Manufacturing Processes

Chapter 8
Objectives

• Describe the role of Computer Aided

Design in project development
• Define rapid prototyping and list four
rapid prototyping technologies
• Describe the role of design for
manufacture, assembly, disassembly,
and service
Objectives (cont.)

• Define modeling for assembly

• Understand material selection and
properties
• List the major manufacturing processes
• Look up accuracy and surface finishes
for manufacturing processes
• Describe the role of measuring devices
in production
Objectives (cont.)

• List factors that determine the cost of

manufactured goods
• Describe net-shape manufacturing
• Define computer integrated
manufacturing
• Describe shared manufacturing
Understanding Manufacturing

• Manufacturing involves making products

from raw materials by various
processes, machinery, and operations
• Manufacturing has the important
function of adding value
• Manufacturing may produce either
discrete or continuous products
Understanding Manufacturing

• Manufacturing activities include:

• Product design
• Purchasing
• Marketing
• Machinery and tooling
• Manufacturing
• Sales
• Process planning
Understanding Manufacturing

• Manufacturing activities include (cont.):

• Production control
• Shipping
• Materials
• Support services
• Customer service
Understanding Manufacturing

• For manufacturing activities to be

responsive to demands and trends:
• A product must fully meet design
requirements and product specifications
and standards
• A product must be manufactured by the
most environmentally friendly and
economical methods
Understanding Manufacturing

• Quality must be built into the product at

each stage, from design to assembly,
rather then relying on quality testing after
the product is made
• Quality must be appropriate to the
product’s use
The Design Process and
Concurrent Engineering
• The design process for a product
requires a clear understanding of the
functions and performance expected of
that product
• Product design is a critical activity
because 70-80% of the cost of product
development and manufacture is
determined at the design stage
The Design Process and
Concurrent Engineering
• Concurrent, or simultaneous,
engineering is a more modern approach
and all disciplines are involved in the
early design stages so iterations result
in less wasted effort and lost time
• The key to success is communication
between and within the disciplines
The Design
Process and
Concurrent
Engineering
The Design Process and
Concurrent Engineering
• Concurrent engineering is a systematic
approach to integrating the design and
manufacture of products with the view
of optimizing all elements involved in
the life cycle of the product
The Design Process and
Concurrent Engineering
• Life cycle means that all aspects of the
product from design to disposal and
recycling are considered simultaneously
• The basic goals are to minimize product
design and engineering changes and
the time and costs involved in taking a
product through the life cycle
The Design Process and
Concurrent Engineering
• For concurrent engineering to succeed
it must:
• Have the support of upper management
• Have multifunctional and interactive
teamwork, including support groups
• Utilize all available technologies
Computer-Aided Design and
Product Development
• Computer-aided design (CAD) allows
the designer to conceptualize objects
more easily without having to make
costly illustrations, models, or
prototypes
Computer-Aided Design and
Product Development
• Computer-aided engineering (CAE)
allows the performance of structures
subjected to static or fluctuating loads
and various temperatures to be
analyzed and tested efficiently,
accurately, and quickly
• Designs can be optimized and modified
Computer-Aided Design and
Product Development
• Computer-aided manufacturing (CAM)
involves all phases of manufacturing by
utilizing and processing further the
information on materials and processes
collected and stored in a database
The Role of Prototypes

• Rapid prototyping can cut both the

costs and time associated with
prototyping
• Tests of prototypes must be designed to
simulate as closely as possible the
conditions under which the product is to
be used
The Role of Prototypes

