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Manufacturing Processes: Instructor: T. Kesavadas (Prof. Kesh)
Manufacturing Processes: Instructor: T. Kesavadas (Prof. Kesh)
Manufacturing Processes
Spring 2005
What is Manufacturing?
(1) (2) (3) (4) (5)
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
3000-2000 B.C. 2000-1000 B.C. 1000-1 B.C. 1A.D 1000 A.D 1000-1500 A.D.
Wrought iron,brass Cast iron, cast steel Zinc steel Blast furnace, type metals,casting of bells,pewter Stamping of coins Armor,coinage,for ging steel swords Wire drawing,gold silver smith work
1600-1700 A.D.
1700-1800 A.D.
1800-1900 A.D.
Centrifugal casting,Bessemer process,electrolytic aluminum,nickel steels,Babbitt, galvanized steel, powder metallurgy, tungsten steel, open hearth steel
Prototype production testing and evaluation Inspection and quality assurance CAD Production drawings; Instruction manuals Packaging; marketing and sales literature
Product
Pilot Production
Style
Metallic - what type Non metallic plastic Diameter of clip Shape of clip Manual Automated Stress, Strain Life of clip Stiffness Appearance,Color,Finish Plating,painting
AISI 1010 welded tubing, assembly resistance welded and electrostatically painted AISI 1010,swaged and cadmium plated AISI 1020,forging and chromium plated
Manufacturing of a bicycle
AISI 1010, luster finished AISI 1008, press coil stock,profile formed,welded and plated milled,resistance welded and chromium plated formed,welded and plated Cold drawn medium carbon steel,( similar to AISI 1035) bright zinc plated
AISI 1010,stamped and coined and chromium plated AISI 1010, stamped and chromium plated
Seamless AISI 1020 tubing swaged tube sections brazed into fork crown,painted
Headed brass,nickel plated Aluminum permanent mold casting,machined , polished Hardened high-carbon and buffed steel,thread rolled and chromium plated AISI 1040 forging,carburized and chromium plated Case hardened forging quality steel parts, black oxide coating
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
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
Upper die
Explosive
water
work piece
Lower Die