Lecture 1: Introduction to Manufacturing (EIM1101) PDF

Lecture.1 Introduction to Manufacturing Manufacturing Technology (EIM1101) Dr. Mohamed Taha Eldaly Reference Book 2  MIDTERM MARKS ACTIVITY MARKS Lab notebook 10 Project 10 Midterm.1 20 Midterm.2 15 Presentation...

Lecture.1 Introduction to Manufacturing Manufacturing Technology (EIM1101) Dr. Mohamed Taha Eldaly Reference Book 2  MIDTERM MARKS ACTIVITY MARKS Lab notebook 10 Project 10 Midterm.1 20 Midterm.2 15 Presentation 5 TOTAL 60 3  Course outlines Week No.1 Introduction to manufacturing. Week No.9 Metal forming (cont.), sheet metal work. Week No.2 Physical and mechanical properties of materials. Week No.10 Machining operations. Week No.3 Classification of materials, metals, and Week No.11 Tool life and materials their alloys. Week No.12 12th Exam Week No.4 Polymers and composites. Week No.13 Joining operations Week No.5 Metal casting Week No.14 Shaping of plastics Week No.6 Metal casting (cont.), mold and riser Week No.15 Revision. design, die casting Week No.16 Final Exam Week No.7 7th Exam Week No.8 Metal forming (Rolling, Extrusion & Drawing). 4 INTRODUCTION TO MANUFACTURING 1. What is Manufacturing? 2. Materials in Manufacturing 3. Manufacturing Processes 4. Production Systems 5 Manufacturing - Technologically Important What is technology? Technology - the application of science to provide society and its members with those things that are needed or desired Technology provides the products that help our society, and its members live better. What do these products have in common? They are all manufactured Manufacturing is the essential factor that makes technology possible. 6  Manufacturing - Economically Important U.S. economy: % of Sector GNP* Manufacturing 20% Agriculture, minerals, etc. 5% Manufacturing is one Construction & utilities 5% way by which nations create material wealth Service sector – retail, 70% transportation, banking, communication, education, and government ,* GNP= Gross Net Product 7  What is Manufacturing? The word manufacture is derived from two Latin words manus (hand) and factus (make); the combination means “made by hand”. ▪ Most modern manufacturing operations are accomplished by mechanized and automated equipment that is supervised by human workers. 8  Manufacturing - Technologically Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a starting material to make parts or products ▪ Manufacturing also includes assembly ▪ Almost always carried out as a sequence of operations Figure 1.1 (a) Manufacturing as a technical process 9  Manufacturing - Economically Manufacturing adds value to the material by changing its shape or properties, or by combining it with other materials (this is done by means of one or more processing and/or assembly operations) Figure 1.1 (b) Manufacturing as an economic process 10  Manufacturing Industries Industry consists of enterprises and organizations that produce or supply goods and services Industries can be classified as: Primary industries - those that cultivate and exploit natural resources, e.g., farming, mining Secondary industries - take the outputs of primary industries and convert them into consumer and capital goods - manufacturing is the principal activity, other examples: construction, and electric power generation Tertiary industries - service sector, eg banking 11 Manufacturing Industries - continued ▪ Manufacturing includes several industries whose products are not covered here; e.g., apparel, beverages, chemicals, and food processing ▪ For our purposes, manufacturing means production of hardware ▪ Nuts and bolts, forgings, cars, airplanes, digital computers, plastic parts, and ceramic products 12  Production Quantity Q The quantity of products Q made by a factory has an important influence on the way its people, facilities, and procedures are organized ▪ Annual production quantities can be classified into three ranges: Production range Annual Quantity Q Low production 1 to 100 units Medium production 100 to 10,000 units High production 10,000 to millions of 13  Product Variety P Product variety P refers to different product types or models produced in the plant. ▪ Different products have different features ▪ They are intended for different markets ▪ Some have more parts than others ▪ When the number of product types made in the factory is high, this indicates high product variety 14 P versus Q in Factory Operations P Q Figure 1.2 P-Q Relationship 15  Manufacturing Capability A manufacturing plant consists of processes and systems (and people, of course) designed to transform a certain limited range of materials into products of increased value. ▪The three building blocks - materials, processes, and systems - are the subject of modern manufacturing. 16 2- Materials in Manufacturing 17  Materials in Manufacturing Most engineering materials can be classified into one of three basic categories: 1. Metals 2. Ceramics 3. Polymers Their chemistries and also their mechanical and physical properties are different ▪ These differences affect the manufacturing processes that can be used to produce products from them 18  1. Metals Usually alloys, which are composed of two or more elements, at least one of which is metallic Two basic groups: Ferrous metals - based on iron, comprises about 75% of metal tonnage in the world: Steel = Fe-C alloy (0.02 to 2.11% C) Cast iron = Fe-C alloy (2% to 4% C) Nonferrous metals - all other metallic elements and their alloys: aluminum, copper, magnesium, nickel, silver, tin, titanium, etc. 19  2. 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 (hydrous aluminum silicates) glass_scene_4_800x600 ▪ Modern ceramics, such as alumina (Al2O3) 2. Glasses – mostly based on silica (SiO2) 20  3. Polymers Compound formed of repeating structural units called mers, whose atoms share electrons to form very large molecules 21  3- 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 (cure) into a rigid structure – cannot be reheated 3. Elastomers - shows significant elastic behavior 22  In addition- Composites Nonhomogeneous mixtures of the other three basic types rather than a unique category Figure 1.3 Venn diagram of three basic material types plus composites 23  Composites Material consisting of two or more phases that are processed separately and then bonded together to achieve properties superior to its constituents 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 24 Composites 25  Recommended video https://www.youtube.com/watch?v=koULXptaBTs&ab_channel= MagicMarks 26 Chapter1- Part1 Thank you 27