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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
Corso diStudi di Fabbricazione
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Introduction to manufacturing
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
MANUFACTURING - TECHNOLOGICALLY IMPORTANT
• Technology provides the products that help our society and its members to live better
• What do these products have in common?
• They are all manufactured
• Manufacturing is the essential factor that makes technology possible
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
MANUFACTURING - ECONOMICALLY IMPORTANT
• Manufacturing creates nation material wealth
• GNP = gross national product
U.S. economy:
Sector% of
GNP
Manufacturing 20%
Agriculture, minerals, etc. 5%
Construction & utilities 5%
Service sector – retail,
transportation, banking,
communication, education, and
government
70%
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
MANUFACTURING - HISTORICALLY IMPORTANT
To a significant degree, the history of civilization is the history of humans' ability to make things
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
WHAT IS MANUFACTURING?
• Manufacture derives from two Latin words manus (hand) and factus (make); “made by hand”
•“Made by hand” fabrication methods used when the English word “manufacture” was first coined around 1567 A.D.
•Most modern manufacturing operations are mechanized and automated (supervising of human workers)
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
MANUFACTURING – TECHNOLOGICAL DEFINITION
• 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
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
EXAMPLE
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
OPERATION: BLANKING (CUTTING)
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
OPERATION: DRAWING
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
OPERATION: DEEP DRAWING
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
OPERATION: FORGING, HEAT TREATING, CUTTING
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
OPERATION: TIG WELDING, FASTENING
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
OPERATION: HIGHLY POLISHING
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
PRODUCTION PROCESSES- OVERVIEW
• MECHANICAL TECHNOLOGY or MECHANICAL PRODUCTION TECHNOLOGY, deals with all processes able to transform raw materials (or semi-finished products) into end products.
• The PRODUCTION ENGINEER, by designing the cycle of transformation from raw materials into end products, allows a design to be physically made.
• Behind each product there is a TECHNOLOGICAL CYCLE, completely detailed, so that each production step can be performed correctly.
• In general, the main guiding issue for cycle selection is ECONOMICAL. Among several possible production routes, the cheapest way is preferred.
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
Wood
Turning and decoration
Metallic spiral
Cold plastic deformation and painting
Example: EGG CUP
Simple product:
• Mono-function
• Mono-material
• Mono-technology
FROM FUNCTIONS TO THE PRODUCT
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
Metallic (steel sheet)
Deep drawing of stainless steel
Metallic (aluminum sheet)
Deep drawing and bending of aluminum
FROM FUNCTIONS TO THE PRODUCT
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
Polymer
Polymeric material injected in moulds
FROM FUNCTIONS TO THE PRODUCT
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
Porcelain
Cold forming, heat treatment and decoration
Glass
Heating of the material and forming
The connection between material, shape, manufacturingtechnology and costs of each product must be taken intoaccount
FROM FUNCTIONS TO THE PRODUCT
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
TYPES OF PRODUCTION
• We can divide production into two main groups:• FLOW production (or continuous p.)
• BATCH production (or discrete p., sometimes the word “manufacturing” is used for this case only)
• Each good is produced using one (sometimes either) of these types.
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
FLOW PRODUCTION
• At the end of the process, it is very difficult to recognize the raw materials. No disassembly is feasible.
• In general flow production involves either:• Mixing, Solving
• Chemical reactions
• Typical FLOW productions involve:• Steel
• Paper
• Cement (for Concrete)
• Chemicals
• Yarn
• ...
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
BATCH PRODUCTION (Manufacturing)
• Batch product is made of individual parts, assembled together, that can be easily distinguished (very often in different materials).
• In general batch production involves two main phases:• Part production
• Assembly
• Therefore, we use batch production for:• Cars
• Computers
• Household Appliances (washing machines, refrigerators)
• ...
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
PART PRODUCTION PHASE
• Part Production: • sequence of OPERATIONS (TRANSFORMATIONS) to change shape,
dimensions, surface finish or other properties of simple (elementary) parts
gearsframe
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
ASSEMBLY PHASE
• Assembly:• Sequence of ACTIONS for grouping, positioning and fixing parts into
an assembly
N.B.: it’s a hierarchicalsequence, i.e. simpleparts are firstassembled into sub-assemblies, then sub-assemblies are groupedinto finished product.
….. …..
