Manufacturing technology Introduction Technology II – Jan Tomíček.

Manufacturing technologyIntroduction

Technology II – Jan Tomíček

Manufacturing

• Important part of World economy. Allmost all products are manufactured.

• Demands are increasing• New issues – energy efficiency, waste, etical

issues

Changes in the world of goods manufacturing

1. World wide competetion2. New materials3. Advanced technologies4. New manufacturing systems5. Enviromental issues

1. World Wide Competetion

• Global business• Market = Whole world• Everybody can make business – – knowledge vs. capital– customization vs. mass production– Product placement vs. variability

2. New materials

• Demands from customers– Smooth surface on plastic parts– Transparency of plastic– Shiny metal look etc.

• New developed materials with better properties– Heat resistant materials– High strength materials– Special materials

3. Advanced technologies

• Complex products• Combined principles– Mechanical principles– Electrical– Electronical– Combination

• Water, steam, electricity,

4. New manufacturing systems

• Manufacturing system

• Manufacturing strategies

• Management

5. Enviromental issue

• Low energy and material consumption

• Utilization of human labor, heavy work

• Healt and security issues

• Ethical problems

Product Life Cycle

Design

Construction

Manufacturing

Sale

Service and recycling

START-UP RAPID GROWTH MATURATION COMODITY or DECLINE

Product variety Great variety, product innovation

Increasing standartization

Emergence of a dominant stadart design

High standardization„comodity“ characteristics

Industry structure Small competetiors Fallout and Consolidation

Few large companies „Survivors“ become comodities

Form of competetion Product characteristics Product Quality, Cost and availability

Price and Quality and Reliability

Price with consistent quality

CostPer unit

Annual sales per model

SATURATION

TIME

Price of the product?

• What is the best price of the product?

Smallest, affordable, highest, psychologically friendly, discounted??

Production costs!

Manufacturing costs40%

Profit20%

Marketing sales, general administra-

tive costs25%

Engineering costs15%

Selling price

Manufacturing costs

• Methods:– Casting, foundry, moulding– Forming of metalforming– Machining(material removal)– Surface treatments(finishing)– Heat treatment– Joining and assembling

• Machining is approx 40% of manufacturing costs

TECHNOLOGY II

Machining• Chip removal process – Material is removed in

form of chips from a piece of raw material to archive the desired shape.

• Material(chips) are removed by a tool from the blank

• This process is called „Chip forming“

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ADVANTAGES• variety of work materials• variety of part shapes and geometric

features• dimensional accuracy• good surface finishes

DISADVANTAGES wasteful of material time consuming

Material utilization

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A CUTTING TOOL• single-point tool (a)• multiple cutting edge tool (b)

Chip forming principle

• Continuous vs. discontinuous chipForce stresswork hardeningsaturation(fully

hardened material)shearconinuous chip

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CHIP FORMATION (orthogonal cutting schema)

• the tool is forced into the material• plastic deformation → hardening of the material• shear deformation – shear plane (angle φ)

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CHIP FORMATION

Secondary deformation zone

Chip breakers

• Preventing the built-up edge– Groove type - premanufactured– Obstruction type

Chip and Tool geometry

• Tool – rake & face angle

Chip thickness

• Chip thickness ratio

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CUTTING CONDITIONS• cutting speed vc [m.s-1]; [m.min-1]• feed f [mm.rev-1]; [m.min-1]• depth of cut d = ap [mm]

Chip types

Chip breaking diagramme

Chip breaking diagramme

Chip volume ratio

• Calculation W =• Value 3-400

• Large volume of chips

Chips removal• Chips must be removed– From the cut – gravity, liquid, air etc.– From the machine – liquid, automatic, manually– From the workshop – conveyors, carriages– From factory – • recycling

What to think about?

• Next time – resistance of material, cutting forces, heat and temperature