IPE 331: Production Process 3.00 Credit Hours

Prof. Dr. Shamsuddin Ahmed

Room 210, GR Campus

Where to Start?

Humour without Malice

1. Ahmad was speaking to his friend and shared his happiness with him. So he said that he is fortunate to have been given two very special gifts in life. The friend was listening – there was a pause. He then asked: what are they Ahmad?

Ahmad replied: one is a very good memory that God has given me. Ahmad paused again, and when his friend asked: what is the second one? Ahmad

replied: Oh, wait a minute, I am trying to remember!

2. A man fell on the ground and soon after fell down again. He said to himself: “Had I known I was going to fall a second time, I would have not gotten up so

soon.”

On Education

“The goal of education is the advancement of knowledge and the dissemination of

truth.” John F Kennedy “The function of Education is to teach one to think intensively and to think critically.

Intelligence plus Character that is the goal of true Education. - Dr. Martin Luther

King, Jr. “Educating the mind without educating the heart is no education at all.” - Aristotle

“Education is not the learning of facts, but the training of the mind to think.” - Alber Einstein

“There are two educations. One should teach us how to make a living and the other

how to live.” - John Adams “You can fool all the people some of the time, and some of the people all the time,

but you cannot fool all the people all the time” - Abraham Lincoln Seek knowledge from the cradle to the grave. He who leaves home in search

of knowledge, walks in the path of God. -Prophet Muhammad (pbuh).

“Who am I?”, “why am I here?”, “what is the purpose of existence?” What is my

worldview?

So, Let’s work for the welfare of mankind.

Let’s collectively SAVE

ENERGY (ELECTRICITY etc.)

FOOD

PAPER/TREE

WATER

ANY OTHER RESOURCES

WASTE NOT ANYTHING

FOR

THE WELFARE OF SU, BANGLADESH AND MANKIND

What is Engineering? Or, Who is an Engineer?

Engineering is a profession in which the knowledge of mathematics and natural

sciences gained by study, experience, and practice is applied with judgment to

develop ways and means to utilize, economically, the material and forces of nature for

the benefit of mankind (ABET).

Engineering and Science

Science is concerned with quest of basic knowledge. Engineering is concerned with

the application of scientific knowledge to the solutions of problems and to the quest

for better life.

Basic science is known as “knowing science”, whereas engineering is known as “doing

science”. However, the development of science and engineering often occur hand-in-

hand. In some cases, a scientist and an engineer might be the same person.

Engineers and other professionals

Engineers solve problems and use mathematics

Engineers analyze data

Engineer design systems. Design = analysis + synthesis

Engineers use resources (materials, machines, men, money). They need to analyze

lots of data and come up with (mostly) tangible solutions.

Engineer comes from old French word in the form of verb (’ingenier)

An engineer is one who seeks in his mind, who sets his mental power in action, in

order to discover or devise some means of succeeding in a difficult task he may have

to perform. To be human is to be an engineer.

Engineer => Art + Artifacts => Design + how it goes about

Key words for an engineer: change, resources, best, and uncertainty.

Engineering method

Strategy for causing the best change in a poorly understood situation within the

available resources.

Engineering process

The basic steps are as below:

1) Problem symptom (need expression) 2) Problem definition

3) Statement of the desired outcome 4) Analysis/experimentation 5) Synthesis of alternative solution

6) Decision (one alternative solution) 7) Solution (system or method)

What is Mechanical Engineering?

Mechanical Engineering is -

If it needs engineering but it doesn’t involve electrons, chemical reactions,

arrangement of molecules, life forms, isn’t a structure (building/bridge/dam) and

doesn’t fly, a mechanical engineer will take care of it… but if it does involve electrons,

chemical reactions, arrangement of molecules, life forms, is a structure or does fly,

mechanical engineers may handle it anyway Although every engineering faculty

member in every engineering department will claim that his/her field is the broadest

engineering discipline, in the case of Mechanical Engineering that’s actually true

because the core material permeates all engineering systems (fluid mechanics, solid

mechanics, heat transfer, control systems, etc.) Mechanical engineering is one of the

oldest engineering fields but in the past 20 years has undergone a rather remarkable

transformation as a result of a number of new technological developments.

Define manufacturing engineering. Why is it important today?

Manufacturing Engineering is the process of designing a product(s) and production

process(es) to produce the product(s). Manufacturing is an industrial activity to

transform (raw) materials and information into goods/products, mainly by machinery,

normally on large scale and with division of labor, for the welfare and satisfaction of

human needs.

Manufacturing is now the primary wealth-generating activity for a nation. It is the

backbone of an industrial nation. Level of manufacturing is related to economic health

and standard of living of the people. It has significant role in national development –

economic development and employment. Service sector is enhanced by increasing

manufacturing activity.

