Fabrication Technology or Manufacturing Technology les 1: Introduction

Herman Terryn Professor Vrije Universiteit Brussel (VUB) Research Group Electrochemical and Surface Engineering (SURF) Department Materials and Chemistry Pleinlaan 2, 1050 Brussels, Belgium Tel:+ 3226293537 (secr 3255) Fax:+3226293200 hterryn@vub.ac.be www.vub.ac.be/SURF part time Professor M2i Materials Innovations Institute Department of Materials Science and Engineering, Tu Delft Surfaces and Interfaces Group, Corrosion Technology and Electrochemistry Mekelweg 2,2628CD Delft,The Netherlands www.m2i.nl

Introduction

Reference book
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Slides are based on that book

Introduction

Manu Factus : Latin for made by hand

Definition: A Well organized method of converting raw material to end product

End Product: Value and utility added to output.

Introduction

Materials in an Automotive Engine

Figure I.1 Section of an automotive engine - the Duratec V-6 - showing various components and the materials used in making them. Source: Courtesy of Ford Motor Company. Illustration by David Kimball.
4 Introduction

AISI 1010 welded tubing, assembly resistance welded and electrostatically painted

Aluminum alloy forging, polished and buffed

Forged aluminum tubing(alloy similar to 6063), polished and buffed

Manufacturing of a bicycle

AISI 1010,swaged and cadmium plated AISI 1020,forging and chromium plated

AISI 1008,press formed resistance welded and painted

AISI 1010, luster finished coil AISI 1008, press stock,profile milled,resistance formed,welded and plated welded and chromium plated formed,welded and plated

Cold drawn medium carbon steel,( similar to AISI 1035) bright zinc plated

AISI 1020 tubing, machine threaded and painted

AISI 1010,stamped and coined and chromium plated

Seamless AISI 1020 tubing swaged tube sections brazed into fork crown,painted

AISI 1010, stamped and chromium plated

Headed brass,nickel plated Aluminum permanent mold casting,machined , polished and buffed AISI 1040 forging,carburized and chromium plated Hardened high-carbon steel,thread rolled and chromium plated AISI 1010,stamped and chromium plated Case hardened forging quality steel parts, black oxide coating

Introduction

Components in Products
Some products are a single components (nail, bolt, fork, coat hanger, etc.) Some products are assemblies of many components (ball point pens, automobiles, washing machines, etc.)

All components are manufactured.

Manufacturing means, literally, Made by Hand.

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History of Manufacturing (until 1700)

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History of Manufacturing (1700-1960)

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History of Manufacturing (1960-2000s)

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Materials Selection for Paper Clips

Questions for consideration: What material properties are required? What manufacturing attributes are required? Would the material and processing strategy change if the desired quantity was 10,000 vs. 1 million per day?

Figure I.2 Examples of the wide variety of materials and geometries for paper clips.
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Manufacture of Light Bulbs

Figure I.3a Components of a common incandescent light bulb. Source: Courtesy of General Electric Company.

Figure I.3b Manufacturing steps in making an incandescent light bulb. Source: Courtesy of General Electric Company.

11 Introduction

Product Design Process

Figure I.4 (a) Chart showing the various steps involved in design and manufacturing a product. Depending on the complexity of the product and the type of materials used, the time span between the original concept and the marketing of the product may range from a few months to many years. (b) Chart showing general product flow in concurrent engineering, from market analysis to selling the product. Source: After S. Pugh, Total Design. Addison-Wesley, 1991.

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Manufacturing Characteristics of Alloys

13 Introduction

Manufacturing Processes: Casting

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Figure I.7a Schematic illustration of various casting processes

Manufacturing Processes: Forming and Shaping

15 Introduction Figure I.7b Schematic illustration of various bulk deformation processes

Manufacturing Processes: Forming and Shaping

16 Introduction Figure I.7c Schematic illustration of various sheet metal forming processes

Manufacturing Processes: Forming and Shaping

17 Introduction Figure I.7d Schematic illustration of various polymer processing methods

Manufacturing Processes: Machining

18 Introduction

Figure 1.7e Schematic illustrations of various machining and finishing processes.

