Manufacturing Processes Lecture Notes (MNG 222)

Manufacturing Processes (MNG 222) Lecture (1) Dr. Sabry Said Youssef Assistant Professor Mechanical Engineering Department Faculty of Engineering, Fayoum University 1  Course description Fundamentals of manufacturing processes such as cas...

Manufacturing Processes (MNG 222) Lecture (1) Dr. Sabry Said Youssef Assistant Professor Mechanical Engineering Department Faculty of Engineering, Fayoum University 1  Course description Fundamentals of manufacturing processes such as casting, heat treating, particulate processing, forming, machining, joining and surface processing, Surface finish, machining symbols, Fits and tolerances, material flow and information flow in the 2  Course Outlines ManufacturingProcesses (MNG222) CoursePlan - Fall semester 2024 #VALUE! # Week Date Dr. Sabry's Lectures 1 Week 1 Tuseday, 01 Oct. 2023 Introduction to Manufacturing processes 2 Week 2 Tuseday, 08 Oct. 2023 Theory of metal machining (Material Removal Processes) 3 Week 3 Tuseday, 15 Oct. 2023 Machining Operations &Machine Tools (Turning and Milling)/ Project Description 4 Week 4 Tuseday, 22 Oct. 2023 Machining Operations &Machine Tools (Drilling and Shaping) / Quize 01 5 Week 5 Tuseday, 29 Oct. 2023 Machining Operations &Machine Tools (Grinding) 6 Week 6 Tuseday, 05 Nov. 2023 Metal forming Processes (Bulk Deformation) / Formative Assessment (Mid-Term: non-graded) 7 Week 7 Tuseday, 12 Nov. 2023 Metal forming Processes (Bulk Deformation) / Quiz02 8 Week 8 Tuseday, 19 Nov. 2023 Mid-Term Exam 9 Week 9 Tuseday, 26 Nov. 2023 Metal forming Processes (Sheet Metalworking) 10 Week 10 Tuseday, 03 Dec. 2023 Metal Casting Processes 11 Week 11 Tuseday, 10 Dec. 2023 Common Welding Processes / Quiz03 12 Week 12 Tuseday, 17 Dec. 2023 Project Discussion 13 Week 13 Tuseday, 24 Dec. 2023- 01 Jan. 2024 Winter Break 14 Week 14 Tuseday, 07 Jan. 2024 Oral Exam This Weekly Plan is Tentative for any changes or updates 3  Aim Manufacturing is introduced in a practical / integrated fashion. Various manufacturing process are explained with direct link to real life applications Expected Outcomes  Understand the basic differences between various manufacturing processes  Choose the appropriate manufacturing process to manufacture a part  Choose the appropriate material to manufacture a product 4  Targeted Learning Outcomes 1. Identify different type of materials which is used in manufacturing. 2. Describe a variety of manufacturing processes such as various casting processes, machining processes, metal working processes, shaping of plastics, and powder methods. 3. State the capabilities and limitations of various manufacturing processes. 4. Select a manufacturing process based on material, part geometry and economic considerations. 5. Produce a useful product using a suitable material and a suitable manufacturing process and making use of the equipment available in the workshop. 6. Identify processes used to make real parts. 7. Acquire team working skills. 5  Teaching and Evaluation Methods  Lectures.  Tutorials and Labs  Assignments.  Quizzes. 6  Course Assessment Item Grade Assignments 10% Quizzes 10% Attendance and 5% participation Midterm Exam 15% Project 10% Oral Exam 10% Final Paper Exam 40% Total 100% 7 Important note !!! 8  Course guidelines PowerPoint lectures and other relevant material will be put on Moodle.  Please do not rely on the Moodle material only, attending lectures and reading the textbook are essential to learn the subject. The most important aspect of our study is to understand rather than to memorize. Please make sure your mobile phone is on silent during lectures. 9 Reference s 10 roduction to manufacturing process 11  What is Manufacturing? The word manufacture is derived from two Latin words, manus (hand) and factus (make); the combination means made by hand. The English word manufacture is several centuries old, and ‘‘made by hand’’ accurately described the manual methods 12  What is Manufacturing? Manufacturing can be defined by two ways, one technologic and the other economic. Technologically, manufacturing is the application of physical and chemical processes to change the geometry, properties, and/or appearance of a given starting material to make parts or products; manufacturing also includes assembly of multiple parts to make products. 13  What is Manufacturing? Manufacturing can be defined by two ways, one technologic and the other economic. Economically, manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations The key point is that manufacturing adds value to the material by changing its shape or properties, or by combining it with other materials that have been similarly changed. 14 Materials in Manufacturing  Most engineering materials can be classified into one of three basic categories: 1. Metals 2. Ceramics 3. Polymers 4. Composites  Their chemistries are different, and their mechanical and physical properties are different.  These differences affect the manufacturing processes that can be used to produce products from them. 15 Materials in Manufacturing 16  Metals  Usually alloys, which are composed of two or more elements, at least one of which is metallic. Two basic groups: 1. Ferrous metals - based on iron, comprises about 75% of metal tonnage in the world:  Steel and cast iron 2. Nonferrous metals - all other metallic elements and their alloys:  Aluminum, copper, nickel, silver, tin, etc. 17  Ceramics Compounds containing metallic (or semi-metallic) and nonmetallic elements.  