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1 Introduction

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13 views10 pages

1 Introduction

Uploaded by

alessandro.zamboni.2
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Introduction (chapter 1)

 What is MANUFACTURING ?
• production engineering, materials process technology, manufacturing
processes for engineering materials
• produzione manifatturiera, produzione industriale, tecnologie e sistemi di
lavorazione, tecnologia meccanica…

 Manufacturing is the transformation of raw materials into components, in


such a shape ready for assembly into the final product

NOTES:
– Manufacturing transformation: DISCRETE, with countable outputs
– Process transformation: CONTINUOUS, with outputs countable only
after assembly into the final product
(process transformation is not MANUFACTURING and therefore not a subject
of this course)
Manufacturing

 Production of components
 Final assembly
Materials selection

 Engineering materials
– Ferrous and non-ferrous metals
– Polymers
– Engineering ceramics
– Composites
– Emerging materials
• nanomaterials, shape memory alloys, superconductors, …

 Criteria for materials selection


– Mechanical properties
– Physical and chemical properties
– Formability
– Costs and availability
– Expected product life
– Recycling chance
Selection of the manufacturing process
▪ CASTING
▪ FORMING
▪ MACHINING
▪ JOINING
▪ FINISHING

Different technologies available to manufacture the same component:


(a) casting, (b) forging, (c) extrusion, (d) machining, (e) joining.
Selection of the manufacturing process
Manufacturing process capabilities - minimum part dimensions
Selection of the manufacturing process
Manufacturing process capabilities - tolerance on dimensions
Selection of the manufacturing process
Manufacturing process capabilities - surface finish
Selection of the manufacturing process
Manufacturing process cost

Type of machinery Price range Type of machinery Price range


Broaching 10–300 Machining center 50–1000
Drilling 10–100 Mechanical press 20–250
Electrical discharge 30–150 Milling 10–250
Electromagnetic and electrohydraulic 50–150 Ring rolling 500
Fused deposition modeling 60–120
Gear shaping 100–200
Grinding Robots 20–200
Cylindrical 40–150 Roll forming 5–100
Surface 20–100 Rubber forming 50–500
Headers 100–150 Stereolithography 80–200
Injection molding 30–150 Stretch forming 400–> 1000
Boring Transfer machines 100–> 1000
Jig 50–150 Welding
Horizontal boring mill 100–400 Electron beam 200–1000
Flexible manufacturing system > 1000 Spot 10–50
Lathe 10–100 Ultrasonic 50–200
Single- and multi-spindle automatic 30–250
Vertical turret 100–400
Note: Prices vary considerably, depending on size, capacity, options, and level of automation and computer controls.
Selection of the manufacturing process

CRITERIA

 Material workability
 Shape, dimensions, dimensional accuracy (tolerances)
 Surface finish
 Production volumes
 Production costs
 Additional processes to finish the part -> process chain

→ near-net-shape or net-shape manufacturing


Tasks for the manufacturing engineer

 To plan the production of components:


– Knowledge about the product, its service-life performances,
specifications, standards
– Choice of the manufacturing process
– Choice of machines, plants, equipment, dies
– Definition of the process chain

 To efficiently interact with:


– Product designers
– Materials experts
– Plants experts
– Production planners
– Quality control engineers

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