Professional Documents
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1 INTRODUCTION TO MANUFACTURING
Manufacture
Process of making raw materials into finished products (Machinery and
division of labor)
Food, drugs, textiles, chemicals, and everything made usable by the
conversion of shape, form, or properties of natural materials
1.1 INTRODUCTION TO MANUFACTURING
Engineering materials includes most metals and those plastics that are
solids and gave reasonable strength at room temperature
1.2 HISTORY OF MANUFACTURING
Family units. Foods and shelter. Factory forms: excess goods were
available for sale and trade.
Early manufacturing. Agricultural and military. Industrial operations:
reduction ore to metal.
1.2 HISTORY OF MANUFACTURING
MATERIALS
One or more materials are needed for any product, and most can be
processed in a number of different ways
Properties. The practical difference between various materials is in
properties or combinations of properties.
Compared to many other materials, steel is hard and strong and may be
chosen as a manufacturing materials for these reasons. Tests: Standard
Tensile Test, Hardness
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
MATERIALS
Property Variations
The properties of an element may be changed by the addition of even
small parts of another element
The properties of elements or combinations of elements (compounds)
can be varied by the type of treatment given the material
The properties are affected by the processes being used with the objetive
of shaping the material
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
MATERIALS
Property Variations
Reducing the cross sectional size during the shaping of most metals
results in an increase in hardness and strenght that may be undesirable if
the metals must undergo further deformation processing. In many cases,
this increase in hardness and strength that occurs as a result of the
processing can be beneficial and part of the product design.
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
ECONOMICS
Designers must not only know the functional requirements of the
product but also have some knowledge of the probable market demands
for various levels of quality and appearance.
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
ECONOMICS
The designer’s choices of materials, shapes, finishes, tolerances, and
other factors restrict the possible choices to be made in the
manufacturing process. The designer may also specify the NDT criteria,
thus influencing the choice of NDT method
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
ECONOMICS
Choice of Materials
Engineering materials, metals and others, have properties that vary over
wide ranges with many overlaps. Costs also vary widely, but the cheapest
material suitable for the product does not necessarily ensure the product
will have the lowest cost.
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
ECONOMICS
Quantity
The number of a product that is made can have more influence on the
cost than the design or the type of material used.
The actual production time for each product is usually inversely related
to the setup cost.
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
ECONOMICS
Quality
Quality costs money. Higher quality implies longer life, better finishes,
better materials, quieter operation, and more precision. These factors all
involve greater costs that may be justified by market demand.
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
ECONOMICS
Inspection
Inspection also costs money to perform, but, in another sense, like
advertising, it pays; in fact, it is essential to ensure better quality product
output and to improve customer relations.
- Inspection equipment, qualified nondestructive testing personnel
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
DESIGN
Appearance in Addition to Function Usually Important
In the case of every product, the manufacturing process must be
preceded by the design.
The designer´s problems arise mainly from the fact that a single solution
is seldom indicated. Of the many possible materials and shapes that may
satisfy the functional requirements, some may have better appearance
than others.
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
DESIGN
Quality and Costs Must Balance
It is generally true that costs will be different for different material and
processing choices, and considerable screening of the alternatives can be
done purely on a cost basis. However, the quality obtained with more
expensive materials or methods may be superior to that of the cheaper
choices, and decisions must often be made regarding some combination
of quality and cost
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
DESIGN
Availability of Facilities Affects Choices
Obviously, the decisions made by the designer are far-reaching and of
extreme importance. These decision are based on:
– Materials and shapes,
– Specified tolerances
– The equipment and the trained personnel
– Economical manufacture
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
DESIGN
Availability of Facilities Affects Choices
In many cases, the decisions that govern the choice of materials and
processes must be made in an arbitrary manner.
Designers cannot be expected to be experts in all the phases of
production that influence the final quality and cost of a product.
1.6 MATERIAL CONSIDERATION IN SELECTION OF PROCESSES
DESIGN
NDT Design
Similarly, the design engineering function must receive technical
guidance from key NDT personnel in order to ensure that the design
requirements can be met.
