University TENAGA Nasional Lecturer: Dr. HABEEB ALANI Dr. HABEEB ALANI Office: BN-Block, Level-3, Room-088 Email: [email protected] [email protected] Ext

University TENAGA Nasional

Lecturer: Dr. HABEEB ALANI

Dr. HABEEB ALANIDr. HABEEB ALANI

Office: BN-Block, Level-3, Office: BN-Block, Level-3, Room-088Room-088

Email: [email protected]: [email protected]. No.: 7292Ext. No.: 7292


UUniversity TENAGA Nationalniversity TENAGA National

College Of EngineeringCollege Of EngineeringMechanical DepartmentMechanical Department

Academic Year – 2009-2010Academic Year – 2009-2010

Lecture NoteLecture Note



Introduction To Manufacturing and

Manufacturing Systems



Japanese sword reworked for hard and soft metal parts




Space Shuttle



The Transistor



Everyday products



Manufacturing derived from:Manufacturing derived from:

“Manufacturing” (derived from Latin)

= “manus” (hand) + “factus” (made)

= “made by hand”

“Manufacturing” (derived from Latin)

= “manus” (hand) + “factus” (made)

= “made by hand”



Manufacturing is an industrial activity that converts raw materials to useful products by the means of machines.

Definition of Manufacturing:Definition of Manufacturing:



Materials Materials

Development of Manufacturing depends on:

Development of Manufacturing depends on:

Machine-ToolsMachine-Tools

Computer-aided Design (CAD)&Computer-aided mfg (CAM).

Computer-aided Design (CAD)&Computer-aided mfg (CAM).

RoboticsRobotics

ElectronicElectronicssElectronicElectronicss

1

2

3

4

5



Evolution of the Enterprise Evolution of the Enterprise

Evolution Steps:Evolution Steps:

Hand Tool Hand Tool

Animals Animals

Water Power Water Power

Steam Engines Steam Engines

Electrical Motors Electrical Motors

1

2

3

4

5

1-1



The MFG System:The MFG System:

INPUT INPUT PROCESS PROCESS OUTPUT OUTPUT



Customer Demand

Customer Demand

Material Material

Money Money

Energy Energy

HR HR

Education Education

R & D R & D

INPUT INPUT



PROCESS PROCESS

Design Design

Production Production

Management Management



OUTPUT OUTPUT

Consumer Goods Consumer Goods

Capital Goods Capital Goods

Quality Quality

Cost Effectiveness Cost Effectiveness



`

Money Money

- Working Capital (Money for employee) - Working Capital (Money for employee)

-Fixed Capital (For machine tools and buildings)

-Fixed Capital (For machine tools and buildings)

INPUT INPUT



Energy Energy

- Electricity To run the machines - Electricity To run the machines

- Compressed air To run the pneumatic systems and clean machines and products

- Compressed air To run the pneumatic systems and clean machines and products

- Steam To run the turbines and utilized in produce of polystyrene (Expansion OP.)

- Steam To run the turbines and utilized in produce of polystyrene (Expansion OP.)

- Gas To use it in Furness, welding operations and boilers.

- Gas To use it in Furness, welding operations and boilers.

INPUT INPUT



- Creating plans for new products- Creating plans for new products

-Lowering the product cost at maintained high quality

-Lowering the product cost at maintained high quality

DesignDesignPROCESS PROCESS



- Designated at the design stage- Designated at the design stage

- Machine tools types- Machine tools types

PROCESS PROCESS

ProductionProduction

- Machining processes- Machining processes

- People are selected at the design stage

- People are selected at the design stage



GoodsGoods

- Consumers goods: People use them (Food, Cars, ….)

- Consumers goods: People use them (Food, Cars, ….)

OUTPUT OUTPUT

ProductsProducts

- Capital goods: Products used to make other consumer goods (Machine tools, Plant, ….)

- Capital goods: Products used to make other consumer goods (Machine tools, Plant, ….)



The Classification of basic Manufacturing

The Classification of basic Manufacturing

Mass productionMass production

1-2

ModerateModerate Job-lotJob-lot

a b c



Mass Production Features: Mass Production Features:

- Goods are produced at a high volume for considerable period of time ( >100.000 parts per year).

- Goods are produced at a high volume for considerable period of time ( >100.000 parts per year).

- Machine are not flexible (They are not able to produce other types of products).

- Machine are not flexible (They are not able to produce other types of products).

- Products of this type of mfg are the cheapest.

- Products of this type of mfg are the cheapest.

a



Moderate production Features: Moderate production Features:

- Variable products (depends on the sale order and the market demand) (2,500-100,000 parts per year).

- Variable products (depends on the sale order and the market demand) (2,500-100,000 parts per year).

- Multipurpose machine tools and CNC machine tools are usually used in this type of mfg.

- Multipurpose machine tools and CNC machine tools are usually used in this type of mfg.

- Product Ex.: Tools, Moulds, Radio transmitters.

- Product Ex.: Tools, Moulds, Radio transmitters.

b



Job-lot production Features: Job-lot production Features:

- The plant does not any specific type of products but it is able to produce any type of product that the market is in need of.

