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HABEEB HATTAB HABEEB
Office: BN-Block, Level-3, Room-088Email: [email protected].
No.: 7292H/P No.: 0126610058
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University TENAGA National College Of Engineering Mechanical
Department Academic Year - 2008Lecture Note
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Introduction To Manufacturing and Manufacturing Systems
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Japanese sword reworked for hard and soft metal parts
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Space Shuttle
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The Transistor
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Everyday products
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Manufacturing derived from:Manufacturing (derived from
Latin)
= manus (hand) + factus (made) = made by hand
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Manufacturing is an industrial activity that converts raw
materials to useful products by the means of machines. Definition
of Manufacturing:
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Materials Development of Manufacturing depends
on:Machine-ToolsComputer-aided Design (CAD)&Computer-aided mfg
(CAM). RoboticsElectronics12345
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Evolution of the Enterprise Evolution Steps:Hand Tool Animals
Water Power Steam Engines Electrical Motors 123451-1
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The MFG System:INPUT PROCESS OUTPUT
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Customer Demand Material Money Energy HR Education R & D
INPUT
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PROCESS Design Production Management
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OUTPUT Consumer Goods Capital Goods Quality Cost
Effectiveness
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`Money - Working Capital (Money for employee) Fixed Capital (For
machine tools and buildings) INPUT
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Energy - Electricity To run the machines - Compressed air To run
the pneumatic systems and clean machines and products - Steam To
run the turbines and utilized in produce of polystyrene (Expansion
OP.) - Gas To use it in Furness, welding operations and boilers.
INPUT
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- Creating plans for new productsLowering the product cost at
maintained high qualityDesignPROCESS
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- Designated at the design stage- Machine tools typesPROCESS
Production- Machining processes- People are selected at the design
stage
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Goods- Customers goods: People use them (Food, Cars, .)OUTPUT
Products- Capital goods: Products used to make other consumer goods
(Machine tools, Plant, .)
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The Classification of basic Manufacturing Mass
production1-2ModerateJob-lotabc
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Mass Production Features: - Goods are produced at a high volume
for considerable period of time ( >100.000 parts per year). -
Machine are not flexible (They are not able to produce other types
of products). - Products of this type of mfg are the cheapest.a
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Moderate production Features: - Variable products (depends on
the sale order and the market demand) (2,500-100,000 parts per
year). - Multipurpose machine tools and CNC machine tools are
usually used in this type of mfg.- Product Ex.: Tools, Moulds,
Radio transmitters.b
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Job-lot production Features: - The plant does not any specific
type of products but it is able to produce any type of product that
the market is in need of.- Products move in lots between mfg
processes (10-500 parts per lot).- Machine are more flexible and
universal.c- Product Ex: Airplanes, Automobile parts, and Plastic
products .
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Organization for Manufacturing -A plant needs an affective
organizing method for manufacturing in order to manage its
resources /
Employees Money Power
Materials Machines .
*A good mfg strategy is needed.
See table 1.1 (Evolution of strategy mfg sys.. 14235
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Concurrent Engineering CE It is a philosophy that promotes
interactive design and manufacturing efforts to develop product and
processes simultaneously. CE is not an enginee- ring
discipline.
- CE Objective: Optimizing the use of companyresources and
reducing time to market cycle.
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General CE phases for a new project: Technology and concept
development: Definition of customer requirement implementation.
Assessment of primary alternatives processes. Development of
required resources. Preparation of product plan.abcdPh.-1
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Product and Process Development and Prototype validation -CE
Function: Product improvement for assembly and mfg Development the
mfg and assembly processes Establish baseline process technology
Establish program goals and risk-reduction plans freezing
abcdPh.-2This is the phase in which the CE team will
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Cont
Generally other project elements are addressed I this phase ,
such as financial business plans, product concept demonstration,
freezing of engineering content, and final project
approval.Note:Ph.-2Ph.-2
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Process Validation and Product Design Confirmation : The
Production process and methods are finalized Simulation and pilot
runs are conducted to test critical steps Machine and equipment are
validated for production readiness, quality and
performanceabcPh.-3This is the execution phase where
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Production and continuous improvement :- This face is the
Acceleration of production floor into Full rated capacity. This
means: Attaining high product quality at the lowest costs.Ph.-4
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Design, Material and Production 1-3According to the existing
machine tools and the designed product we choose the raw
materials.
