Production Technology - Safety & Measurement - GIU PDF

Production Technology Safety & Measurement Dr.-Ing. Amr Nounou Tips and Important Remarks - Attending the Lecture is very important - Lecture slides and Lecture notes are to be studied for the Assessments - Participate actively in the Lecture - Also write down your...

Production Technology Safety & Measurement Dr.-Ing. Amr Nounou Tips and Important Remarks - Attending the Lecture is very important - Lecture slides and Lecture notes are to be studied for the Assessments - Participate actively in the Lecture - Also write down your notes during the lecture and revise them → Examination - Be in the Lecture and the Workshop EXACTLY on TIME - Entry to the Workshop is only permitted with Lab Coat and Goggles / Safety Glasses - NO delayed students are permitted for ANY REASON - Concentrate in the Workshop Tutorials → Lab Assignments will be taken during the tutorials Safety & Measurement 2 Dr.-Ing. Amr Nounou - Winter 2024-2025  Introduction Safety & Measurement 3 Dr.-Ing. Amr Nounou - Winter 2024-2025 Production The action of making or manufacturing from components or raw materials. Source: https://www.lexico.com/definition/production Safety & Measurement Retrieved: 10/08/2022 4 Dr.-Ing. Amr Nounou - Winter 2024-2025 Technology The application of scientific knowledge for practical purposes, especially in industry. Source: https://www.lexico.com/definition/technology Safety & Measurement Retrieved: 10/08/2022 5 Dr.-Ing. Amr Nounou - Winter 2024-2025 Production Technology Production technology is about machinery used in making a physical product for a business. For a small business, this takes place usually in a workshop. For a larger scale business, high volume production machines and assembly lines are typically used. Source: https://smallbusiness.chron.com/production-technology- Safety & Measurement manufacturing-25068.html 6 Retrieved: 19/08/2022 Dr.-Ing. Amr Nounou - Winter 2024-2025 Production Technology Production technology refers to all measures and facilities for the industrial production of goods. The basis is the transfer of scientific knowledge into technologically controllable and economically usable production systems. Source: https://refa-international.com/en/refa-lexicon/p/production- Safety & Measurement technology#:~:text=Production%20technology%20refers%20to%20 7 all,and%20economically%20usable%20production%20systems. Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved: 10/08/2022  Pyramid of Production Systems Source: https://en.wikipedia.org/wiki/Product_lifecycle Safety & Measurement Retrieved: 11/08/2022 8 Dr.-Ing. Amr Nounou - Winter 2024-2025  Production process Source: https://ceopedia.org/index.php/Serial_production Safety & Measurement Retrieved: 10/08/2022 9 Dr.-Ing. Amr Nounou - Winter 2024-2025  Source: https://www.mobinius.com/blogs/role-of- Safety & Measurement industry-4-0-in-digital-transformation/ 10 Retrieved: 20/08/2022 Dr.-Ing. Amr Nounou - Winter 2024-2025 Engineering Materials Some of the metallic and nonmetallic materials used in a typical automobile Source: E Serope Kalpakjian and Steven Shmid, “Manufacturing Safety & Measurement Engineering and Technology” (6th edition), Prentice Hall, 2010 (book 11 support resources) Dr.-Ing. Amr Nounou - Winter 2024-2025 Engineering Materials An outline of the engineering materials Source: E Serope Kalpakjian and Steven Shmid, “Manufacturing Safety & Measurement Engineering and Technology” (6th edition), Prentice Hall, 2010 (book 12 support resources) Dr.-Ing. Amr Nounou - Winter 2024-2025 Engineering Materials The Crystal Structure of Metals unit cell single crystal with many unit cells. Body-centered cubic (bcc); such as alpha iron, chromium and tungsten Face-centered cubic (fcc); such as gamma iron, aluminum and copper Hexagonal close-packed (hcp); such as cobalt, magnesium and zinc These arrangements can be modified by adding atoms of some other metals or nonmetals, known as alloying, it is often done to improve various properties of the metal Sources: E Serope Kalpakjian and Steven Shmid, “Manufacturing Safety & Measurement Engineering and Technology” (6th edition), Prentice Hall, 2010 13 (book support resources) and E Serope Kalpakjian and Steven Shmid, “Manufacturing Engineering and Technology” (5th edition), Dr.