- The plant does not any specific type of products but it is able to produce any type of product that the market is in need of.

- Products move in lots between mfg processes (10-500 parts per lot).

- Products move in lots between mfg processes (10-500 parts per lot).

- Machine are more flexible and universal.- Machine are more flexible and universal.

c

- Product Ex: Airplanes, Automobile parts, and Plastic products .

- Product Ex: Airplanes, Automobile parts, and Plastic products .



Organization for Manufacturing Organization for Manufacturing

-A plant needs an affective organizing method for manufacturing in order to manage its resources /

Employees Money Power

Materials Machines .

*A good mfg strategy is needed.

See table 1.1 (Evolution of strategy mfg sys..

-A plant needs an affective organizing method for manufacturing in order to manage its resources /

Employees Money Power

Materials Machines .

*A good mfg strategy is needed.

See table 1.1 (Evolution of strategy mfg sys..

1

4

2 3

5



Concurrent Engineering CE Concurrent Engineering CE

-It is a philosophy that promotes interactive design and manufacturing efforts to develop product and processes simultaneously. CE is not an engineering discipline.

- CE Objective: Optimizing the use of companyresources and reducing time to market cycle.

-It is a philosophy that promotes interactive design and manufacturing efforts to develop product and processes simultaneously. CE is not an engineering discipline.

- CE Objective: Optimizing the use of companyresources and reducing time to market cycle.



General CE phases for a new project: General CE phases for a new project:

Technology and concept development: Technology and concept development:

Definition of customer requirement implementation.

Definition of customer requirement implementation.

Assessment of primary alternatives processes.

Assessment of primary alternatives processes.

Development of required resources. Development of required resources.

Preparation of product plan. Preparation of product plan.

a

b

c

d

Ph.-1



Product and Process Development and Prototype validation -CE Function:

Product and Process Development and Prototype validation -CE Function:

Product improvement for assembly and mfg

Product improvement for assembly and mfg

Development the mfg and assembly processes

Development the mfg and assembly processes

Establish baseline process technology Establish baseline process technology

Establish program goals and risk-reduction plans freezing

Establish program goals and risk-reduction plans freezing

a

b

c

d

Ph.-2

This is the phase in which the CE team willThis is the phase in which the CE team will



Cont…… Cont……

Generally other project elements are addressed I this phase , such as financial business plans, product concept demonstration, freezing of engineering content, and final project approval.

Generally other project elements are addressed I this phase , such as financial business plans, product concept demonstration, freezing of engineering content, and final project approval.

Note:

Ph.-2

Ph.-2



Process Validation and Product Design Confirmation :

Process Validation and Product Design Confirmation :

The Production process and methods are finalized

The Production process and methods are finalized

Simulation and pilot runs are conducted to test critical steps

Simulation and pilot runs are conducted to test critical steps

Machine and equipment are validated for production readiness, quality and performance

Machine and equipment are validated for production readiness, quality and performance

a

b

c

Ph.-3

This is the execution phase where This is the execution phase where



Production and continuous improvement :Production and continuous improvement :

- This face is the Acceleration of production floor into “ Full rated capacity”. This means: Attaining high product quality at the lowest costs.

- This face is the Acceleration of production floor into “ Full rated capacity”. This means: Attaining high product quality at the lowest costs.

Ph.-4



Design, Material and Production Design, Material and Production 1-3

-According to the existing machine tools and the designed product we choose the raw materials.

On the other hands, according to the existing materials and required quality we choose the machine tools.

-According to the existing machine tools and the designed product we choose the raw materials.

On the other hands, according to the existing materials and required quality we choose the machine tools.



- In order to attain a high production rate with a low labor cost, Automatic features have been built gradually in different machine tools. Nowadays we deal with fully automatic machine tools and computer aided design and manufacturing (CAD/CAM). But the problem is that maintenance of such automatic machines is very expensive.

- In order to attain a high production rate with a low labor cost, Automatic features have been built gradually in different machine tools. Nowadays we deal with fully automatic machine tools and computer aided design and manufacturing (CAD/CAM). But the problem is that maintenance of such automatic machines is very expensive.

- Efficiency of production :- Efficiency of production :



- The quality and accuracy must be maintained for the whole mfg processes so at the output we produce parts that can be quickly assembled (interchangeable).

- The quality and accuracy must be maintained for the whole mfg processes so at the output we produce parts that can be quickly assembled (interchangeable).

Cont….. Efficiency of production



- Economical production is determined by:

- Economical production is determined by:

A functional simple design that has appropriate quality (no more or less).

A functional simple design that has appropriate quality (no more or less). 1

A material choice that represents the best compromise among physical properties, cost, and machinability.

A material choice that represents the best compromise among physical properties, cost, and machinability.

2

The selection of mfg processes that provide the plant with required quality and accuracy (no more accuracy than necessary) at the lowest possible cost.

The selection of mfg processes that provide the plant with required quality and accuracy (no more accuracy than necessary) at the lowest possible cost.