On the other hands, according to the existing materials and
required quality we choose the machine tools.
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In order to attain a high production rate with a low labor cost,
Automatic features have been built gradually in different machine
tools. Nowadays we deal with fully automatic machine tools and
computer aided design and manufacturing (CAD/CAM). But the problem
is that maintenance of such automatic machines is very expensive.-
Efficiency of production :
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The quality and accuracy must be maintained for the whole mfg
processes so at the output we produce parts that can be quickly
assembled (interchangeable). Cont.. Efficiency of production
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- Economical production is determined by: A functional simple
design that has appropriate quality (no more or less). 1 A material
choice that represents the best compromise among physical
properties, cost, and machinability. 2 The selection of mfg
processes that provide the plant with required quality and accuracy
(no more accuracy than necessary) at the lowest possible cost.
3
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MaterialsEngineering MaterialsMetallic Non-Metallic Ferrous
Non-Ferrous OrganicNon- Organic
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Materials Application
ChainProcessingStructurePropertiesPerformanceSelectionField
Application* SELECTION is the Critical Step for Technologists.
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Stress & StrainDislocations & DeformationElasticity
& PlasticityElastic ConstantsMechanical Properties
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Mechanical TestingMechanical PropertiesStrengthening
MechanismsFailure Analysis
Tests
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Resistivity & ConductivityElectronic-Band
StructureSemiconductivityRefraction &
ReflectionTransmissionElectrical PropertiesElectrical
Properties
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The Evolution of Materials
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Classes of
MaterialsBasicMetalsCeramicsPolymersAdvancedCompositesSemiconductorsBiomaterials
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Materials that are normally combinations of "metallic
elements".
Metals usually are good conductors of heat and electricity.
Metals are quite strong but malleable and tend to have a lustrous
look when polishedMetals
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Ceramic materials developed for gas turbine rotors are used in
aircraft and diesel engine parts.
CeramicsCeramics are generally compounds between Metallic and
NONmetallic elements and include such compounds as: -Oxides
-Nitrides -Carbides
Typically they are insulating and resistant to high temperatures
and harsh environments.
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Using advanced polymer materials, organic light emitting diode
(OLEDs) displays produce bright, high-contrast display panels with
a wide viewing angle. OLED panels are emissive, eliminating the
need for the backlight required in display technologies such as
liquid crystal displays (LCDs). PlasticsPlastics (or polymers) are
generally compounds based upon carbon and hydrogen (Organic
Compounds). They are very large molecular structures. Usually they
are low density and are not stable at high temperatures.
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SemiconductorsSEMIconductors have electrical properties
intermediate between Metallic conductors and Ceramic insulators.
Also, the electrical properties are strongly dependent upon small
amounts of Impurities.
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CompositesComposites consist of more than one material type.
Fiberglass, a combination of glass and a polymer, is an example.
Concrete and plywood are other familiar composites. Many new
combinations include ceramic fibers in a metal or polymer
matrix.
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Composites
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CompositesGraphite Matrix Composite ShaftLiquid Metal
FacePlateGolf ClubsHand bagGhost airplane
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BioMaterialsMaterials compatible with an organism (e.g. Humans)
that can be used to make implants, prostheses, and surgical
instruments. Designed not to provoke rejection by our bodies (skin,
blood, bone, etc.), they can be natural (collagen, cellulose, etc.)
or synthetic (metallic, alloy, ceramic, plastic, and others).
Dental crowns and contact-lenses use biomaterials.
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StructuredinformationUnstructuredinformationData Organization of
Materials
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mountMetallography: to see microstructuresmetalSteel
(Fe-C)Nickel Alloy 242
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The goal of design:To create products that perform their
function effectively, safely, at acceptable costWhat do we need to
know about materials to do this? More than just test
data.Stat/MathanalysisDesign dataSelection ofmaterial and
processPotential applications Materials Information for Design
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Next Lecture:Nature And Properties of Materials
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THANK YOU
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