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Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:1
Environmentally Conscious Design & Manufacturing
Class 5: Manufacturing
Prof. S. M. Pandit
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:2
Manufacturing
Agenda
What is a Manufacturing Enterprise? Systems View - Manufacturing Manufacturing Processes Modeling
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:3
Manufacturing Enterprise
Manufacturing Enterprise
Product DesignMarketing
Finance Manufacturing
TechnologyManagement
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:4
Manufacturing Enterprise - Product Design
Product Design
Traditional Functional Requirements Cost, Time & Material constraints Design tools for CAE
(Integrated CAD - CAM +..
Research Areas Computer Aided Design Tools Environmentally-Friendly Product
Design and Packaging Human Machine Interface Rapid Prototyping
Stereolithography:
http://www.nitc.qub.ac.uk/divs/pddc.htm
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:5
Manufacturing Enterprise - Product Design
CAD
• Drafting function
• Divide into elements
• Optimize storage and processing
• Finite element / Finite difference analysis
2D .. 2.5D .. 3D
Solid Stress / Thermal / Fluid Flow
Material Properties -- Isotropic
Anisotropic
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:6
Manufacturing Enterprise - Manufacturing
Manufacturing
Traditional Machining
Single and multi-point cutting Joining, Forming, Casting .. Metrology
Non-Traditional Laser Cutting Abrasive jet machining Electrochemical machining Explosive deformation and joining Hydroforming http://www.servicemetal.com
Laser Cutting
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:7
Manufacturing Enterprise - Manufacturing
CAM
- Data transfer (integrated CAD - CAM)
- Machine tool controller (language)
- Program entry / debugging / dry run
- Tool wear / breakage
- Dimensional accuracy
- Temperature effects
- Elastic deformation
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:8
Manufacturing Enterprise - Manufacturing
http://www.ab.com/cnc
CNC information flow
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:9
Systems View
Finite-Element Analysis
Computational Fluid Dynamics
Kinematic / Dynamic Analysis
Design Visualization and Animation
Drafting
CAM
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:10
Manufacturing Processes
• Solidification
• Forming Processes
• Particulate Processing
• Material Removal
• Joining
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:11
Manufacturing Processes
Solidification Processes
MeltingFurnace (Metals: 800 C to 3000 C)
- Alloying- Phase stability- Inclusions and impurities
(chemical metallurgy)- Stirring and agitation- Buoyancy and surface tension
driven flow- Bubbles in the melt
{Chemical and Physical Metallurgy}
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:12
Manufacturing Processes - Solidification 1
Sand Casting
SprueRiserSand Core
Parting Line
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:13
Manufacturing Processes - Solidification 2
SolidificationTime - temperature - compositionQuenching (conduction heat transfer)
- Simple analysis: Lumped parametertransient temperature profiles
)(
0 T - T
T - )T( p
s
VC
hA
e
‘T’ is a function of time, , the initial temperature, T0 , and the ambient temperature, T . ‘h’, As , r, V, and Cp are the convective heat transfer coefficient, Surface area, density, Volume, and specific heat capacity, respectively.
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:14
Manufacturing Processes - Forming
MoldingInjectionBlow
ExtrusionRollingForging
• Polymer processing• Cost advantages• Rheological properties and
temperature dependent properties
• Temperature & pressure
• Influence on grain structure• Diffusion processes• Directional properties
Reference: Physical Metallurgy by Dieter
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:15
Manufacturing Processes - Powder Metallurgy
Powder production
Blending
Compaction
Sintering
Creating a “die compaction tool”
1) Develop a user-friendly software simulation model2) Develop the required material models and incorporate them into the
software, 3) Determine the material properties necessary to verify and implement the
model, 4) Verify model output through experimental techniques, and 5) Demonstrate the applicability of the process model.
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:16
Machining - 1
Metal removalTurning, Milling, Drilling:
Primary Inputs: Electrical EnergyCutting fluid
Primary Outputs: Finished productsSpent cutting fluid
Others: Lubricants, oils, machined chips, tool debris, heat
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:17
Machining - 2
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:18
Machining - 3
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:19
Machining - 4
Radial drilling machine
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:20
Machining - 5
Metal removal Electro discharge / Electro-chemical /
Primary Inputs: Electrical EnergyCutting fluid / Electrolytes
Primary Outputs: Finished productsSpent cutting fluid / Electrolyte
Others: Lubricants, oils, work-piece debris, tool debris, heat, Metal vapor, Metallic compounds, ...
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:21
Machining - 6
Electro-chemicalmachining of blades
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:22
Machining - 7
Abrasive jet machining - schematic
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:23
Machining - 8
Metal removal - no ‘tooling’Electron beam, Laser, Abrasive jet, Water jet
Primary Inputs: Electrical EnergyFluids & abrasives
Primary Outputs: Finished productsSpent fluid & abrasives
Others: Heat, Metal vapor, Metallic compounds, ...
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000 Slide:24
Machining - 9
http://www.llnl.gov/IPandC/op96/09/9c-com.html
Electron - beam machining:
• Intense energy densities
• Non - contact
• Clean