-Ing. Amr Nounou - Winter 2024-2025 Prentice Hall, 2006. Engineering Materials Polymer chains (a) Linear structure; thermoplastics such as acrylics, nylons, polyethylene, and polyvinyl chloride have linear structures. (b) Branched structure; such as in polyethylene. (c) Cross-linked structure; many rubbers, or elastomers, have this structure, and the vulcanization of rubber produces this structure. (d) Network structure; which is basically highly cross-linked—examples are thermosetting plastics, such as epoxies and phenolics. Adapted from the source: E Serope Kalpakjian and Steven Shmid, Safety & Measurement “Manufacturing Engineering and Technology” (6th edition), Prentice 14 Hall, 2010 (book support resources) Dr.-Ing. Amr Nounou - Winter 2024-2025 Engineering Materials Molecular structure of various polymers These are examples of the basic building blocks for plastics Source: E Serope Kalpakjian and Steven Shmid, “Manufacturing Safety & Measurement Engineering and Technology” (6th edition), Prentice Hall, 2010 (book 15 support resources) Dr.-Ing. Amr Nounou - Winter 2024-2025 Manufacturing Processes - Polymer-processing methods Source: E Serope Kalpakjian and Steven Shmid, “Manufacturing Safety & Measurement Engineering and Technology” (6th edition), Prentice Hall, 2010 (book 16 support resources) Dr.-Ing. Amr Nounou - Winter 2024-2025 Manufacturing Processes - Casting processes Source: E Serope Kalpakjian and Steven Shmid, “Manufacturing Safety & Measurement Engineering and Technology” (6th edition), Prentice Hall, 2010 (book 17 support resources) Dr.-Ing. Amr Nounou - Winter 2024-2025 Manufacturing Processes - Bulk- deformation processes (Bulk Forming) Adapted from the source: E Serope Kalpakjian and Steven Shmid, Safety & Measurement “Manufacturing Engineering and Technology” (6th edition), Prentice 18 Hall, 2010 (book support resources) Dr.-Ing. Amr Nounou - Winter 2024-2025 Manufacturing Processes - Sheet-metal- forming processes Adapted from the source: E Serope Kalpakjian and Steven Shmid, Safety & Measurement “Manufacturing Engineering and Technology” (6th edition), Prentice 19 Hall, 2010 (book support resources) Dr.-Ing. Amr Nounou - Winter 2024-2025 Manufacturing Processes - Machining and finishing processes Source: E Serope Kalpakjian and Steven Shmid, “Manufacturing Safety & Measurement Engineering and Technology” (6th edition), Prentice Hall, 2010 (book 20 support resources) Dr.-Ing. Amr Nounou - Winter 2024-2025 Manufacturing Processes - Joining processes Source: E Serope Kalpakjian and Steven Shmid, “Manufacturing Safety & Measurement Engineering and Technology” (6th edition), Prentice Hall, 2010 (book 21 support resources) Dr.-Ing. Amr Nounou - Winter 2024-2025  Industrial Safety Safety & Measurement 22 Dr.-Ing. Amr Nounou - Winter 2024-2025 Safety Signs Safety & Measurement Source: https://www.moglix.com/blog/the-purpose- 23 of-safety-sign-at-your-workplace/ Dr.-Ing. Amr Nounou - Winter 2024-2025 retrieved 16/10/2021 Safety Signs Mandatory signs Mandatory signs often indicate required PPE (personal protective equipment). Safety & Measurement Source: http://www.mrbillington.com/health--- 24 safety.html Dr.-Ing. Amr Nounou - Winter 2024-2025 retrieved 10/08/2022 Safety Protective clothing / Personal Protective Equipment (PPE) Overall / Lab Coat Safety shoes Source: Source: https://www.alibaba.com/product-detail/Factory-wholesale- https://www.indiamart.com/proddetail/workshop-safety-shoes- lightweight-multi-purpose-practical_1600086341167.html 24230446562.html Retrieved 27/08/2022 Retrieved 27/08/2022 Safety & Measurement 25 Dr.-Ing. Amr Nounou - Winter 2024-2025 Safety Protective clothing / Personal Protective Equipment (PPE) Safety glasses Source: https://redasafe.com/ppe/eye- Safety & Measurement protection/safety-glasses 26 retrieved 12/08/2022 Dr.