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Module 1:
Introduction
ir. Hans Ponsen
Master Engineering & Management
April 2011
Content of module 1
Introduction
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Examination requirements
Lecturer
Lecturer : ir. Hans Ponsen
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Educational concept
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To be able to select the most appropriate manufacturing process for the production of any product
or product part.
Design guidelines related to manufacturing processes.
Main objective: Answer the questions
What is the best way to manufacture an arbitrary
product or product part?
How are existing products made?
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Examination requirements
Final mark:
- 30% participation in group discussions and work
- 70% written or oral examination
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What is manufacturing?
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Literal:
What is manufacturing?
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Representation of manufacturing
in a technological way
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What is manufacturing?
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Representation of manufacturing
in a economical way
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Importance of manufacturing
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Manufacturing
: ~ 20% of the GNP
Agriculture, mining
: < 5% of the GNP
Construction, public utilities : ~ 5% of the GNP
Service sector
: ~ 70% of the GNP
(GNP = Gross National Product)
In broad outlines:
Mans discovery and invention of materials and
processes to make things, since 6000 years ago
Principle of division of labour Adam Smith (~1750)
Industrial Revolution (1770 1850), steam engine,
machine tools, machinery for textile industry
Factory system, UK
American system, interchangeable parts
Whitney (~1800), guns (muskets), USA
Second Industrial revolution mass production,
scientific management, assembly lines, Ford
(~1915), cars, USA
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Manufactured products
-
Product example
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Electric shaver
Manufacturing capability
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Materials in Manufacturing
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Metals
- Ferrous: Steel (iron-carbon, 0,02% - 2,11% C)
Cast iron (iron + 2% - 4% C + silicon)
- Nonferrous: copper, aluminium, nickel, alloys
Ceramics: clay, silica, carbides (Al, Si), nitrides (Ti)
Polymers
- Thermoplastic polymers: PE, PP, PS, PVC
- Thermosetting polymers: phenolics, epoxies
- Elastomers: rubber, neoprene, silicone, PU
Composites: more phases, particles/fibres + matrix
glass reinforced plastic, Kevlar, WC in cobalt
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Materials in Manufacturing
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Venn diagram
Classification
of
Manufacturing
processes
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Manufacturing processes
Processing operations
1) Shaping operations
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3) Surface processing
- Cleaning, coating, plating, deposion
Pouring of the
liquid or melt
Solidification
Particulate processing
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Sintering
Powder
Pressing
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Deformation processes
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Forging
Extrusion
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Shaping processes
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Turning
Drilling
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Milling
Manufacturing processes
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1) Processing operations
2) Assembly operations
- Permanent joining: welding, brazing, adhesives
- Mechanical assembly: bolts, screws, rivets, etc.
3) Production machines and tooling
- Machine tools: lathe, milling machine, etc.
- Presses, forge hamers, rolling mills
- Welding machines and equipment
- General and special purpose equipment
- Tooling
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Production systems
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Plant layouts
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Fixed-position layout
Cellular layout
Process layout
Product layout
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Production System
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Mutual relationships
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Function
Shape
Material
Process
Product attributes
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Specification of tolerances
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Bilatertal
tolerance
Unilateral
tolerance
Limit
dimensions
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Geometric
tolerances
a. Flatness
b. Circularity
c. Cylindricity
d. Perpendicularity
e. Concentricity
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Surfaces
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Characteristics of surfaces
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Surface texture
Surface texture Deviations from the surface
-
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Possible lays
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Lm
L
0
.dx
Ra
i 1
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yi
n
Symbols on
engineering drawings
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Final remarks
Final remarks related to product attributes:
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Surface integrity
- Changes in the subsurface layer
- Alterations like cracks, craters, hardness changes
inclusions, residual stresses, etc. (See Table 5.2)
- Different reasons: mechanical, thermal,etc.
Effect of manufacturing processes on
- Tolerance limits: See Table 5.4
- Surface roughness values: See Table 5.5
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Tolerance limits
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Table 5.4
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Table 5.5
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Aspects:
Batch size: Single product, medium size or mass
production
Geometric requirements: Shape and tolerances
Manufacturing phase: Primary or secondary
Tools: General purpose or product specific
Assembly:
Pay attention to assembly aspects
during process selection for part manufacturing
Minimize costs: Costs per product + Costs per
batch + Once-only costs
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Problem 1.1
Subject: Manufacturing in Yemen
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Video films
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