MAE364

Manufacturing Processes
Spring 2005
Instructor: T. Kesavadas (Prof. Kesh)
Associate Professor,
Mechanical and Aerospace Engineering,
1006 Furnas Hall.

http://wings.buffalo.edu/courses/sp04/mae/364/

Teaching Assistants (more details later):
Govindarajan Srimathveeravalli Sridhar Seshadri



What is Manufacturing?
(1)
(2)
(3)
(4)
(5)



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.
Manufacturing Process

History of Manufacturing
Manufacturing started during 5000 4000 BC
Wood work,ceramics,stone and metal work
Steel Production 600-800 AD
Industrial Revolution 1750 AD: Machine tools run by
invention of steam engine
Mass Production and Interchangeable Parts
Computer Controlled Machines 1965
CNC,FMS systems
Historical development of materials
- The Early Days
Period Metals and Casting Forming Process
Egypt ~3100 B.C. to ~
300 B.C
Greece ~1100 B.C. to
~146 B.C
Roman Empire ~500
B.C. to 476 A.D
Middle Ages 476 to
1492
Renaissance 14
th
to
16
th
centuries
Before 4000
B.C
Gold,copper and meteoritic
iron
Hammering
4000-3000
B.C.
Copper casting,stone and
metal molds,lost wax
process,silver,lead,tin,bron
ze
Stamping Jewelry
3000-2000
B.C.
Bronze casting Wire by cutting
and drawing, gold
leaf
2000-1000
B.C.
Wrought iron,brass
1000-1 B.C. Cast iron, cast steel Stamping of coins
1A.D 1000
A.D
Zinc steel Armor,coinage,for
ging steel swords
1000-1500
A.D.
Blast furnace, type
metals,casting of
bells,pewter
Wire drawing,gold
silver smith work
Industrial Revolution
1750-1850
1500-1600 A.D. Cast iron cannon, tinplate Water power for metal
working,rolling mill for
coinage

1600-1700 A.D. Permanent mold casting,brass
from copper and metallic zinc
Rolling(lead,gold,silver
)
Shape rolling(lead)

1700-1800 A.D. Malleable cast iron,crucible steel Extrusion (lead pipe),
deep drawing,
rolling(iron bars and
rods)

1800-1900 A.D. Centrifugal casting,Bessemer
process,electrolytic
aluminum,nickel steels,Babbitt,
galvanized steel, powder
metallurgy, tungsten steel, open
hearth steel
Steam hammer, steel
rolling,seamless tube
piercing,steel rail
rolling, continuous
rolling , electroplating
Historical development of materials
- The Industrial Revolution
WW I and WW II

1900-1920
A.D.
Tube rolling, hot extrusion
1920-1940
A.D.
Die casting Tungsten wire from
powder
1940-1950
A.D.
Lost wax for engineering
parts
Extrusion (steel),swaging,
powder metal for
engineering parts
Space Age 1950-1960
A.D.
Ceramic mold, nodular
iron,
semiconductors,continuou
s casting
Cold extrusion
(steel),explosive
forming,thermo
mechanical treatment

1960-1970 A.D Squeeze casting, single
crystal turbine blades
Hydrostatic
extrusion,electroforming
1970-1980 s Compacted
graphite,vacuum
casting,organically bonded
sand,automation of
molding and pouring, large
aluminum castings for
aircraft structures rapid
solidification technology
Precision
forging,isothermal
forging, super plastic
forming,die design by
analytical methods, net
shape forming
Historical development of materials
- The Modern Age
Req. for a good manufacturing
system

Requirements of a good manufacturing system
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.

Steps in Modern Manufacturing
Production drawings;
Instruction manuals
Conceptual design and
evaluation Feasibility study
Design
analysis;codes/standards
review; physical and
analytical models
Prototype production
testing and evaluation
Definition of product need,
marketing information
Material Specification;
process
and equipment selection;
safety review
Pilot Production
Production
Inspection and quality
assurance
Packaging; marketing and
sales literature
Product
CAD
CAM and CAPP
Manufacturing of a Paper Clip
What is the function
How long does it last
How critical is the part
Material Metallic - what type
Non metallic plastic
Dimension Diameter of clip
Shape of clip
Method of manufacturing Manual
Automated
Function based design Stress, Strain
Life of clip
Stiffness
Style Appearance,Color,Finish
Plating,painting


AISI 1010,swaged
and cadmium plated
AISI 1020,forging
and chromium plated
AISI 1010, luster finished
coil stock,profile
milled,resistance welded
and chromium plated
formed,welded and plated
AISI 1008, press
formed,welded and plated
Cold drawn medium
carbon steel,( similar to
AISI 1035) bright zinc
plated
Headed brass,nickel plated
Aluminum permanent mold
casting,machined , polished
and buffed
Hardened high-carbon
steel,thread rolled and
chromium plated
AISI 1010,stamped and
chromium plated
Case hardened forging
quality steel parts, black
oxide coating
AISI 1040
forging,carburized and
chromium plated
AISI 1010,stamped and
coined and chromium
plated
AISI 1010, stamped and
chromium plated
Aluminum alloy forging,
polished and buffed
Forged aluminum
tubing(alloy similar to
6063), polished and buffed
AISI 1010 welded tubing,
assembly resistance welded
and electrostatically
painted
AISI 1008,press formed
resistance welded and
painted
AISI 1020 tubing, machine
threaded and painted
Seamless AISI 1020 tubing
swaged tube sections
brazed into fork
crown,painted
Manufacturing
of a bicycle

Assignment 1
Select a simple product of your choice
Try to analyze the different materials,
processes, etc
Use library resources
We will discuss this in the class on Friday
Selection of Process: Topic to be
covered
Casting
Sand/Expandable Mold,Permanent Mold

Forming and Shaping
Rolling,forging,extrusion,powder metallurgy

Machining
Turning,Boring,Drilling,Milling,Planing,Broaching,Grin
ding
Selection of Process
Unconventional Method
EDM,ECM,Ultrasound,High Energy Beam,machining
Joining
Welding,Brazing,Soldering
Finishing
Honing,Lapping,Polishing,Burnishing,Deburring

Objectives of this course and what is
expected of you
Manufacturing processes and fundamentals
Selection of appropriate process to meet design
requirements
Effect of process parameters and variables on the
quality of parts produced
Effect of material properties on a given process
Decision and methods for different product size and
mix
Effect of design on manufacturability
Overview of computer aided methods in traditional
manufacturing processes


Lower Die
work piece
Upper die
Explosive
water
pressure
Two methods of forming a dish shaped part from sheet metal
Left: conventional hydraulic/mechanical press using male and female dies
Right: explosive forming using only one die.
Three methods of casting turbine blades
A: conventional casting with ceramic mold
B: directional solidification
C: Method to produce single crystal blade
Selection of Process depends on
Dimensional and surface finish requirements
Operational Cost
Design and strength requirements
Consequences of various methods
Design for Assembly
Design of the product to permit assembly
Possibility of multipurpose parts
Capability of manufacturing process to consistently
produce parts which can be assembled without
problem
Method or process of assembly
Automated Systems,Manual Systems etc
Design for Assembly
Automation and Impact of Computers
Machine Control Systems
Computer Numerical Control machines,
Robots,Machines,Processes
Computer Integrated Technology
Responsive to market change
Better use of process,man,machining management etc
CAD/CAM: Computer Aided Design And Manufacturing
FMS: Flexible Manufacturing System
GT: Group Technology
VR: Virtual Reality