Both the capabilities and limitations of the various methods of NDT must
be considered in the design phases of the product life cycle in order to
achieve optimum product effectiveness
1.7 EFFECT OF MANUFACTURING PROCESS ON THE PROPERTIES
OF THE PRODUCT
STATES OF MATTER
Material may exists in one of the three states of matter, gas, liquid, or
solid, but except for some special processes with relatively small use,
such as vapor deposition, or for zinc refining, the gaseous state is of small
importance in manufacturing
1.7 EFFECT OF MANUFACTURING PROCESS ON THE PROPERTIES OF THE
PRODUCT
Most Manufacturing Processes Are to Change Material Shapes
For manufacturing purposes in which shape changing is the
objective, the solid state may be though of as existing in two forms.
Below the elastic limit, materials are dealt with as rigid materials.
Above the elastic limit, solid materials may flow plastically and
shape changing may be accomplished by application of external
loads to cause permanent relocations within the structure of the
material.
1.7 EFFECT OF MANUFACTURING PROCESS ON THE PROPERTIES OF THE
PRODUCT
Most Manufacturing Processes Are to Change Material Shapes
The end result of dealing with materials in the liquid form are
similar to those with materials above the elastic limit. No
appreciable density or volume change occurs, and the shape may
be changed without loss of material.
1.7 EFFECT OF MANUFACTURING PROCESS ON THE PROPERTIES OF THE
PRODUCT
SHAPE-CHANGING PROCESSES
Shapes Changed with No Volume Change, by Additions, and by
Subtractions. Shape changing is possible in any of theses states,
but most manufacturing processes by definition or nature deal with
materials in only one of these possible forms. Figure 1.4 shows the
processes for shape changing without material loss and those in
which material is added or taken away
1.7 EFFECT OF MANUFACTURING PROCESS ON THE PROPERTIES OF THE
PRODUCT
1.7 EFFECT OF MANUFACTURING PROCESS ON THE PROPERTIES OF THE
PRODUCT
SHAPE-CHANGING PROCESSES
No volume Change. In those processes in which no volume change
occurs, property changes are usually large and distributed
throughout the material.
1.7 EFFECT OF MANUFACTURING PROCESS ON THE PROPERTIES OF THE
PRODUCT
SHAPE-CHANGING PROCESSES
No volume Change. In casting, the shape change occurs by melting
and subsequent solidification to a prescribed shape. Casting is
often the most economical method for producing complex shapes,
particularly where reentrant angles exist
1.7 EFFECT OF MANUFACTURING PROCESS ON THE PROPERTIES OF THE
PRODUCT
SHAPE-CHANGING PROCESSES
No volume Change. Wrought materials, are produced by plastic
deformation that can be accomplished by hot-working (above the
recrystallization temperature) or cold-working.
1.7 EFFECT OF MANUFACTURING PROCESS ON THE PROPERTIES OF THE
PRODUCT
SHAPE-CHANGING PROCESSES
Additions or Combinations. New shapes can be produced either by
joining pre-formed shapes mechanically or by any of various
bonding means. Some examples are: welding, soldering and
brazing, mechanical fastening, shaping, and powder processing.
1.7 EFFECT OF MANUFACTURING PROCESS ON THE PROPERTIES OF THE
PRODUCT
SHAPE-CHANGING PROCESSES
Subtraction or Removal. Shape changing may also be accomplished
by taking material away in chip or bulk form or by material
destruction. The property changes in theses processes are more
localized, and energy requirements are generally smaller.
Mechanical separation can be performed by removal of chips or by
controlled separation along predetermined surfaces: machining,
shearing.
1.7 EFFECT OF MANUFACTURING PROCESS ON THE PROPERTIES OF THE
PRODUCT
SHAPE-CHANGING PROCESSES
Special Shape-Changing Methods. With the advent of new
materials difficult to fabricate by convention means and of many
designs requiring shapes and tolerances and material combinations
difficult to achieve with conventional processes, a number of
electrical and chemical processes have been developed for
removing or adding material: metal plating, electrical discharge
machining chemical milling, ultrasonic grinding, and electron beam
machining.