01 Introduction

Manufacturing Processes
Introduction
Introduction
© Pearson & MIT & GNU Su-Jin Kim
What is Manufacturing?
• Manufacturing is the process of converting raw materials
into products.
• Nations with largest GDP growth concentrated on high value-
added products, such as automobiles and machinery.
Powder Manufactu Bread

ring?
Introduction
What did we make?
Paper  Mask Paper+Bamboo  Kite Pet bottle  Rocket
Who to make it?

Manufacturing Process
Introduction
ManufacturingChopstick
Processes  Gun Paper+Bamboo  Airplane
Materials
The types of materials generally used in manufacturing:

1. Ferrous metals : Steels
2. Nonferrous metals and alloys : Aluminium, copper
3. Plastics
4. Ceramics
5. Composite materials
6. Silicon
Introduction
Metals
• Iron (Fe): Cast iron, Steel, Carbon steel, High strength
steel, Stainless steel, Tool steel
• POSCO: http://www.posco.com -> Products and Technology
• Copper (Cu), Brass (Cu+Zn,Zinc), Bronze (Cu+Sn,Tin)

• Aluminum (Al), Duralumin (Al+Cu+Mg+Mn)
• Lead, Titanium, Nickel, (Zinc), Gold, Silver
Introduction
Polymer (Plastic)
• Thermoplastics: Nylon, Polyethylene, Polystyrene, Vinyl
• Thermosets: Epoxy, Phenolic, Polyester
• Elastomer: Rubber
Introduction
Ceramics
Ceramics
• Clay, Glass (SiO2), Diamond (C), Alumina (Al2O3),
Semiconductor (Si+P+?)
Powder metals
Introduction
Composite
• Reinforced plastics, Concrete (Cement + Sand), Concrete-
steel wire, Wood, Polywood, Polymer matrix
• FRP, Glass reinforced plastic, Carbon reinforced plastic
Introduction
Material property
• Melting temperature, Density (Specific weight)
• Harness, Toughness (Ductile-Brittle), Strength
• Chemical stability (Corrosion), Electric property
Properties
• Recycle, Price Metal Plastic Ceramic
Melting temperature 1,000℃ 200℃ 3,000℃
Strength 200GPa 10GPa -300GPa, +50GPa
Toughness Ductile Ductile Brittle
Hardness High Low Very High
T. E. conductivity High Low Low
Stiffness (=E) High Low High
Chemical stability Mid High Very high
Density High Low High

Introduction
ManufacturingPrice
Processes High Low High
Material & Process
Materials Process Products
Machining Axis
Metals Forming Crank arm
Casting Engine housing
Plastics Injection molding Toy
Ceramic Powder forming

Welding Ship
Joining processes
Mechanical assembly Car
Silicon Deposition, Etching Memory
Introduction
Manufacturing Process
Market & Conceptual Design for

Specification Design Manufacture
Unit
UnitManufacturing
Manufacturing
•Machining
Assembly
Assemblyand
and
Product •Injection molding
Joining
Joining
Sell •Welding •Casting
•Bolting •Stamping
•Bonding •Chemical vapor deposition
Introduction •Soldering
Manufacturing Attributes for
Decision Making
1. Cost
2. Quality
3. Flexibility
4. Rate
Introduction
Machining (Cutting)
1. Cost: Expensive $100(Cylinder)-$10,000(Mold)
2. Quality: Very high, precise
3. Flexibility: Any shape cut by tool, Small production
4. Rate: Slow
Introduction
Forming (Metal squeezing)
1. Cost: Cheap, $0.1 - $100, Expensive equipments, over
$100,000
2. Quality: Reasonable
3. Flexibility: Shapes limited constant cross-section, Mass
production
4. Rate: Fast (cycle time in sec), high volume
Introduction
Casting
1. Cost: Expensive $100 - $10,000
2. Quality: Requires post finishing (except Die casting)
3. Flexibility: Very flexible, Good for large parts
4. Rate: Very slow
16V engine block Machine tool surface

plate
Introduction
Plastics Injection
1. Cost: Cheap, $0.1 , Expensive mold, over $10,000
2. Quality: Very high
3. Flexibility: Opening for ejection , Mass production
4. Rate: Very fast
Introduction
Welding
1. Cost: Cheap, but expensive labor
2. Quality: Wide range
3. Flexibility: Manual vs automated
4. Rate: Slow in general
Introduction
Manufacturing Processes Very Large Crude Carrier (VLCC)
Thinfilm fabrication
1. Cost: Very expensive equipments, $Millions
2. Quality: Very high, Nanometer pattern
3. Flexibility: Any shape in 2-D
4. Rate: Slow
300mm dual stage lithography

system capable of 110nm
Introduction resolution

01 Introduction

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

01 Introduction

Uploaded by

Copyright:

Available Formats

Manufacturing Processes

Powder Manufactu Bread

Paper  Mask Paper+Bamboo  Kite Pet bottle  Rocket

Who to make it?

The types of materials generally used in manufacturing:

• Copper (Cu), Brass (Cu+Zn,Zinc), Bronze (Cu+Sn,Tin)

Chemical stability Mid High Very high

Density High Low High

Ceramic Powder forming

Market & Conceptual Design for

16V engine block Machine tool surface

300mm dual stage lithography

You might also like