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Powerpoint format of lectures in MECH 213, 2004 edition.

Lecture 1
The contents of this lecture are the sole copyright of J. Jeswiet,
Professor of Mechanical Engineering.

They are intended for use only by students in MECH 213,


Manufacturing Methods,
Mechanical Engineering,
Queen’s University, Kingston, ON, Canada.
Queen’s University, Mechanical Engineering
Unlicensed use of the contents of this lecture outside MECH 213 is illegal.
illegal.
© J. Jeswiet

Inquiries should be addressed to: J. Jeswiet, Mechanical Engineering, McLaughlin


Hall, Queen’s University, Kingston, ON, Canada K7L 3N6 MANUFACTURING ENGINEERING
Fax: 613-533-6489
jeswiet@me.queensu.ca
MECH 213
Welcome to everyone.
Course introduction

Instructor: Professor J. Jeswiet The lecture for today includes:

McLaughlin Hall 1. Course


1. Course details
details
Room 303A 2. Introduction
2. Introduction to
to Manufacturing
Manufacturing Engineering
Engineering

533 - 2577

Email: jeswiet@me.queensu.ca

Laboratory sections and times:


Course Details
Course Details
Section A: 1130 – 1330 Monday
Textbook:Manufacturing
Textbook: ManufacturingEngineering
Engineeringand
andTechnology,
Technology,44ththedition;
edition;
byS.
by S.Kalpakjian
Kalpakjian&&S.R.
S.R.Schmid;
Schmid;Prentice
PrenticeHall
Hall©©2001
2001 Section B: 1530 – 1730 Monday

Lectureswill
willbe
beavailable
availablein
inpdf
pdfformat
formatat
atthe
thecourse
coursewebsite.
website.
Section C: 1430 – 1630 Tuesday
Lectures website
Eachlecture
Each lecturewill
willbe
beavailable
availableat
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oneday
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ofthe
the
th lecture.
e lecture. Section D: 1230 – 1430 Thursday
Section E: 1130 – 1330 Wednesday
Please note: all exams are open book,
book, and most
textbook,
assignments will be from the textbook,
There are no laboratories in the week of Oct 11.
Exam questions may come directly from the textbook,
therefore you will need a textbook for this course.

Lectures are in slot 1: 0830 Mon, 1030 Tues, 0930 Thurs.


Laboratories will be in the afternoon; see posted schedules

The first laboratory will be in the week of Sept 27

1
Lect # subject 18 Materials II
Lecture list 19 Materials III
1 Introduction
for 2004;
20 Steel I
Mark
Mark distribution:
distribution:
subject to 2 Geometry/dimensioning
change 3 Surface roughness I 21 Steel II
22 Steel III Assignments: 10%
4 Surface roughness II
5 metrology 23 Other alloys Laboratories: 20%
6 Machining I 24 Metal forming I
25 Metal forming II There are 7 laboratories
7 Machining II
26 Metal forming III Term exam 20%
8 Machining III
27 Metal forming IV;rolling
9 Machining IV
28 Metal forming V; rolling Project 15%
10 Machining V
29 Metal forming VI; piping Project proposal 5%
11 Machining VI
30 Casting I
12 Machining VII Final Exam 30%
31 Casting II
13 Machining VIII
32 Casting III
14 Manufacturing systems/FMS
33 Plastics All exams are open book,
book including the final exam.
15 Mechanical Testing I 34 Welding I
16 Mechanical Testing II 35 Welding II
17 Materials I 36 Summary

Due dates:
Mechanical Engineering 213 project proposal > first lecture after Thanksgiving Weekened,
Manufacturing Laboratories October 12 @ 1630. Put in the assignment box
Subject Experiment No. projects due > December 2 @ 1130 they will be put on
1. Metrology 201 display for everyone to view in room 405.

2. Arc Welding 202 assignments > are due one week after being assigned. They
should be put in the assignment box for
3. Thermal Cutting 203 MECH 213 by 1700 hrs.
4. Drilling 204
About the Assignments:
5. Turning, NC 205
6. Milling, NC 206 There will be assignments, usually at the end of the week.
7. Grinding 207 These will not all be marked, questions which must be
submitted for marking will be indicated at the lecture.
All questions will be representative of the type of question
that will appear on the quiz and the final exam.

Project
Project information:
information:
The project must describe Project Details

™ a manufacturing process or The project submission must be on a poster board with the
longest side vertical; these are available in the machine shop.
™ the manufacture of a product
Diagrams, descriptions and actual components [where possible]
A project proposal must be submitted; a maximum of two pages.
should be included.
It must must include:
The display must be simple, easy to follow, yet present
™ A title and cover page; not included in two page maximum.
engineering information essential to the process
™ Names of those submitting the report; on cover page.
™ The proposed subject matter. A professional “ appearance” is expected

™ Methods that will be used in collecting data & components.


™ Sources that will be used for references; including people.
Questions?
™An estimated timeline.
™ Groups may be formed, to a maximum of three.
Project proposal due date is the first lecture after Thanksgiving
Thanksgiving.

