOTORESIST ELECTRON BEAM, X-RAY, ION BEAM LITHOGRAPHY WET ETCHING CHEMICAL DRY ETCHING PLASMA SPUTTER REACTIVE ION PACKAGING DICING DIE ATTACHMENT WIRE BONDING ENCAPSULATION

Source: Gutowski

Manufacturing process (page 2)

Materials used in a car

Source: K. H. Grote

Effect of manufacturing on geometry

Source: Magrab

Performance measures
What makes a good manufacturing process?
Rate
Material flow through system

Time
Order to receipt Setup time + part process time

Cost
Material + Labor + Tooling + Equipment

Quality
Deviation from target
Source: Gutowski

Manufacturing processes
1. Subtractive
Material removal

2. Additive
Material addition, often in layers

3. Continuous
Continuous output (wire, rod)

4. Net shape
Output is the same as (or near) final shape
Source: Gutowski

1. Subtractive Processes
Machining
Turning milling boring grinding

Non-traditional machining
Chemical milling Waterjet machining

Micro-electronics processes
etching processes using either masks or beam

Milling

Basic Types of Milling Cutters and Operations

Source: K. H. Grote and Kalpakjian

Non-traditional machining
Laser machining

Waterjet machining

Source: K. H. Grote

2. Additive Processes
Joining
Welding, soldering, adhering

Rapid Prototyping/Layered manufacturing

Stereolithography, 3D printing

Composites

Welding
Shielded Metal-Arc Welding Process. 50% of all industrial welding employs this.

Source: K. H. Grote

Stereolithography (SLA)
Photopolymers are exposed by laser and cured from a liquid to a solid.

Source: http://cybercut.berkeley.edu/mas2/html/processes/stereolith/more.html

3D printing
Thin layer of powder spread over surface Like an ink-jet printer, binder material selectively joins particles to form the object

Source: http://web.mit.edu/tdp/www/whatis3dp.html

From: http://web.mit.edu/tdp/www/applications.html

Composites
Hand lay-up of layers of resin and fiber. Lightweight & strong, but process is labor intensive.

Source: http://www.saint-gobain-vetrotex.com.br/process_handlay.htm#01

3. Continuous Processes
Extrusion of metals Plastic Extrusion Pultrusion of composites

Metal extrusion
Direct extrusion

Indirect

Hydrostatic

Source: K. H. Grote and Kalpakjian

Plastic extrusion

Source: http://www.telfordsmith.com.au/products/

Pultrusion
For composites Fiber reinforcing material is pulled through resin bath and into a die.

Source: http://users.techline.com/lord/manu.html

4. Net Shape forming

Solids
Metal Forming stamping, forging Powders

Liquids
Casting Injection Molding, thermoforming, blow molding

Mixtures
Infiltration Viscoelastics

Tolerances not as tight

Drawing and stretching

Sheet metal

From: http://www.tms.org/pubs/journals/JOM/9911/Hosford-9911-figure1.html

Forging
Metal workpiece pressed under great pressure into high strength parts

workpiece

Closed die forging

From: http://www.forging.org/facts/idproc.htm

Investment/lost wax Casting

A wax pattern is surrounded with investment material (sand), baked out, then metal is poured in the cavity.

1. Create wax pattern

2. Assemble patterns

3. Apply investment

4. Dewax

5. Fill shell

6. Knockout

7. Cutoff

8. Finished castings From: http://www.hitchiner.com/home.html

Compression Molding

Rubber trivet

Source: Byars 1998

1. Compression molding machine

2. Slabs of HTV silicone rubber

3. Trim excess

4. Finished trivets

Injection Molding

From: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm

Injection molding example

Cutlery made of biodegradable starch

Source: Byars 1998

1. Starch

2. Pellets are formed

3. Injection molded forks on stem

4. Decomposing cutlery

Thermoforming
Very inexpensive for low volumes

Plastic sheet Pattern

From: http://www.kenplas.com/topic/thermoforming.aspx