Typical nonmetallic elements are oxygen, nitrogen, and carbon  For processing, ceramics divide into: 1. Crystalline ceramics – includes:  Traditional ceramics, such as clay, and modern ceramics, such as alumina (Al2O3) 2. Glasses – mostly based on silica (SiO2) 18  Polymers Three categories: 1. Thermoplastic polymers - can be subjected to multiple heating and cooling cycles without altering molecular structure 2. Thermosetting polymers - molecules chemically transform into a rigid structure – cannot reheat 3. Elastomers - shows significant elastic behavior 19  Composites Material consisting of two or more phases that are processed separately and then bonded together to achieve properties proper to its application  Phase - homogeneous mass of material, such as grains of identical unit cell structure in a solid metal  Usual structure consists of particles or fibers of one phase mixed in a second phase  Properties depend on components, physical shapes of components, and the way they are combined to form the final material 20  Manufacturing Process A manufacturing process is a designed procedure that results in physical and/or chemical changes to a starting work material with the intention of increasing the value of that material. Manufacturing operations can be divided into two basic types: 1. Processing operations - transform a work material from one state of completion to a more advanced state  Operations that change the geometry, properties, or appearance of the starting material 2. Assembly operations - join two or more components to 21 Manufacturing Process 22  Solidification Processes  Starting material is heated sufficiently to transform it into a liquid or highly plastic state  Casting process at left and casting product at right 23  Particulate Processing  (1) Starting materials are metal or ceramic powders, which are (2) pressed and (3) sintered 24  Deformation Processes  Starting workpart is shaped by application of forces that exceed the yield strength of the material  Examples: (a) forging and (b) extrusion 25  Assembly Operations Two or more separate parts are joined to form a new entity  Types of assembly operations: 1. Joining processes – create a permanent joint  Welding, brazing, soldering, adhesive bonding 2. Mechanical assembly – fastening by mechanical methods  Threaded fasteners (screws, bolts and nuts); press fitting, expansion fits 26  Assembly Operations Two welders perform arc welding on a large steel pipe section (photo courtesy of Lincoln Electric Company). 27  Assembly Operations Assembly workers on an engine assembly line (photo courtesy of Ford Motor Company). 28 Material Removal Processes  Excess material removed from the starting piece so what remains is the desired geometry  Examples: (a) turning, (b) drilling, and (c) milling 29 Material Removal Processes 30  Material Removal Processes  The material removal processes are a family of shaping operations in which excess material is removed from a starting workpart so that what remains is the desired final geometry.  Categories: – Machining – material removal by a sharp cutting tool, e.g., turning, milling, drilling – Abrasive processes – material removal by hard, abrasive particles, e.g., grinding – Nontraditional processes - various energy forms other than sharp cutting tool to remove material 31  Material Removal Processes The family tree 32 Material Removal Processes 33 Machining Machining types types Turning Turning Drilling Drilling Milling Milling Shaping Shaping Planning Planning Broaching Broaching Grinding Grinding 34 Machining Machining types types Turning Turning Drilling Drilling Milling Milling Shaping Shaping Planning Planning Broaching Broaching Grinding Grinding 35 Machining Machining types types Turning Turning Drilling Drilling Milling Milling Shaping Shaping Planning Planning Broaching Broaching Grinding Grinding 36 Machining Machining types types Turning Turning Drilling Drilling Milling Milling Shaping Shaping Planning Planning Broaching Broaching Grinding Grinding 37 Machining Machining types types Turning Turning Drilling Drilling Milling Milling Shaping Shaping Planning Planning Broaching Broaching Grinding Grinding 38 Machining Machining types types Turning Turning Drilling Drilling Milling Milling Shaping Shaping Planning Planning Broaching Broaching Grinding Grinding 39 Machining Machining types types Turning Turning Drilling Drilling Milling Milling Shaping Shaping Planning Planning Broaching Broaching Grinding Grinding 40 Metal Forming Processes 41  Metal forming Processes The family tree 1. Bulk deformation – Rolling processes – Forging processes – Extrusion processes – Wire and bar drawing 2. Sheet metalworking – Bending 42 Forming Forming types types –– Rolling Rolling –– Forging Forging –– Extrusion Extrusion –– Wire Wire and and bar bar drawing drawing –– Bending Bending –– Deep Deep or or cup cup drawing drawing –– Shearing Shearing 43 Forming Forming types types –– Rolling Rolling –– Forging Forging –– Extrusion Extrusion –– Wire Wire and and bar bar drawing drawing –– Bending Bending –– Deep Deep or or cup cup drawing drawing –– Shearing Shearing 44 Forming Forming types types –– Rolling Rolling –– Forging Forging –– Extrusion Extrusion –– Wire Wire and and bar bar drawing drawing –– Bending Bending –– Deep Deep or or cup cup drawing drawing –– Shearing Shearing 45 Forming Forming types types –– Rolling Rolling –– Forging Forging –– Extrusion Extrusion –– Wire Wire and and bar bar drawing drawing –– Bending Bending –– Deep Deep or or cup cup drawing drawing –– Shearing Shearing 46 Forming Forming types types –– Rolling Rolling –– Forging Forging –– Extrusion Extrusion –– Wire Wire and and bar bar drawing drawing –– Bending Bending –– Deep Deep or or cup cup drawing drawing –– Shearing Shearing 47 Forming Forming types types –– Rolling Rolling –– Forging Forging –– Extrusion Extrusion –– Wire Wire and and bar bar drawing drawing –– Bending Bending –– Deep Deep or or cup cup drawing drawing –– Shearing Shearing 48 Forming Forming types types –– Rolling Rolling –– Forging Forging –– Extrusion Extrusion –– Wire Wire and and bar bar drawing drawing –– Bending Bending –– Deep Deep or or cup cup drawing drawing –– Shearing Shearing 49 Thanks 50