2
Important dates to remember in MECH 213 : MANUFACTURING ENGINEERING

Preliminary comments:
date
Quiz October 28, 2004 @ 1900hrs The lectures in this course will:
Final exam Dec ?, 2004 give you an exposure to manufacturing;
not answer all questions about manufacturing;
be descriptive in many instances;
sometimes have calculation content;
examinations will have calculations.

Background – J. Jeswiet:
Research Activities – J. Jeswiet
Industry
Design Engineer at Dupont Canada.
Design and Maintenance Engineer at Celanese Canada. 1. Single Point Incremental Forming [SPIF] & Rapid Prototyping with
Sheet Metal – Metal Forming.
Forming.
Research Engineer at ALCAN Research.
Academic 2. (a) Friction Measurement in Metal Forming.
Forming.
University of New Brunswick. (b) Development of Dynamic Neural Networks for Machining systems.
Queen’s University, Kingston, Ontario; started 1982.
3. Forming of Tailor Welded Blanks.
Blanks. Metal Forming.
Sabbaticals – keeping up to date.
1988, TNO Research Netherlands; FMS systems, 4. Material Characterization of Fuel Cell Bipolar Plates. Materials.
Materials.
1995 [6 months] Corus [British Steel] Research; Rolled Products, 5. Life Cycle Engineering/EcoDesign. Environmental.
Environmental.
1996 [6 months] Delft University; Life Cycle Engineering, LCE,
2003 [fall 2003] Danish Technical University; Metal Forming & LCE
On to MANUFACTURING
2004 [winter 2004] Katholiek Universiteit Leuven; Metal Forming
2004 [Feb 18 – June 30] Australian National University, Canberra, Australia

So what is manufacturing?
manufacturing
wherever you are in the future,
The word manufacturing* is derived from Latin: ask yourself the following question:
manus = hand factus = made
How were the parts around you made?
and the definition is
“the making of goods and articles by hand or, For example: in a room, a car, train, a
especially, by machinery, often on a large scale and boat, a lecture theatre, a kitchen, etc.
with a division of labour”

Making things is what Manufacturing Engineering is all about.


This was Designed
and Manufactured

* John Schey, Professor Emeritus, University of Waterloo.

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The three main types of manufacturing processes
are discussed in this course include: In addition:
1. Material removal, cut into a desired shape. the manufacture of
2. Deformation of material, squash into the shape we want. • textiles,
3. Melting and cooling of material, pouring a fluid into a • petroleum products,
shape and then freeze it.
• liquid products
In all cases we need a raw material. are all manufacturing processes,
processes however due to
Therefore we need to know something about materials. time constraints, these will not be discussed.

Materials and Manufacturing are inextricably intertwined.


intertwined

When talking about manufacturing we need to understand


Management that first an engineer has to develop a design.
design

Modern manufacturing includes management of


processes, facilities, people, time, etc.
For every
There will be references to management techniques The design is design there is
eventually a
such as JIT manufacturing, TQM. First there sent to the manufacturing
JIT: Just in Time manufacturing is a design manufacturer phase

TQM: Total Quality Management

In general, there will not be enough time to deal with


these and they will be left to other courses.
Having said that, most of you will be managers of
some sort in your future.

Having said all that, in practice, This


Thisleads
leads to
to concepts
conceptssuch
suchas
asDFMA:
DFMA:
the design may well be impossible to manufacture.

From Boothroyd
& Dewhurst

DFMA seeks to
resolve the conflict
between Design and
Manufacture

4
DFMA case study One solution is:

Questions:
How are these parts made?
What materials are needed?
Can the design be simplified to
reduce manufacturing costs,
costs
and increase productivity.
productivity

on to manufacturing

Some historical background: For many centuries manufacture was essentially an


individual activity, practiced by artisans and apprentices
Manufacturinghas
Manufacturing has been
been practiced
practiced for
for thousand
thousandof
of years
years Production was limited to low volumes until the advent of
startingwith
starting with the
theproduction
productionof of stone,
stone,ceramic
ceramic&&metallic
metallic power
articles
articles Initially power was in the form of water and wind power
in the Middle Ages
mass production has been around a long time:
It was not until the +/-1750 that power
The Romans had manual, mass production of produced by steam was available
glassware which led to the
mining FIRST INDUSTRIAL REVOLUTION
metallurgy
textiles

The labour to do this was manual


today it is automated, giving higher Productivity.

Gradually manual functions became mechanized, creating Manufacturing and technology are interwoven.
“hard automation” and with it came electric power
Consider a map of dominant technology systems and innovation
leading to the SECOND INDUSTRIAL REVOLUTION
around +/-1900

Next came electronic circuitry which allows a high


degree of sophistication in controls,
and the invention of the transistor which gave rise to
computers and the THIRD INDUSTRIAL REVOLUTION
+/-1970

Put it all together and we have modern manufacturing

From Dr. Paul Sheng, formerly of UC Berkeley

5
Increase of complexity of industrial products over time Most observers now agree that we are still in the
3rd INDUSTRIAL REVOLUTION
a characteristic of this revolution is that,
in addition to the possibility of replacing physical labour,
it is now feasible to enhance, and sometimes replace, mental
effort.