IPE 331: Production Process 3.00 Credit Hours

Syllabus: Selection of machining. Casting: sand, die, centrifugal and other types of

casting, casting design and casting defects Chip less metal forming process: different

types of hot and cold working processes. Welding arc, gas, TIG, MIG, resistance,

thermite, and special types, Brazing and soldering. Tool geometry and chip formation

processes. Metal removing processes: turning, drilling, shaping, planning, milling,

broaching, grinding, precision and non-precision finishing processes. Plastic, ceramic

and glass product manufacturing processes.

Manufacturing vs production

Manufacturing is a process of converting raw material in to finished product by using

various processes, machines and energy. It is a narrow term. Production is a process

of converting inputs in to outputs. It is a broader term. Every type of

manufacturing can be production, but every production is not a manufacturing.

Manufacturing encompasses –

Design of the product

Selection of raw materials

Sequence of processes to produce/manufacture the product.

Basic manufacturing processes – Casting: expandable molding and permanent molding

– Deformation - Forming and shaping: rolling, forging, extrusion, drawing, sheet forming, powder metallurgy molding – Machining: turning, boring, drilling, milling, planing, shaping, broaching, grinding,

ultrasonic machining; chemical, electrical, and electrochemical machining and high energy electron beam machining

– Joining: welding, brazing, soldering, diffusion bonding, adhesive bonding and mechanical joining – Micro and nano manufacturing: surface micromachining, dry and wet etching, and

electroforming – Finishing: honing, lapping, polishing, burnishing, deburring, surface treating,

coating and plating

Factors affecting process selection • Component/part shape

• Materials characteristics – castability, formability, machinability, weldability, etc. • Part size and dimensional accuracy

• Volume of production

Manufacturing and operational cost

Process manufacturing

Process manufacturing is the production of goods that are typically produced in bulk

quantities, as opposed to discrete and countable units. Process

manufacturing industries include chemicals, food and beverage, gasoline, paint and

pharmaceutical.

Fabrication

Fabrication is an industrial term that refers to the manipulation of raw materials (such

as steel) for the making of machines and structures. Steel and other metals are cut and shaped during the fabrication process. Fabrication is a very hands-on part of

the manufacturing process.

Sheet metal fabrication is using sheet metal to build metal machines and structures.

It can be a complex process involving many different professionals. Businesses that

specialize in sheet metal fabrication are commonly referred to as fabrication shops,

or fab shops for short.

Materials used in today’s manufacturing

Ferrous metals: carbon steels, alloy steels, stainless steels, and tool and die steels

Nonferrous metals and alloys: Al, Mg, Cu, Ni, superalloys, Ti, refractory metals (Mb, Nb, W, beryllium, Zr, low melting alloys (lead, zinc and tin), and

precious metals

Plastics: Thermosets, thermoplastics, and elastomers

Glass and Ceramics: Glass ceramics, glasses, graphite, and diamond

Composites: Reinforced plastics, metal-matrix and ceramics-matrix composites, and honeycomb structures

Nanomaterials, shape-memory alloys, metal foams, amorphous alloys, super conductors and Semiconductors

Material substitution

Material properties: mechanical, physical, chemical, manufacturing

Manufacturing System Designs

Job Shop Production

Small quantities of products

Large variety of products

Products move through the shop to various machines

General-purpose machines

Flow Shop

o Larger quantities of products

o Production line

o Special purpose machines

Linked-Cell Shop

o Manufacturing and subassembly cells connected to final assembly

o Lean production system

o One piece flow system

Project Shop

o Product being manufactured cannot be easily moved during production.

o Production processes are brought to the product.

o Examples: Bridges, ships, large airplanes, locomotives, large machinery.

Continuous Process

o Large plants

o Utilized in the manufacture of liquids, oils, gases, and powders

Casting and Foundry Processes

In a step, raw materials are transformed into a desirable shape

Parts require finishing processes

Excess material is recyclable

Basic Casting Process

A mold is created – A cavity that holds the molten material in a desired shape

until it is solidified

o Multiple-use mold

o Single-use molds

Material is heated to a specified temperature

Molten material is poured into a mold cavity

Molten material solidifies into the shape of the cavity

Casting or mold is removed

Casting is cleaned, finished, and inspected

Deformation process

Utilizing property of metals, that is ability to flow plastically in the solid state without

deteriorating their properties. Application of high pressure to move material to desired

shape with negligible wastage. Expensive tools and machines are needed, so large

production volume is important.

