isat 430 introduction spring 2001 dr. ken lewis. module 1 spring 2001dr. ken lewis isat 4302...

ISAT 430

Introduction

Spring 2001

Dr. Ken Lewis

Spring 2001 Dr. Ken Lewis ISAT 430 2Module 1

Preliminary Stuff

• Professor – Dr. Ken Lewis• Office – ISAT 125• Phone – 2753• Email – lewisgk• Office hours – Whenever you want

(assuming no other conflicts)• Call me? – ANYTIME!• Ask questions? -- ANYTIME!


Meeting Place and Times -- Syllabus is WRONG!!!!

•Lectures: MW 1010 – 1100 in room 148

•Recitations: Tu 1100 – 12345 in room 1027


Preliminary Stuff -- Grading

Hourly Exams (2) 15% (30%)

Project 15%

Quizzes 15%

Homework and class participation

10%

Final exam 30%

100%


Preliminary Stuff

• Units If a problem uses units, be explicit and clear,

and use units. Units are your friend.

ISAT 430

Manufacturing Processes

Spring 2001

Dr. Ken Lewis


What are we about? Material Manipulation

• conversion & forming, the molding and shaping of metals, glasses, ceramics, polymers and composites. From the earth to a part.

• removal, the machining, grinding, cutting, lithography and etching of materials. Getting rid of the excess stuff.

• joining, the welding, brazing, and soldering of materials. The sticking of things together.

• Assembly, mechanical assembly and electronics manufacturing. Putting together dissimilar materials.


We will delve into the sciences which are behind these

processes.


Objectives of the Course

• We will look at the following:

How does stuff come from the Earth and become cool and useful?

What is the “process – structure – property – performance continuum”?

What are the material concerns that we have as we make a material selection to make a particular product?

What are the practical concerns that we have?


What will we look at first?

• The process – structure – property – product – performance continuum.

• An overview of the main methods of manufacturing. The materials The methods of change

• What factors affect the selection of manufacturing processes.


Process-Microstructure-Property-Product Performance Continuum

Product Performanceor Function

Composition &Structure

Synthesis/Processing

Properties/Behavior

Changes

Dictate

Dictate

Changes Control

Limit

Affects

Indicate


What are Manufacturing Processes???


Manufacturing Processes of Today

• Essentially, these are the ways that Man has found to take the characteristics of a material (mud, gold, a tree, a pile of ore, sea water….. ) and:

Make parts or things

Make things of greater value

Make things do something


Manufacturing Processes of Today2

• These processes change or alter the materials

State Geometry Properties Microstructure Appearance ERGO “Value”


Primary Goals of a Manufacturing Process

• Produce components from selected materials

At the lowest possible cost

In the correct shape

Having optimum properties for its proposed use.

• Key Point – manufacturing adds value to the materials.

A Small History

of Manufacturing


History

• First came the discovery of materials. Wood tools Fibers

Clothshelter

ClayPotteryBricks

MetalsCopperBronze iron

Note that not only was the material discovered but processes which wouldchange the materials form had to be

Discovered.


History

• All that was available for millennia was simple hand crated materials. One of a kind Produced in a shop fashion. Even when the Romans were churning out armor and

weapons, it was just a shop multiplied many times.

• First step forward was the discovery of ‘division of labor’ Dividing the total process into a number of sub

processes and making an individual worker and expert in just one or two sub processes.


The Industrial Revolution (1760 – 1845)

• Four things changed production forever.

The steam engine

Machine tools

Textile machinery

The factory system


History3 – The Industrial Revolution

• All was what are called “cottage industries”.• The Industrial Revolution

Change was driven by the discovery of a new source of power “STEAM”!John Watt invented the steam engine.

Steam power quickly replace the traditional water wheels, animal wheels, and windmills.Developed in EnglandEngland tried to keep the new technologies to give

themselves an economic edge• Didn’t work.


History4 – The Industrial Revolution2

• Possible only because of machine tools... John Wilkinson invented the boring machine in 1775.

Allowed Watts to make the steam engine Henry Maudsley developed the screw cutting lathe in

1800Allowed turning with much greater precision and speed.

• The textile industry was vastly changed The spinning jenny Power loom Jacquard loom


History5 – The Industrial Revolution3

• The factory system Division of labor Several fold increase in labor efficiency


History6

• Other forces Eli Whitney in the US developed the concept of

interchangeable parts.Precursor to mass production and assembly lines.

Henry Ford introduced the assembly in Detroit in 1913


Classification of Manufacturing Processes

Conversion Processes


Processing Operations Assembly Operations

Extraction

Casting Particulate processing

Formingprocesses

Material removal

Permanentjoining

processes

Brazing &soldering

Adhesive bonding

Shapingprocesses

Propertyenhancingprocesses

Heat treatment

Surfacecleaning

Coating/depositn.

Mechanicalfastening

Welding

Surfaceprocessingoperations

Threadedfasteners

Permanentfasteningmethods



• Conversion Transform materials from their raw or natural

state to a more useful semi-finished form

• Processing Operations Transform a material in transit from one state

of completion to a state closer to the desired product.

• Assembly Operations Unit separate parts to from a new entity


Conversion Processes

• Extraction Conversion of metals from their natural ores

by mining, separation and reduction to the metallic state.

• Casting shaping by the transformation of the liquid to

the solid state;

exploits the fluidity of a liquid as it takes shape and solidifies in a mold.


Processing Operations

• Add value by: Changing the geometry Properties Appearance

• Achieved by the controlled application of thermal, mechanical, electrical or chemical energy to accomplish the above


Processing Operations2

• Can be divided into three divisions

Shaping Operations

Property Enhancing Operations

Surface Processing Operations


Shaping Operations

• Processes that alter the geometry and maybe the physical and mechanical properties.

• Examples Casting (of metals) Molding of plastics Deformation processes – sheet forming, forging,

extrusion, drawing, etc., Particulate processing – powder metallurgy Material removal processing – machining,

cutting and grinding


Property Enhancing Operations

• Operations that manipulate or enhance both the physical and mechanical properties of the starting solid semi-finished material or product.

• Control of properties of a part during manufacture Allow properties to be matched to the application Especially when the magnitude or directionality of

the mechanical properties is important


Property Enhancing Operations2

• Examples Heat treatment Organic composite cure schedules Deformation processes


Surface Processing Operations

• Operations performed to clean, treat, coat, or deposit material onto the exterior surface of the part

• Examples Electroplating – anodizing Nit riding Case hardening Grinding painting


Assembly Operations

• Joining Processes

• Mechanical Assembly


Joining Processes

• Uniting individual workpieces Permanently Semi-permanently

• Melting, using adhesive bonding materials• Usually results in added weight• Examples

Welding Brazing & soldering Adhesive bonding Solid state bonding.


Mechanical assembly

• Units sub assemblies without melting• Examples

Semi-permanentNutsBoltsScrewsThreaded fasteners

PermanentPress-fittingExpansion fits.

isat 430 introduction spring 2001 dr. ken lewis. module 1 spring 2001dr. ken lewis isat 4302...

Documents

ken lewisoffice isat

ken lewisdr

electronics manufacturing

manufacturing processesspring

main methods of manufacturing

key point manufacturing

material selection

material concerns