Professional Documents
Culture Documents
Manufacturing Processes
Spring 2005
What is Manufacturing?
(1) (2) (3) (4) (5)
Manufacturing Process
History of Manufacturing
Manufacturing started during 5000 4000 BC Wood work,ceramics,stone and metal work Steel Production 600-800 AD Industrial Revolution 1750 AD: Machine tools run by invention of steam engine Mass Production and Interchangeable Parts Computer Controlled Machines 1965 CNC,FMS systems
Copper casting,stone and Stamping Jewelry metal molds,lost wax process,silver,lead,tin,bronze Bronze casting Wire by cutting and drawing, gold leaf
2000-1000 B.C. Wrought iron,brass 1000-1 B.C. 1A.D 1000 A.D Cast iron, cast steel Zinc steel Stamping of coins Armor,coinage,forgin g steel swords
1000-1500 A.D. Blast furnace, type Wire drawing,gold metals,casting of bells,pewter silver smith work
1600-1700 A.D.
Permanent mold casting,brass fromRolling(lead,gold,silver) copper and metallic zinc Shape rolling(lead)
1700-1800 A.D.
1800-1900 A.D.
Centrifugal casting,Bessemer process,electrolytic aluminum,nickel steels,Babbitt, galvanized steel, powder metallurgy, tungsten steel, open hearth steel
Steam hammer, steel rolling,seamless tube piercing,steel rail rolling, continuous rolling , electroplating
1950-1960 A.D. Ceramic mold, nodular iron, Cold extrusion semiconductors,continuous (steel),explosive casting forming,thermo mechanical treatment 1960-1970 A.D 1970-1980 s Squeeze casting, single crystal turbine blades Hydrostatic extrusion,electroforming
Compacted graphite,vacuum Precision forging,isothermal casting,organically bonded forging, super plastic sand,automation of molding forming,die design by and pouring, large aluminum analytical methods, net castings for aircraft structures shape forming rapid solidification technology
CAD
Product
Pilot Production
Metallic - what type Non metallic plastic Diameter of clip Shape of clip Manual
Automated
Stress, Strain Life of clip Stiffness Appearance,Color,Finish Plating,painting
Style
AISI 1010 welded tubing, assembly resistance welded and electrostatically painted AISI 1010,swaged and cadmium plated
Forged aluminum tubing(alloy similar to 6063), polished and buffed AISI 1008,press formed resistance welded and painted
Manufacturing of a bicycle
AISI 1010, luster finished AISI 1008, press coil stock,profile formed,welded and plated milled,resistance welded and chromium plated formed,welded and plated Cold drawn medium carbon steel,( similar to AISI 1035) bright zinc plated
AISI 1010,stamped and coined and chromium plated AISI 1010, stamped and chromium plated Headed brass,nickel plated Aluminum permanent mold casting,machined , polished and buffed
Seamless AISI 1020 tubing swaged tube sections brazed into fork crown,painted
AISI 1040 forging,carburized and chromium plated Case hardened forging quality steel parts, black oxide coating
Assignment 1
Select a simple product of your choice
Try to analyze the different materials, processes, etc Use library resources We will discuss this in the class on Friday
Machining
Turning,Boring,Drilling,Milling,Planing,Broaching,Grinding
Selection of Process
Unconventional Method EDM,ECM,Ultrasound,High Energy Beam,machining Joining Welding,Brazing,Soldering Finishing Honing,Lapping,Polishing,Burnishing,Deburring
Two methods of forming a dish shaped part from sheet metal Left: conventional hydraulic/mechanical press using male and female dies Right: explosive forming using only one die.
pressure Upper die Explosive
water
work piece
Lower Die
Three methods of casting turbine blades A: conventional casting with ceramic mold B: directional solidification C: Method to produce single crystal blade