Forming and Metalworking Processes

Utilizes material that has been cast

Modify the shape, size, and physical properties of the material

Hot and cold forming

Rolling – Material passes through a series of rollers, reducing its thickness with each

pass

Forging – Material is shaped by the controlled application of force (blacksmith)

Extrusion – Material is compressed and forced through a die to produce a uniformed

cross section

Wire, rod, and tube drawing – Material is pulled through a die to produce a uniformed

cross section

Cold forming and forging – Slugs of material are squeezed into dies

Machining Processes

Controlled removal of material from a part to create a specific shape or surface finish

Cutting element is used

Movement must exist between the part and cutting element

Turning Processes

Operations that create cylindrical parts

Work piece rotates as cutting tool is fed into the work

Lathes and turning centers

Processes include: Straight, taper, contour turning, facing, forming, necking, parting,

boring, threading, and knurling

Milling Process

Operations that create flat or curved surfaces by progressively removing

material

Cutting tools rotate as the work piece is secured and fed into the tool

Mills – Vertical and horizontal

Processes include: Surfacing, shaping, forming, slotting, T-slotting, angle, straddle,

dovetailing, and slab milling

Drilling process

Operations that create holes

Cutting tools rotate and are fed into nonmoving secured work pieces

Drilling and boring machines

Processes include: Drilling, counter drilling, step drilling, boring, counter boring,

countersinking, reaming, spot facing, and tapping

Shearing processes

Operations that break unwanted material away from the part

A material is placed between a stationary and movable surface. The movable

surface (blade, die, or punch) applies a force to the part that shears away the

unwanted material.

Automated hole punch, squaring shear, and rotary cutter

Processes include: Shearing, blanking, cutoff, and parting; punching,

perforating, and slotting; notching, lacing, and trimming

Abrasive machining processes

Operations in which small particles of materials (abrasives) remove small chips

of material upon contact

Drum, disc, and belt sanders; surface, vertical and horizontal spindle; disc

grinders; media blaster; tumblers

Thermal and Chemical Processes

Operations that cut and shape materials through chemical means

No mechanical force is used

Electrical discharge, electrochemical, chemical, laser, electron beam, flame

cutting, and plasma-arc cutting

Processes include: Grinding, sawing, cutting, machining, milling, blanking, and

etching

Heat Treating Processes

Controlled heating and cooling of a material to alter its properties while

maintaining its shape

Properties include: Strength, toughness, machinability, wear resistance, and

corrosion resistance

90% of heat treating is preformed on steel and other ferrous metals

To aid in the manufacturing process, materials can be treated to be weak and

ductile and then can be re-treated to provide high strength.

Can also occur incidentally during the manufacturing process

Joining and Assembly Processes

Can you think of a product with only one part?

Most products consist of multiple parts that are assembled to form a finished

product.

Typical assembly processes include: Mechanical fastening; soldering and

brazing, welding; adhesive bonding

Mechanical Fastening

Use physical force to hold parts together

Mechanical fasteners or part design

Screws, bolts, nails, rivets, cotter pins, retaining clips, and edge design

Welding

Operations that use heat, pressure, or both to permanently join parts

Gas, arc, stud, spot, forge, roll laminating, resistance, and induction welding

Adhesive bonding

Bonding of adjoining surfaces by filling the gap between each surface with a bonding

material

Glue, cement, thermoplastic, thermosetting, and elastomers

Soldering and Brazing

Operation in which metal surfaces are bonded together by an alloy

Heated molten alloy flows between the adjoining surfaces

When the heat is removed, the molten metal solidifies and the metal surfaces are

bonded.

Rapid prototyping

Additive process

Parts are produced directly from software applications

Common rapid prototyping systems include: stereolithography (SLA), selective

laser sintering (SLS), fused deposition modeling (FDM), laminated object

manufacturing (LOM), digital light processing (DLP).

Finished parts can be field tested depending upon building material

Created parts can be used to create a mold

Modifications to design can be implemented quickly.

Other Manufacturing Processes

Testing

Transportation

Material handling

Packaging

Material-Specific Manufacturing Processes

Plastic Processes

Ceramic Processes

Plastics Manufacturing Processes

A rotating screw forces plastic through a heating chamber and then through a

heated die

Produces long plastic parts with uniform cross sections.

Injection Molding on Plastic Mfg process

Heated plastic is forced by a movable plunger through a nozzle and then into a

mold. The material fills the mold and then is cooled.

Most widely used high-volume production process.

Casting (Plastics Manufacturing Processes)

Plastic is melted and poured into a mold – No pressure or fillers are required.

Rotational Molding

A closed mold is filled with a predetermined amount of plastic. The mold is heated,

rotated, and then cooled to create a hollow plastic object with uniform wall thickness.

Blow Molding

A solid bottom hollow tube is placed between two mold halves and heated. The heated

tube is then expanded into the sides of the mold with compressed air.

Thermoforming

Plastic sheets are heated over an open mold to a working temperature. Once

workable, a vacuum is applied to the mold, forcing the plastic sheet to take the shape

of the mold.

Reaction Molding

Liquid reactants are mixed and then pressurized into a mold.

No heat is needed. Curing time is typically less than 1 minute.

Ceramic Manufacturing Processes

Two distinct classes of materials and processes exist.

Glass is heated to a molten state, shaped by viscous flow, and then cooled to produce

a solid.

Crystalline Ceramics

Material is shaped and then heated to produce a permanent solid.

Manufacturing Importance - Typical product cost breakdown