Manufacturing Processes: Joining

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Figure I.7f Schematic illustration of various joining processes

Laser Cutting
Figure I.8 Cutting sheet metal with a laser beam. Source: Courtesy of Rofin-Sinar, Inc. and Manufacturing Engineering Magazine, Society of Manufacturing Engineers

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Hip Replacement

Figure 1.9 Components of a total hip replacement. Source: Courtesy of Zimmer, Inc.

21 Introduction

Manufacturing of Hip Replacement

Figure 1.10 (a) Manufacturing steps in the production of a roll-formed and machined total hip replacement stem; (b) Manufacturing steps in the production of a forged stem. Hip stems can also be produced by investment casting, metal injection molding, insert injection molding, and assorted other processes. Source: Courtesy of Zimmer, Inc. 22 Introduction

Salt and Pepper Shakers

Figure I.12 A salt and pepper mill set. The two metal pieces (at the bottom) for the pepper mill are made by powdermetallurgy techniques. Source: Reproduced with permission from Success Stories on P/M Parts, Metal Powder Industries Federation, Princeton, NJ, 1998.

23 Introduction

Automated welding of automobiles

Figure I.13 Automated spot welding of automobile bodies in a mass production line. Source: Courtesy of Ford Motor Company.

24 Introduction

Application of CAD/CAM to make sunglasses mold

Figure I.14 Machining a mold cavity for making sunglasses. (a) Computer model of the sunglass as designed and viewed on the monitor. (b) Machine the die cavity using a computer numerical-control milling machine (c) Final product. Source: Courtesy of Mastercam/CNC Software, Inc.

25 Introduction

Hourly Compensation for Production Workers

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Requirements of a good manufacturing system

n n n n n Product should meet design requirement Economical Process Quality should be built into the system Should be flexible and responsive to new technology High productivity: Best utilization of man, material, machine, capital and available resources.

27 Introduction

Design for Assembly

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Manufacturing Technology Whole process of transformation from raw material into a product
Fabrication of a Product Selection of the Materials, mostly objects are constructed by assembling different components, often consisting of a variety of materials Property driven Production of the Material Completely different metals, polymers, ceramics en composites Forming of the Material, Producing its shape Completely Different metals, polymers, ceramics en composites Surface Engineering Joining of Materials Durability degradation (polymers) corrosion (metal, glass) End of Life Recycling Waste

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Relative Cost of Repair at Stages of Product Development and Sale

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Average Life Expectancy for Various Products

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Commercially Available Shapes of Materials

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Cost per Unit Volume for Wrought Metals and Polymers Relative to Cost of Carbon Steel

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Approximate Ranges of Scrap Produced in Various Manufacturing Processes

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Example: Material Changes in Transport Aircraft

Figure 40.1 Advanced materials in the Lockheed C-5A transport aircraft. (Note: FRP is fiber-reinforced plastic.)

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Methods of Making a Part

Figure 40.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, and (e) joining two pieces

37 Introduction

Two Methods of Making Dish-Shaped Sheet-Metal Part

Figure 40.7 Two methods of making a dish-shaped sheet-metal part: (a) pressworking using a male and female die, (b) explosive forming using one die only. 38 Introduction

Three methods of casting turbine blades A: conventional casting with ceramic mold B: directional solidification C: Method to produce single crystal blade

FIGURE 3.1 Turbine blades for jet engines, manufactured by three different methods: (a) conventionally cast; (b) directionally solidified, with columnar grains, as can be seen from the vertical streaks; and (c) single crystal. Although more expensive, single-crystal blades have properties at high temperatures that are superior to those of other blades. Source: Courtesy of United Technologies Pratt and Whitney.

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