• Virtual prototypes can serve many of

the purpose of physical models
• 3D solid models can be used to evaluate
appearance, customer appeal, fit and
clearance for assembled parts, mass
properties, kinematics, and other
characteristics of the design
Types of Rapid Prototyping
Systems
• Stereolithography apparatus (SLA) uses
laser-hardened resins to form models
• A laser hardens each layer in the shape of
the cross section of a part
• Holes and pockets in the model are formed
by uncured resin
Types of Rapid Prototyping
Systems
• Solid ground curing (SGC) systems are
similar to SLA systems except they use
ultraviolet light to cure an entire cross
section at once in a polymer pool
• A negative of the shape of the cross
section is created on a glass plate using
electrostatic toner that masks ultraviolet
light in the shape of the cross section
• These systems are not common
Types of Rapid Prototyping
Systems
• Selective laser sintering (SLS) uses a
focused laser to fuse powdered metals,
plastics or ceramics
• The fused layers is covered with additional
powder and the next layer fused to it
• To form a hole, the powdered material is
simply not fused in that area
Types of Rapid Prototyping
Systems
• Fused deposition modeling (FDM)
systems use molten plastic deposited in
layers corresponding to cross sections
on the part
• To make holes, a second type of plastic is
used to create a support structure that is
later separated from the actual part
Types of Rapid Prototyping
Systems
• Laminated object manufacturing (LOM)
produces solid parts from sheets of
material such as paper or vinyl
• Software generates cross-sectional slices, a
laser cuts it from the sheet of material and
a heated roller bonds the next sheet to the
previous layer
• LOM can make larger parts than some
other systems
Types of Rapid Prototyping
Systems
• Topographic shell fabrication (TSF) uses
layers of high-quality silica sand fused
together with wax to build shells that
can be used to mold rapid prototypes of
large-scale parts
• The shell is used as a temporary mold for
creating parts of fiberglass, epoxy, foam,
concrete or other materials
Types of Rapid Prototyping
Systems
• 3D printing systems “print” layers of
molten thermoplastic material
• These low-cost machines were designed
to enable the use of prototypes early
and often in the design cycle
Rapid Tooling

• Rapid tooling creates a tool (usually a

mold for molded plastic or cast metal
parts) through a rapid prototyping
process
• Rapid tools can be used to produce test
products and get products to market
early
Cores and Cavities

• The cavity is the part of the mold that

forms the outside shape of an object
• A core is a solid shape that fits inside
the mold and forms a hole in a cooled
cast metal or molten plastic object
Direct Shell Production Casting

• Direct shell production casting (DSPC) is

used in directly creating molds for metal
casting
• It is based on 3D printing technologies
and uses 3D digital models to produce
molds
Design for Manufacture

• Design for manufacture (DFM) is a

comprehensive approach to produce
goods and integrate the design process
with materials, manufacturing methods,
process planning, assembly, testing,
and quality assurance
Design for Assembly

• Design for assembly (DFA) is recognized

as an important part of manufacturing
because assembly operations can
contribute significantly to product cost
Design for Manufacturing
and Assembly
• Design for manufacture and assembly
(DMFA) recognizes the inherent
interrelationships between design and
manufacturing
Material Selection

• General types of materials used in modern

manufacturing, individually or in combination:
• Ferrous materials
• Nonferrous materials
• Plastics
• Ceramics
• Composite materials
• Nanomaterials
Properties of Materials

• When selecting materials for products,

the following properties are considered:
• Mechanical properties
• Chemical properties
• Manufacturing properties
Cost and Availability of Materials

• Cost and availability of raw and

processed materials and manufactured
components are major concerns in
manufacturing
• The economic aspects of material selection
are as important as technological
considerations of properties and
characteristics of materials
Appearance, Service Life,
and Recycling
• The appearance of manufactured
materials influences their appeal to the
consumer
• Wear, fatigue, creep and dimensional
stability are important to product
performance and affect product life
• Recycling or proper disposal has
become increasingly important
Manufacturing Processes

• Categories of processing methods:

• Casting
• Forming and shaping
• Machining
• Joining
• Finishing
Dimensional Accuracy
and Surface Finish
• Size, thickness, and shape complexity of
the part have a major bearing on the
manufacturing process selected to
produce it
• Nanotechnology or nanofabrication are
terms used to describe extremely small-
scale operations
Measuring Devices

• The machinist uses various measuring

devices depending on the kind of
dimensions shown on the drawing
• Machinists scale
• Dial or digital calipers
• Fixed gages
Operational and Manufacturing
Costs
• The design and cost of tooling, the lead
time required to begin production, and
the effect of workpiece material on tool
and die life are major considerations
Consequences of Materials and
Process Selection
• A component or product is generally
considered to have failed when:
• It stops functioning
• It does not function properly or perform
within required specification limits
• It becomes unreliable or unsafe for further
use
Net-shape Manufacturing

• In net-shape or near-net-shape
manufacturing, the part is made as
close to the final desired dimensions,
tolerances, surface finish, and
specifications as possible to cut down
on the cost of finishing operations
Computer-Integrated
Manufacturing
• Computer-integrated manufacturing
(CIM) is particularly effective because of
its capability for:
• Responsiveness to rapid changes
• Better use of materials, machinery and
personnel, and reduced inventory
• Better control and management of
production and manufacturing operations
• High quality products at low cost
Shared Manufacturing

• Shared manufacturing consists of a

regional or nationwide network of
manufacturing facilities with state-of-
the-art equipment for training,
prototype development, and small scale
production runs to help small
companies develop products that
compete in the global marketplace