Sub-assembly
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
PRODUCTION QUANTITY Q
• The quantity of products Q made by a factory influences the way it works, and so the 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
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
PRODUCT VARIETY P
• Product variety P refers to different product types or models produced in the plant
• Different products have different features • They have different geometry, properties, appearance
• They are intended for different markets
• Some have more parts than others
• Number of different product types made each year
• When the number of product types made in the factory is high, this indicates high product variety
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
P VERSUS Q IN FACTORY OPERATIONS
• Figure 1.2 P-Q Relationship
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Prodotti
Vo
lum
i d
i p
rod
uz
ion
e
LINEE
CELLE
JOB-SHOP
FROM FUNCTIONS TO THE PRODUCT
Cell
Line
Job-shop
Products
Pro
duct
ion V
olu
me
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
MATERIALS IN MANUFACTURING
• Three basic categories: • Metals
• Ceramics
• Polymers
• Their chemistries are different
• Their mechanical and physical properties are dissimilar
• These differences affect the manufacturing processes that can be used to produce products from them
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
IN ADDITION: COMPOSITES
• Nonhomogeneous mixtures of the other three basic types rather than a unique category
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
Raw, semifinished
MANUFACTURE
Component
Assembly
ASSEMBLY
FINISHING , TEST, …
Finish product
MANUFACTURING PROCESSES
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
MANUFACTURING PROCESSES
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
PROCESSING OPERATIONS
• Alters a material’s shape, physical properties, or appearance in order to add value
• Three categories of processing operations: • Shaping operations - alter the geometry of the starting work
material
• Property-enhancing operations - improve physical properties without changing shape
• Surface processing operations - to clean, treat, coat, or deposit material on exterior surface of the work
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
SHAPING PROCESSES – MAIN CATEGORIES
1. Solidification processes - starting material is a heated liquid or semifluid
2. Particulate processing - starting material consists of powders
3. Deformation processes - starting material is a ductile solid (commonly metal)
4. Material removal processes - starting material is a ductile or brittle solid
5. Other processes - (nonconventional) EDM, Laser, AWJ…
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
WASTE IN SHAPING PROCESSES
• Desirable to minimize waste in part shaping
• Material removal processes are wasteful in unit operations,
• Most casting, molding, and particulate processing operations waste little material
• Terminology for minimum waste processes:• Net shape processes - when most of the starting material is used
and no subsequent machining is required
• Near net shape processes - when minimum amount of machining is required
Waste is different from Scrap(due to defective products)
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
PROPERTY-ENHANCING PROCESSES
• Performed to improve mechanical or physical properties of work material
• Examples: • Heat treatment of metals and glasses
• Sintering of powdered metals and ceramics
• Part shape is not altered, except unintentionally• Example: unintentional warping of a heat treated part
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
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SURFACE PROCESSING OPERATIONS
• Cleaning - chemical and mechanical processes to remove dirt, oil, and other contaminants from the surface
• Surface treatments - mechanical working such as sand blasting, and physical processes like diffusion
• Coating and thin film deposition - coating exterior surface of the workpart
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
ASSEMBLY OPERATIONS
• Two or more separate parts are joined to form a new entity
• Types of assembly operations:• Joining processes – create a permanent joint
Welding, brazing, soldering, and adhesive bonding
• Mechanical assembly – fastening by mechanical methods
Threaded fasteners (screws, bolts and nuts); press fitting, expansion fits
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
MANUFACTURING PROCESSES
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
SOLIDIFICATION PROCESSES
• Starting material is heated sufficiently to transform it into a liquid or highly plastic state
• Examples: metal casting, plastic molding
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
Sand castingExpanded polystyrene
casting Shell Molding
Die Casting Investiment and microcasting
SOLIDIFICATION PROCESSES
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
PARTICULATE PROCESSING
• Starting materials are powders of metals or ceramics
•Usually involves pressing and sintering, in which powders are first compressed and then heated to bond the individual particles
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
DEFORMATION PROCESSES
• Starting workpart is shaped by application of forces that exceed the yield strength of the material
• Examples: (a) forging, (b) extrusion
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
Hot Rolling Cold RollingShape Rolling
Mannesmann roll mill for producing seamless tubing
DEFORMATION PROCESSES
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
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Roll bending
BendingDrawing
DEFORMATION PROCESSES
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
MATERIAL REMOVAL PROCESSES
• Excess material removed from the starting piece so what remains is the desired geometry
• Examples: machining such as turning, drilling, and milling; also grinding and nontraditional processes
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
Raw materials
Components
DESIGN
PRODUCTION
Product Specifications
Functions
Product
FROM FUNCTIONS TO THE PRODUCT
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
PRODUCT
Idea and functions
Materials and components
characteristics
• Physical
• Resistence
• Cost
Technologies
• Manufacturing
• Joining
• Protection
• Cost
Global cost
• Starting cost
• Working cost
MAIN ELEMENTS
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
Costs
Technologies
Materials
PRODUCT REALIZATION
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
They represent the «connection» necessary to realize ‘ideas’ and ‘functions’ by means of materials
transformation
TECHNOLOGIES
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Università di Bergamo – DIGIPTecnologie e Sistemi di Lavorazione
Studi di Fabbricazione – 2018 - 1
QUESTIONS ?