MAE364 Manufacturing Processes Spring 2005

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MAE364Manufacturing ProcessesSpring 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

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What is Manufacturing?

• (1)
• (2)
• (3)
• (4)
• (5)

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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.
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Manufacturing Process
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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

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Historical development of materials - The Early
Days
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Historical development of materials - The
Industrial Revolution
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Historical development of materials - The Modern
Age
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Req. for a good manufacturingsystem
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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.

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Steps in Modern Manufacturing
Definition of product need, marketing information
Design analysiscodes/standards review physical
and analytical models
CAM and CAPP
Production
Conceptual design and evaluation Feasibility
study
Prototype production testing and evaluation
Inspection and quality assurance
CAD
Production drawings Instruction manuals
Packaging marketing and sales literature
Material Specification process and equipment
selection safety review
Product
Pilot Production
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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

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Manufacturing of a bicycle
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
AISI 1010,swaged and cadmium plated
AISI 1008,press formed resistance welded and
painted
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
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
AISI 1040 forging,carburized and chromium plated
Aluminum permanent mold casting,machined ,
polished and buffed
Case hardened forging quality steel parts, black
oxide coating
Hardened high-carbon steel,thread rolled and
chromium plated
AISI 1010,stamped and chromium plated
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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

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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
  ,Grinding

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Selection of Process

• Unconventional Method
• EDM,ECM,Ultrasound,High Energy Beam,machining
• Joining
• Welding,Brazing,Soldering
• Finishing
• Honing,Lapping,Polishing,Burnishing,Deburring

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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

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Two methods of forming a dish shaped part from
sheet metal Left conventional hydraulic/mechanica
l press using male and female dies Right
explosive forming using only one die.
pressure
Upper die
Explosive
water
work piece
Lower Die
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Three methods of casting turbine blades A
conventional casting with ceramic mold B
directional solidification C Method to produce
single crystal blade
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Selection of Process depends on

• Dimensional and surface finish requirements
• Operational Cost
• Design and strength requirements
• Consequences of various methods

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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

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Design for Assembly
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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