3



MaterialsMaterials

Engineering MaterialsEngineering Materials

Metallic Metallic Non-Metallic Non-Metallic

Ferrous Ferrous

Non-Ferrous Non-Ferrous

OrganicOrganic

Non- Organic Non- Organic



Materials Application ChainMaterials Application Chain

ProcessingProcessing

StructureStructure

PropertiesProperties

PerformancePerformance

SelectionSelection

Field ApplicationField Application

* SELECTION is the Critical Step

for Technologists.



Stress & Strain Dislocations &

Deformation Elasticity & Plasticity Elastic Constants

Mechanical PropertiesMechanical Properties



TestsTests

Mechanical Testing Mechanical Properties Strengthening

Mechanisms Failure Analysis



Resistivity & Conductivity Electronic-Band Structure Semiconductivity Refraction & Reflection Transmission

Electrical PropertiesElectrical Properties

Electrical Properties



The Evolution of Materials

University TENAGA Nasional Lecturer: HABEEB ALANI

Classes of MaterialsClasses of Materials

BasicBasic

MetalsMetals

CeramicsCeramics

PolymersPolymers

AdvancedAdvanced

CompositesComposites SemiconductorsSemiconductors BiomaterialsBiomaterials



Materials that are normally combinations of "metallic elements".

Metals usually are good conductors of heat and electricity.

Metals are quite strong but malleable

and tend to have a lustrous look when polished

MetalsMetals

University TENAGA Nasional Lecturer: HABEEB ALANI

Ceramic materials developed for gas turbine rotors are used in aircraft and diesel engine parts.

CeramicsCeramics

Ceramics are generally compounds between Metallic and NONmetallic elements and include such compounds as:

-Oxides -Nitrides

-Carbides

Typically they are insulating and resistant to high temperatures and harsh environments.



Using advanced polymer materials, organic light emitting diode (OLEDs) displays produce bright, high-contrast display panels with a wide viewing angle. OLED panels are emissive, eliminating the need for

the backlight required in display technologies such as liquid crystal displays (LCDs).

PlasticsPlastics Plastics (or polymers) are generally

compounds based upon carbon and hydrogen (Organic Compounds).

They are very large molecular structures. Usually they are low density and are not

stable at high temperatures.



SemiconductorsSemiconductors

SEMIconductors have electrical properties intermediate between Metallic conductors and Ceramic insulators.

Also, the electrical properties are strongly dependent upon small amounts of Impurities.



CompositesComposites

Composites consist of more than one material type.

Fiberglass, a combination of glass and a polymer, is an example. Concrete and plywood are other familiar composites.

Many new combinations include ceramic fibers in a metal or polymer matrix.







Graphite MatrixComposite Shaft

Liquid MetalFacePlate

Golf Clubs

Hand bagGhost airplane



BioMaterialsBioMaterials Materials compatible with an organism

(e.g. Humans) that can be used to make implants, prostheses, and surgical instruments. Designed not to provoke rejection by our bodies

(skin, blood, bone, etc.), they can be natural (collagen, cellulose, etc.) or synthetic (metallic, alloy, ceramic, plastic, and others).

Dental crowns and contact-lenses use biomaterials.



Kingdom Family Class AttributesMember

• Ceramics

• Polymers

• Metals

• Natural

• Foams

• Composites

Steels

Cu-alloys

Al-alloys

Ti-alloys

Ni-alloys

Zn-alloys

1000

2000300040005000600070008000

Materials

A material recordor “properties”

Density

Mechanical props.

Thermal props.

Electrical props.

Optical props.

Corrosion props.

Supporting information

-- specific

-- general

Structured

information

Unstructured

information

Data Organization of MaterialsData Organization of Materials



mount

Metallography: to see microstructures

metal

Steel (Fe-C)

Nickel Alloy 242



The goal of design:“To create products that perform their function effectively, safely, at acceptable cost”

What do we need to know about materials to do this? More than just test data.

Test Test data

Data capture

Stat/Mathanalysis

Design data Successful applications

$

Economic analysisand business case

Selection ofmaterial and process

Potential applications

Mechanical Properties

Bulk Modulus 4.1 - 4.6 GPaCompressive Strength 55 - 60 MPaDuctility 0.06 - 0.07Elastic Limit 40 - 45 MPaEndurance Limit 24 - 27 MPaFracture Toughness 2.3 - 2.6 MPa.m1/2

Hardness 100 - 140 MPaLoss Coefficient 0.009- 0.026Modulus of Rupture 50 - 55 MPaPoisson's Ratio 0.38 - 0.42Shear Modulus 0.85 - 0.95 GPaTensile Strength 45 - 48 MPaYoung's Modulus 2.5 - 2.8 GPa

Characterization Selection and implementation

Materials Information for Design Materials Information for Design



Next Lecture:Nature And Properties

of Materials



THANK YOU

Documents

University TENAGA Nasional Lecturer: Dr. HABEEB ALANI Dr. HABEEB ALANI Office: BN-Block, Level-3, Room-088 Email: [email protected] [email protected] Ext