And a new trend is micro/nano


micro/nano manufacturing.
manufacturing

From Dr. Paul Sheng, formerly of UC Berkeley

Manufacturing was once


Some already evident consequences are: relatively simple:
many dangerous physically demanding, boring jobs are It has gone from simple Lego
performed by machines or robots which are controlled assembly
by computers; with an increase of productivity.
CAD: computer aided design
product variety has increased.
CAM: computer aided manufacturing
quality has improved. CIM: computer integrated manufacturing
To a Rubic cube
productivity is rising. FMS: flexible manufacturing systems of manufacturing
So what is the measure of productivity? FAS: flexible automated systems
FMC: flexible manufacturing cell
North America: output per hour,
GT: group technology
The Europe: output per employee.
JIT: just in time manufacturing
From Economist May 18 2002, p 73
SQC: statistical quality control
TQC: total quality control

Examples of manufacturing:
Boeing 747 being manufactured in Seattle

Boeing 777

One of the first examples of Concurrent Engineering

6
Aircraft landing gear: Automobiles

Automobile parts

Including automobile
electrical parts:

Manufacturing
Manufacturingis is an
animportant
important economic
economic factor
factor
in
in all
alldeveloped
developedcountries.
countries.
and many other parts

This
Thiscan
canbe
beillustrated
illustrated by
bythe
the following
followinggraph
graph

Source: World Bank 1998 G7 members

7
What does a Manufacturing/Design Engineer need to know?
A lot.
.. strength of materials, material properties, graphics, fluids,
heat transfer, thermodynamics, control theory, statistics,
economics, environmental requirements, ……….
These are all subjects studied in Mechanical Engineering.
The Manufacturing Engineer is involved in all industries:
aerospace, automotive, textile, chemical, petrochemical,
white goods and many more…….

By the end of this course you should be able to understand the following:
Transverse automotive linkage to be machined for a German car
manufacturer [2003]. Source Industrial Diamond Review, 3/03, p 27.
Aluminum sand casting, AlSi7Mg, 70 – 100 HB, cycle time of 200 s; 10 s
for pallet change and 190 s for machining. Machine four bearings W, H, G
and V.
Tolerance on each diameter: 0.05 mm, surface roughness Rz = 16 :m.
Six M8 blind Stone impact
hole threads protection pan

SUMMARY
SUMMARY

Manufacturing is an important factor


Thank
Thank you
you for
for your
your attention
attention
to both Engineering & the Economic Life of a country.

In this course we will look at manufacturing in general

Course Objective
Course Objective
Togive
To givean
anoverview
overviewof
ofManufacturing
ManufacturingEngineering
Engineering

8
REFERENCES: The following is a list of sources used for the course material.

1. Metal Cutting. Edward M. Trent and Paul Wright, 4th edition, © B&H 2000 Footnote to
Footnote to the
the22nd
nd Industrial revolution
Industrial revolution
2. Dimensioning & Tolerancing for Quantity Production. M.F. Spotts, © 1983 Prentice-Hall
3. Modern Metal Cutting. © 1994 Sandvik Cormorant
In a recent poll, in 2000, the readers of Mechanical Engineering,
4. Metalworking Science and Engineering. E.M. Mielnik. © 1991 McGraw-Hill
5. Annals of CIRP. an American Society of Mechanical Engineers [ASME] publication;
6. Machining and Metalworking. R.A. Walsh. © 1994 McGraw-Hill (ASME has at least 80,000 members +, hence readers)
7. Tribology in Metalworking, J.A. Schey. © 1983 American society for Metals
8. Introduction to Manufacturing Processes. J. A.. Schey,. © 2000, 3rd ed. McGraw-Hill
They listed the top ten engineering achievements of the 20th century as:
9. ASM [American Society for Metals] handbooks. On reserve in Douglas
10.Design of Manufacturability. J.G. Brall. 2nd edition, © 1999 McGraw-Hill Automobile Integrated circuit mass production
11.Product Design for Manufacture & Assembly. G. Boothroyd, P. Dewhurst, W. Knight. © 1994 Marcel Dekker
Apollo spacecraft Air conditioning & mass production
12.Metal Forming. W. F. Hosford & R.M. Caddel. © 1983 Prentice-Hall
13.Omvormen van Metalen. J.A.H. Ramaekers & P.G.B. Peeters. © 1998 Raemakers/Academic Service. Power generation CAD/CAM & CAE technology
14.Fundamentals of manufacturing for engineers; by T.F. Waters; UCL Press © 1996. Course textbook Agricultural mechanization Bioengineering
15. Handbook of Metal Forming. K. Lange. © 1985 McGraw-Hill
16. Manufacturing Engineering & Technology. 4th ed. S. Kalpakjian & S.Schmidt. © 2001 Prentice Hall
Airplane Codes & Standards
17. http://www.matweb.com : materials information data base
18. http://madmax.me.berkeley.edu : machining information database
19. http://dnclab.berkeley.edu : burr formation data base
20. 21st Century Manufacturing. Paul Kenneth Wright © 2001 Prentice-Hall

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