Department of Mechanical EngineeringChung-Ang UniversityDepartment of Mechanical EngineeringChung-Ang University1

Modern Manufacturing

Seok-min Kim

Department of Mechanical EngineeringChung-Ang University2

Administrative DetailsInstructor : Prof. Seok-min Kim

Office : Bobst hall #429 , E-mail : smkim@cau.ac.kr

Class Meeting Time and Place

Monday: 2, Wednesday: 1, 2 ( Room # 404, Bldg. #207)

Text book

Mikell P. Groover, Principles of Modern Manufacturing 4th Ed. Wiley

Lecture Note

http://nmtl.cau.ac.kr

Midterm exam : 40%, Final exam : 40 %, Quiz & H/W : 10%, Attendance : 10%

* Attendance Point = 10 – 2 X (│( day of absent -3)│)

* Late : 0.5 day of absent , No excuse without official absent reason

Department of Mechanical EngineeringChung-Ang University3

Schedule Day Topic Day Topic09/03 Introduction 10/29 Solidification Process

09/05 Manufacturing materials 10/31 Solidification Process

09/10 Manufacturing materials 11/05 Solidification Process

09/12 Manufacturing materials (Quiz) 11/07 Solidification Process

09/17 Material Removal Processes 11/12 Solidification Process

09/19 Material Removal Processes 11/14 Solidification Process

09/24 Material Removal Processes 11/19 Particulate Processes

09/27 Material Removal Processes 11/21 Particulate Processes

10/01 No class (national holiday) 11/26 Non traditional manufacturing

10/03 No class (national holiday) 11/28 Non traditional manufacturing

10/08 Deformation Processes 12/03 Non traditional manufacturing

10/10 Deformation Processes 12/06 Non traditional manufacturing

10/15 Deformation Processes 12/10 Non traditional manufacturing

10/17 Deformation Processes 12/13 Non traditional manufacturing

10/22 Midterm 12/17 Final

10/24 Midterm 12/20 Final

Department of Mechanical EngineeringChung-Ang University4

H/W #1 국제 자동화 정밀기기전 참관 및 보고서 제출

Report (A4 3 page )- MS word format

Margin : 3.00cm (top) 2.54cm (other)

Font : 굴림 (10pt) line space : 1.15

- 1st page (표지)학번, 이름, 증빙 사진

- 2nd page ~ 3rd page방문후 느낀점방문시 인상깊게 본 장비에 대한소개 (동작원리, 응용 분야, 해당 장비의 특징 )3rd page 는 꽉 채우지 않아도 됨(그림을 제외한 글자가 1page 이상이어야 함)

- 9월 15일 밤 12시까지E-class 홈페이지에 upload

Department of Mechanical EngineeringChung-Ang UniversityDepartment of Mechanical EngineeringChung-Ang University

What is Manufacturing?

Seok-min Kimsmkim@cau.ac.kr

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Department of Mechanical EngineeringChung-Ang University

Science Vs. Technology(Engineering)

Science

과학은 자연세계에서 보편적 진리나 법칙의 발견을 목적으로 한 체계적 지식

Technology

인간이 자신의 욕구(편리하게, 안락하게, 유익하게)를충족시키기 위하여 자원의 형태를

변화시키는 수단이나 활동

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Department of Mechanical EngineeringChung-Ang University

Basic Definition for Manufacturing Systems

Manufacturing processes are the lower-level manufacturing

activities used to make products. There are traditional machining

processes, for example, turning, milling, and grinding, and more

advanced nonchipping processes, for example, electro-chemical

machining (ECM) and electro-discharge machining (EDM).

Manufacturing is a set of correlated operations and activities, which

includes product design, material selection, planning, production,

inspection, management, and marketing of the products, for the

manufacturing systems.

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Department of Mechanical EngineeringChung-Ang University

Manufacturing system is an organization that comprises several

interrelated manufacturing subsets. Its objective is to interface with

outside production functions in order to optimize the total productivity

performance of the system, such as production time, cost, and

machine utilization. The activities of these subsets include design,

planning, manufacturing, and control. These subsets are also

connected with production functions outside the system, such as

accounting, marketing, financing, and personnel.

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Department of Mechanical EngineeringChung-Ang University

Manufacturing-system Diagram

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Department of Mechanical EngineeringChung-Ang University

Four Categories of Main Manufacturing Processes

Material removal processes

- starting material is a solid (ductile or brittle), from which material is

removed so resulting part has desired geometry

Deformation processes

- starting material is a ductile solid (commonly metal) that is deformed

Solidification processes

- starting material is a heated liquid or semifluid that solidifies to form

part geometry

Particulate processing

- starting material is a powder, and the powders are formed into

desired geometry and then sintered to harden

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Department of Mechanical EngineeringChung-Ang University

Material Removal Processes Excess material removed from the starting workpiece so what

remains is the desired geometry

Examples: machining such as turning, drilling, and milling;

also grinding and nontraditional processes

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Department of Mechanical EngineeringChung-Ang University

Deformation ProcessesStarting workpart is shaped by application of forces that

exceed the yield strength of the material

Examples: (a) forging, (b) extrusion

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Department of Mechanical EngineeringChung-Ang University

Solidification Processes

Starting material is heated sufficiently to transform it into a

liquid or highly plastic state

Examples: Casting for metals, molding for plastics

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Department of Mechanical EngineeringChung-Ang University

Particulate Processing Starting materials are powders of metals or ceramics

Usually involves pressing and sintering, in which powders are

first squeezed in a die cavity and then heated to bond the

individual particles

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Department of Mechanical EngineeringChung-Ang University

Assembly Operations

Two or more separate parts are joined to form a new entity

1. Joining processes – create a permanent joint Welding, brazing, soldering, and adhesive bonding

2. Mechanical assembly – fastening by mechanical methods Threaded fasteners (screws, bolts and nuts) Fitting

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Department of Mechanical EngineeringChung-Ang University

Property-Enhancing Processes

Performed to improve mechanical or physical properties of

work material

Part shape is not altered, except unintentionally• Example: unintentional warping of a heat treated part

Examples: • Heat treatment of metals and glasses • Sintering of powdered metals and ceramics

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Department of Mechanical EngineeringChung-Ang University

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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Department of Mechanical EngineeringChung-Ang University

Design Activities for Manufacturing System

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Department of Mechanical EngineeringChung-Ang University

Various Steps in Designing and Manufacturing a Product

Definition of product need;Marketing information

Conceptual design and evaluation;Feasibility study

Design analysis; codes/ standards review;Physical and analytical models

Production drawings; instruction manuals

Material specification; process and equipment selection; safety review

Pilot production

Production

Inspection and quality assurance

Packaging; marketing and sales literature

Product

Prototype production; testing and evaluationComputer-aided design

(CAD)

Computer-aided manufacturingand process planning

(CAM and CAPP)

Computer-integrated manufacturing(CIM)

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Department of Mechanical EngineeringChung-Ang University

Various Factors Influencing Product Cost

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Department of Mechanical EngineeringChung-Ang University

Engineering Materials

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