(lect 1) manufacturing

7/30/2019 (Lect 1) Manufacturing

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Materials


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Teaching Faculty

The Materials Processing Group

Dr. Hasan Bin Awais

Dr. Fahad Ali

Mr. Naeem-ul-Haq Tariq

Mr. Hafiz Rubnawaz


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Manufacturing

The Process of Converting Raw

Materials Into Products


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Manufacturing Processes - 1


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Process

Casting

Permanent mold Centrifugalcasting

PermanentPattern

InvestmentCasting

Expendable moldand pattern

Ceramicmould casting

Cutting

Forming

Fabrication


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Properties of Materials

Mechanical Properties: strength, toughness,ductility, hardness, elasticity, fatigue, creep.

Behavior Under Loading: tension, compression,

bending, torsion, shear.

Physical Properties: density, specific heat, thermalexpansion, thermal conductivity, melting point,

electrical and magnetic properties.

Chemical Properties: oxidation, corrosion,degradation, toxicity, flammability.


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Types of Materials

Ferrous Metals: iron and steel.

Nonferrous Metals and Alloys: aluminum,magnesium, copper, nickel, titanium, superalloys,

beryllium, zirconium, low-melting alloys, precious metals.

Plastics: thermoplastics, thermosets, elastomers.

Ceramics: glass, graphite, diamond.

Composite materials: reinforced plastics, metal-matrix and ceramic-matrix composites, honeycomb

structures.


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Ferrous Metals: Applications

Structural: building structures, concrete

reinforcement

Automotive: chassis, engine parts, drive train,body parts

Marine: ship hulls, structure, engines

Defense: tanks, weapons

Consumer Products: appliances, recreational

vehicles, toys, utensils and tools


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Nonferrous Metals: Applications

Architectural: aluminum windows and doors

Automotive: aluminum engine blocks, copper

wiring, mag wheels

Marine: brass/bronze fittings, bearings,

propellers

Defense: brass shell casings

Consumer Products: electrical wiring, utensils,

jewelry, electronics


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Plastics (Polymers)

Compared to metals, plastics have lower density,

strength, elastic modulus, and thermal and

electrical conductivity, and a higher coefficient

of thermal expansion

The design of plastic parts should include

considerations of their low strength and stiffness,and high thermal expansion and low resistance to

temperature.


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Plastics: Applications

Architectural: electrical and thermal insulation, weather

seals, carpets, wall coverings, paint

Aerospace: electrical and thermal insulation, instrument

panels,upholstery, seals

Automotive: body panels, instrument panels, upholstery,

electrical and thermal insulation, seals, hoses, tires

Consumer Products: toys, sporting goods, appliances,

tools, utensils, clothing, shoes, packaging


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Manufacturing

The Process of Converting Raw

Materials Into Products


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Manufacturing a Product:

General Considerations

Material Selection

Processing Methods

Final Shape and Appearance

Dimensional and Surface Finish

Economics of Tooling Design Requirements

Safety and Environmental Concerns


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Choosing Methods of Production

Use a Selection Chart


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Manufacturing Processes for Metals

Casting: expendable mold and permanent mold.

Forming and Shaping: rolling, forging, extrusion, drawing,sheet forming, powder metallurgy, molding

Machining: turning, boring, drilling, milling, planing, shaping,broaching, grinding, ultrasonic machining, chemical machining,

electrical discharge machining (EDM), electrochemical

machining, high-energy beam machining

Joining: welding, brazing, soldering, diffusion bonding,adhesive bonding, mechanical joining

Finishing: honing, lapping, polishing, burnishing, deburring,

surface treating, coating, plating


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Casting Processes

Introduction of molten metal into a mold cavity; uponsolidification, metal conforms to the shape of the cavity.

Die Casting Sand Casting


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Forming and Shaping Processes

Bulk deformation processes that induce shape changesby plastic deformation under forces applied by tools

and dies.

Forging

Extrusion


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Machining Processes

Material removal from a work piece: cutting, grinding,

nontraditional machining processes.

Milling Lathe Machine


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NC Machine Tool and Controller


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NC Punch Press Machine


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Manufacturing Processes

for Plastics

Plastics are shipped to manufacturing plants as

pellets or powders and are melted just before the

shaping process. Polymers melt at relatively lowtemperatures and are easy to handle.

Plastics can be molded and formed, as well asmachined and joined, into many shapes with

relative ease.


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Injection Molding of Plastics


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Selective Laser Sintering System

Courtesy of the University of Texas


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ShapeComplexity

The shape complexity index is obtained by using a

feature based classification system which enables

the important design issues.

Classification of different shape complexity:-

A Part envelop is largely a solid of revolution.

B Part envelope is largely a prismatic solid.

C Flat or thin wall section component.


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Sub-ClassificationsofCategories

A,B,C Basic features

Secondary features

Multi axis Non-uniform

Single axis

Through features


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1. Basic FeaturesStraight forward processing where

the operation can be carried out

without a change of setting or theneed of complex tooling. Parts are

usually uniform in cross section.


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2.Secondary features

Same as basic features but whereadditional processing is necessary or

more complex tooling is required.

3.Multi-axis Features

Parts require to be processed in more than

a single axis/set-up.


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4.Non-uniform Features

Parts require the development of

more complex processing techniques.

5.Complex FormsParts need dedicated tooling and the

development of specialized

processing techniques.


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6. Single Axis

This is usually the axis along the

components largest dimension, howeverin the case of cylindrical or disc shapedcomponents it is more convenient to

consider the axis of revolution as theprimary axis.

7. Through Features

Features which run along across orthrough a component from one end orside to the other


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8. ImportantIf the component falls into more than

one category, always choose the one

that gives highest value of complexity.


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Basic Rotational features Regular Secondary features

A1 A2

Category includes Rotationally

symmetrical/groove holes along the

primary axis

Internal/external threads around primary

axis.


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Secondary Axis Complex forms

Interna Internal or external features Irregular or complex forms

A3 A4 A5

Holes/threads counterbores

and other internal features

not on primary axis

Projections, complex

features.

Complex contoured

surfaces


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Single Axis Secondary/Repetitive

Basic features only Uniform thickness

C1 C2

Blanks, washers, simple bends etc Plain cogs/gears


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Regular forms Complex forms

cup., cone and box-type parts Non-uniform forms

C4 C5

Components may involve changes in

section thickness

Complex or irregular features

(lect 1) manufacturing

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