-Ing. Amr Nounou - Winter 2024-2025 Safety Protective clothing / Personal Protective Equipment (PPE) Safety goggles Safety face shield / visor Source: Source: https://www.amazon.ae/Sellstrom-Industrial-Chemical- https://www.amazon.ae/Safety-Shield-Droplet-Protective- Laboratory-Protective/dp/B00CA8NWM8 Covering/dp/B087ZNTNR5 Retrieved 27/08/2022 Retrieved 27/08/2022 Safety & Measurement 27 Dr.-Ing. Amr Nounou - Winter 2024-2025 Safety Protective clothing / Personal Protective Equipment (PPE) Welding goggles Welding helmet Source: https://redasafe.com/ppe/head- Safety & Measurement protection/welding-helmets 28 retrieved 12/08/2022 Dr.-Ing. Amr Nounou - Winter 2024-2025 Safety Protective clothing / Personal Protective Equipment (PPE) Dust mask Source: Safety & Measurement https://en.wikipedia.org/wiki/Dust_mask 29 retrieved 27/08/2022 Dr.-Ing. Amr Nounou - Winter 2024-2025 Safety Protective clothing / Personal Protective Equipment (PPE) Cut resistance gloves Chemical resistant gloves Heat resistance gloves Source: https://redasafe.com/ppe/hand-protection Safety & Measurement retrieved 12/08/2022 30 Dr.-Ing. Amr Nounou - Winter 2024-2025 Safety Protective clothing / Personal Protective Equipment (PPE) Safety helmet Source: https://redasafe.com/ppe/head- Safety & Measurement protection/safety-helmets 31 retrieved 12/08/2022 Dr.-Ing. Amr Nounou - Winter 2024-2025 Safety Protective clothing / Personal Protective Equipment (PPE) Ear muffs Ear plugs Source: https://redasafe.com/resources/post/ear- Safety & Measurement plugs-vs-ear-muffs-which-are-better 32 retrieved 11/07/2022 Dr.-Ing. Amr Nounou - Winter 2024-2025 Safety Signs Examples of mandatory signs. Safety & Measurement Adapted from the source: https://blog.sliceproducts.com/industrial- 33 safety-topics\ Dr.-Ing. Amr Nounou - Winter 2024-2025 retrieved 16/10/2021 Safety Signs Safe Condition signs Safe Condition signs are designed to notify people of potentially life/injury saving information. Safety & Measurement Source: http://www.mrbillington.com/health--- 34 safety.html Dr.-Ing. Amr Nounou - Winter 2024-2025 retrieved 10/08/2022 Safety Signs Prohibition signs Prohibition signs prohibit (forbid) the use or doing of a certain specified action by visually representing "Do Not". Safety & Measurement Source: http://www.mrbillington.com/health--- 35 safety.html Dr.-Ing. Amr Nounou - Winter 2024-2025 retrieved 10/08/2022 Safety Signs Warning signs Warning signs make people aware of a potential nearby danger. Safety & Measurement Source: http://www.mrbillington.com/health--- 36 safety.html Dr.-Ing. Amr Nounou - Winter 2024-2025 retrieved 10/08/2022 Safety Signs Examples of warning signs. Safety & Measurement Source: https://www.labelsource.co.uk/news/post/ho 37 w-to-prevent-slips-trips-and-falls Dr.-Ing. Amr Nounou - Winter 2024-2025 retrieved 16/10/2021 In Workshop Tutorials: - Lab coats + Goggles/safety glasses are obligatory Safety & Measurement 38 Dr.-Ing. Amr Nounou - Winter 2024-2025  Measurement Safety & Measurement 39 Dr.-Ing. Amr Nounou - Winter 2024-2025 Standardization - International Organization for Standardization (ISO), - the Deutsches Institut für Normung (DIN), - American Section of the International Association for Testing Materials (ASTM) - the British Standards Institution (BSI), are among the most noticeable organizations. Standards provide a reference for all manufacturers. Testing standards help in product verification. Safety & Measurement Source: https://empoweringpumps.com/henri- 40 azibert-importance-and-drawbacks-of- Dr.-Ing. Amr Nounou - Winter 2024-2025 industry-standards/ retrieved 13/08/2022 Accuracy and Precision Source: https://sciencenotes.org/what-is-the-difference-between- Safety & Measurement accuracy-and-precision/ 41 Retrieved: 11/08/2022 Dr.-Ing. Amr Nounou - Winter 2024-2025 Measurement: Measuring tools - Workshop steel ruler - Vernier caliper - Micrometer - Try-square - Simple workshop protractor - Vernier bevel protractor Safety & Measurement 42 Dr.