Lecture 9 - Manufacturing in Engineering

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1 Introduction Dr. Carolyn Skurla Speaking Slide 2 Process Selection Choice depends on: The material from which the component is to be made. The size, shape, and dimension tolerances for the component. The number of components to be manufactured. Slide 3 Process Selection Each process is characterized by: The materials it can handle. The shapes it can make and the dimension tolerances it can achieve. The complexity and size of the shape it can make. The effect the process has on the material s properties. Slide 4

2 Process Selection Finding the between design requirements and process attributes Iterative procedure Interaction between function, material, shape, and process are taken into account. Slide 5 Class of Manufacturing Processes Raw Material Casting Methods Gravity, Pressure, Die Casting Pressure Molding Polymer Molding, Glass Molding Deformation Processing Roll, Forge, Draw, Press Powder Methods Sinter, Slipcast, Hot Isostatic Pressure Special Methods Lay-Up CVD, Electroform Machining Cut, Turn, Plane, Drill, Grind Heat Treat Quench, Temper Steels, Age-Harden Al-Alloys Joining Bolt, Rivet, Weld, Braze, Adhesive Slide 6 Finish Polish, Plate, Anodize, Paint Casting Methods Sand casting Sources: Slide 7 Materials Science: A Multimedia Approach, John C. Russ

3 Die casting Casting Methods Source: Materials Selection in Mechanical Design, Michael F Ashby Slide 8 Casting Methods So, which one do we choose? It depends Source:Materials Selection in Mechanical Design, Michael F Ashby Slide 9 Pressure Molding Compression molding Transfer molding Source:Materials Selection in Mechanical Design, Michael F Ashby Slide 10

4 Pressure Molding Blow molding Source: Materials Selection in Mechanical Design, Michael F Ashby Materials Science: A Multimedia Approach, John C. Russ Slide 11 Pressure Molding Injection molding > 50% of polymer components are manufactured by this method Source: Materials Selection in Mechanical Design, Michael F Ashby Slide 12 Deformation Processing Rolling Cold rolling Warm rolling Hot rolling Sources: Materials Science: A Multimedia Approach, John C. Russ Slide 13

5 Deformation Processing Forging Example Closeddie forging A heated blank is placed between 2 halves of a die A single compressive stroke squeezes the blank into the die to form the part. Sources: Materials Selection in Mechanical Design, Michael F Ashby Slide 14 Deformation Processing Closed-die forging (cont) Once the die halves have separated, the part can be ejected immediately using an ejector pin. The waste material, called flash, is removed later. Source: Slide 15 Deformation Processing Extrusion Source: Materials Selection in Mechanical Design, Michael F Ashby Slide 16

6 Powder Methods Source:Materials Selection in Mechanical Design, Michael F Ashby Powder sintering Hot isostatic pressing (HIPing) Slide 17 Machining Cutting Turning Drilling Milling Grinding Source:Materials Selection in Mechanical Design, Michael F Ashby Slide 18 Joining & Fastening Welding Mechanical joining Source: Materials Selection in Mechanical Design, Michael F Ashby Slide 19

7 Manufacturing Process Sand Casting Die Casting Compression molding Transfer molding Blow molding Injection molding Rolling Forging Extrusion Powder sintering Machining Joining Fastening Relative Tooling Costs Relative Equipment Costs Relative Labor Costs Materials Shapes Surface Finish Economic Batch Sizes Examples Additional Comments

8 Manufacturing Methods Sample Problem Based on your notes from Lecture 9, match the following items to be manufactured with the manufacturing process. Note some methods may be used more than once and some possibly not at all!! 500 items of steel; complex shape; rough surface A. Die casting finish acceptable Aluminum for window frames B. Blow molding 50,000 large gears of steel; simple shape; good C. Rolling surface finish required 25,000 items of aluminum; simple shape; good D. Sand casting surface finish required Structural I-beams of steel E. Forging 10,000 ceramic components F. Injection molding 100,000 plastic bottles G. Extrusion Copper pipes for household plumbing H. Powder sintering 100,000 small, plastic gears for a toy; good surface finish required, simple shape

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