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Manufacturing technologyIntroduction
Technology II – Jan Tomíček
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Manufacturing
• Important part of World economy. Allmost all products are manufactured.
• Demands are increasing• New issues – energy efficiency, waste, etical
issues
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Changes in the world of goods manufacturing
1. World wide competetion2. New materials3. Advanced technologies4. New manufacturing systems5. Enviromental issues
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1. World Wide Competetion
• Global business• Market = Whole world• Everybody can make business – – knowledge vs. capital– customization vs. mass production– Product placement vs. variability
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2. New materials
• Demands from customers– Smooth surface on plastic parts– Transparency of plastic– Shiny metal look etc.
• New developed materials with better properties– Heat resistant materials– High strength materials– Special materials
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3. Advanced technologies
• Complex products• Combined principles– Mechanical principles– Electrical– Electronical– Combination
• Water, steam, electricity,
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4. New manufacturing systems
• Manufacturing system
• Manufacturing strategies
• Management
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5. Enviromental issue
• Low energy and material consumption
• Utilization of human labor, heavy work
• Healt and security issues
• Ethical problems
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Product Life Cycle
Design
Construction
Manufacturing
Sale
Service and recycling
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START-UP RAPID GROWTH MATURATION COMODITY or DECLINE
Product variety Great variety, product innovation
Increasing standartization
Emergence of a dominant stadart design
High standardization„comodity“ characteristics
Industry structure Small competetiors Fallout and Consolidation
Few large companies „Survivors“ become comodities
Form of competetion Product characteristics Product Quality, Cost and availability
Price and Quality and Reliability
Price with consistent quality
CostPer unit
Annual sales per model
SATURATION
TIME
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Price of the product?
• What is the best price of the product?
Smallest, affordable, highest, psychologically friendly, discounted??
Production costs!
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Manufacturing costs40%
Profit20%
Marketing sales, general administra-
tive costs25%
Engineering costs15%
Selling price
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Manufacturing costs
• Methods:– Casting, foundry, moulding– Forming of metalforming– Machining(material removal)– Surface treatments(finishing)– Heat treatment– Joining and assembling
• Machining is approx 40% of manufacturing costs
TECHNOLOGY II
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Machining• Chip removal process – Material is removed in
form of chips from a piece of raw material to archive the desired shape.
• Material(chips) are removed by a tool from the blank
• This process is called „Chip forming“
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ADVANTAGES• variety of work materials• variety of part shapes and geometric
features• dimensional accuracy• good surface finishes
DISADVANTAGES wasteful of material time consuming
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Material utilization
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A CUTTING TOOL• single-point tool (a)• multiple cutting edge tool (b)
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Chip forming principle
• Continuous vs. discontinuous chipForce stresswork hardeningsaturation(fully
hardened material)shearconinuous chip
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CHIP FORMATION (orthogonal cutting schema)
• the tool is forced into the material• plastic deformation → hardening of the material• shear deformation – shear plane (angle φ)
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CHIP FORMATION
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Secondary deformation zone
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Chip breakers
• Preventing the built-up edge– Groove type - premanufactured– Obstruction type
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Chip and Tool geometry
• Tool – rake & face angle
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Chip thickness
• Chip thickness ratio
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CUTTING CONDITIONS• cutting speed vc [m.s-1]; [m.min-1]• feed f [mm.rev-1]; [m.min-1]• depth of cut d = ap [mm]
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Chip types
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Chip breaking diagramme
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Chip breaking diagramme
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Chip volume ratio
• Calculation W =• Value 3-400
• Large volume of chips
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Chips removal• Chips must be removed– From the cut – gravity, liquid, air etc.– From the machine – liquid, automatic, manually– From the workshop – conveyors, carriages– From factory – • recycling
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What to think about?
• Next time – resistance of material, cutting forces, heat and temperature