-Ing. Amr Nounou - Winter 2024-2025 Workshop steel ruler Safety & Measurement Source: https://www.pntools.com.au/product/engineer-rulers- 43 workshop/ Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 16/08/2022 The Vernier Caliper Parts of the Vernier caliper 1.External jaw 2.Internal jaw 3.Sliding jaws 4.Metric Vernier scale 5.Locking screw 6.Main scale 7.Depth gauge Safety & Measurement Source: https://www.craftsmanspace.com/knowledg 44 e/vernier-calipers.html Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 27/08/2022 The Vernier Caliper Measuring with a Vernier caliper 1.Measuring external dimensions 2.Measuring internal dimensions 3.Measuring depth dimensions Safety & Measurement Source: https://www.craftsmanspace.com/knowledg 45 e/vernier-calipers.html Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 27/08/2022 The Vernier Caliper the reading is 28mm plus 30 divisions of 0,02mm TOTAL: 28mm + 30 * 0.02 = 28.6mm Safety & Measurement Adapted from the source: https://www.craftsmanspace.com/knowledg 46 e/vernier-calipers.html Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 27/08/2022 The Digital Vernier Caliper Safety & Measurement Source: https://mechanicalbasics.com/what-is- 47 digital-vernier-caliper-how-it-works/ Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 27/08/2022 The Digital Vernier Caliper Safety & Measurement Source: https://mechanicalbasics.com/what-is- 48 digital-vernier-caliper-how-it-works/ Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 27/08/2022 The Micrometer Safety & Measurement Source: https://www.theengineerspost.com/types-of- 49 micrometers-screw-gauge/ Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 29/07/2022 The Micrometer Safety & Measurement Source:https://www.ebay.com/itm/1214032 98231 50 Retrieved 27/08/2022 Dr.-Ing. Amr Nounou - Winter 2024-2025 The Micrometer One revolution of the spindle advances or withdraws the screw a distance equal to 0.5 mm. TOTAL: 16.00mm + 0.50mm + 0.16mm = 16.66mm Safety & Measurement Adapted from the source: https://www.craftsmanspace.com/knowledg 51 e/micrometers-measuring-instruments.html Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 27/08/2022 Try-square Safety & Measurement Source: https://www.craftsmanspace.com/knowledg 52 e/try-square.html Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 29/07/2022 Try-square Engineer's square (machinist square) is the metalworkers' equivalent of a try square. Machinist try squares are made entirely from metal to guarantee accuracy. Engineer’s (Machinist) Try-square Safety & Measurement Source: https://www.craftsmanspace.com/knowledg 53 e/try-square.html Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 29/07/2022 Simple workshop protractor Safety & Measurement Source: https://www.leevalley.com/en-us/shop/tools/hand- 54 tools/marking-and-measuring/protractors/76526-workshop- Dr.-Ing. Amr Nounou - Winter 2024-2025 protractor?item=99N0423 Retrieved 16/08/2022 Vernier bevel protractor It reads to 5 minutes and can be used completely through 360º. The bevel protractor consists of a beam, graduated dial and blade which is connected to swivel plate (with Vernier scale) by thumb nut and clamp. Safety & Measurement Source: https://www.craftsmanspace.com/knowledg 55 e/vernier-bevel-protractor.html Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 30/07/2022 Vernier bevel protractor Safety & Measurement Source: https://www.craftsmanspace.com/knowledg 56 e/vernier-bevel-protractor.html Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 30/07/2022 Vernier bevel protractor It has 12 divisions on each side of the center zero. These are marked 0-60 mins of the arc so that each division equals 1/12 of 60, that is 5 min of arc. The reading of the vernier protractor is equal to the largest “whole” degree of the main scale + the reading on the vernier scale in line with the main scale division. Safety & Measurement Source: https://www.theengineerspost.com/bevel- 57 protractor/ Dr.-Ing. Amr Nounou - Winter 2024-2025 Retrieved 30/07/2022 Enhance your German terminology … English term German term Safety Sicherheit Risk Risiko Danger Gefahr Protection Schutz Attention Achtung Measurement Messung Distance Abstand Angle Winkel Safety & Measurement 58 Dr.-Ing. Amr Nounou - Winter 2024-2025  Thank you for your attention... Safety & Measurement 59 Dr.-Ing. Amr Nounou - Winter 2024-2025