Download Introduction to Industrial Materials and Processes and more Lecture notes Materials Processing in PDF only on Docsity!
LESSON 1: Introduction to Industrial Materials and Processes ● requires a sound and broad understanding of materials, processes, and equipment on the part of the decision makers, ● accompanied by an understanding of the manufacturing systems Introduction ● All of us live in a world of dynamic change, and materials are no exception. ● The advancement of civilization has historically depended on the improvement of materials to work with. ➔ Over time, they moved from the materials Stone Age into the newer Copper (Bronze) and Iron Ages ➔ Today's competitive manufacturing era of high industrial development and research, is being called the age of mechanization, automation and computer integrated manufacturing. ● Manufacturing is the backbone of any industrialized nation. Since products require materials, engineers should be knowledgeable about the internal structure and properties of materials so that they can choose the most suitable ones for each application and develop the best processing methods. ● Manufacturing and technical staff in industry must know the various manufacturing processes, materials being processed, tools and equipment for manufacturing different components or product with optimal process plan using proper precautions and speci ed safety rules to avoid accidents. ● Future engineers must know the basic requirements of manufacturing activities in terms of man, machine, material methods, money and other infrastructure facilities needed to be positioned properly for optimal shop layouts or plant layout and other support services effectively adjusted or located in the industry or plant with in a well planned manufacturing organization. ● In many cases what was impossible yesterday is a reality today! ➢ Thirty years ago, many people would not have believed that some day computers would become a common household item similar to a telephone or a refrigerator. ➢ And today, we still nd it hard to believe that some day space travel will be commercialized and we may even colonize Mars. History of Materials ● The development of materials and man's ability to process them is linked to the history of man ➔ Stone Age ➔ Copper and Bronze Age ➔ Iron Age ➔ Steel Age ● The current age is that of plastics, composite materials, and exotic alloys New Researchers in the Manufacturing Field ● The advancement has come to this extent that every different aspect of this technology has become a full- edged fundamental and advanced study in itself. ➢ This has led to introduction of optimized design and manufacturing of new products. ➢ New developments in manufacturing areas are deciding to transfer more skill to the machines for considerably reduction of manual labor. ➢ It speci es the need of greater care for man, machine, material and other equipment involving higher initial investment by using proper safety rule and precautions. Materials, Manufacturing, and the Standard of Living ● Standard of living of a society is determined by the goods and services that are available to its people
● Manufactured goods ➔ Producer goods - Intermediate goods used to manufacture either producer or consumer goods ➔ Consumer goods - Purchased directly by the consumer Product Development ● Sustaining technology ➢ Innovations bring more value to the consumer ➢ Improvements in materials, processes, and design ● Product growth normally follows the "S" curve Simpli ed Steps of the Product Life Cycle ● Start up - new product or new company, low volume, small company ● Rapid Growth - products become standardized and volume increases rapidly. Company's ability to meet demand stresses its capacity. ● Maturation - standard designs emerge. Process development is very important. ● Commodity or Declined ➢ Commodity - long-life, standard-of-the-industry type of product or ➢ Decline - product is slowly replaced by improved products The stage of the product life cycle affects ➢ the product design stability ➢ the length of the product development cycle ➢ the frequency of engineering change orders and ➢ the commonality of components Interactive Factors in Manufacturing ● Factors ➔ Product design ➔ Materials ➔ Labor costs ➔ Equipment ➔ Manufacturing cost ● Strategies to reduce cost ➔ Lean manufacturing ➔ Systems approach Manufacturing cost is the largest part of the selling price, usually around 40% The largest part of the manufacturing cost materials usually 50% Materials and Processes ● Manufacturing cost is the largest cost in the selling price. ➢ The largest manufacturing cost is material costs, not direct labor ● Materials, men, methods, and equipment are interrelated factors in manufacturing that must be combined properly to achieve low cost, superior quality, and on-time delivery. ● Materials to be used must be selected and speci ed to meet the design engineer's requirements.
Basic Manufacturing Processes ● Casting, foundry, or molding process ● Forming or metalworking processes ● Machining (material removing/removal) processes ● Joining and assembly ● Surface treatments ( nishing) ● Rapid prototyping ● Heat treating 7 Basic Machining Processes ● Shaping ● Drilling ● Turning ● Milling ● Sawing ● Broaching ● Abrasive Machining 8 Basic Types of Machine Tools ● Shapers (Planers) ● Drill Presses ● Lathes ● Boring Machines ● Milling Machines ● Saws ● Broaches ● Grinders Common Aspects of Manufacturing ● Job and station ➢ Job - is a group of related operations generally done at one station ➢ Station is the location or area where production is done ● Operations ➢ Distinct action to produce a desired result or effect ➢ Categories of operations ➔ Materials handling and transport ➔ Processing ➔ Packaging ➔ Inspecting and testing ➔ Storing ● Treatments operate continuously on a workpiece ➢ Heat treating, curing, galvanizing, plating, nishing. chemical cleaning, painting ● Tools, tooling and workholders ➢ Lowest mechanism in the production is a tool ➔ Used to hold, shape or form the un nished product ● Tooling for measurement and inspection ➢ Rulers, calipers, micrometers, and gages ➢ Precision devices are laser optics or vision systems that utilize electronics to interpret results Products and Fabrications ● Products result from manufacture ➢ Manufacturing can be from either fabricating or processing ➔ Fabricating is the manufacture of a product from pieces such as parts, components, or assemblies ➔ Processing is the manufacture of a product by continuous operations ● Workpiece and its con guration ➢ Primary objective of manufacturing is to produce a component having a desired geometry, size, and nish Roles of Engineers in Manufacturing ● Design engineer responsibilities ➢ What the design is to accomplish ➢ Assumptions that can be made ➢ Service environments the product must withstand ➢ Final appearance of the product ➢ Product designed with the knowledge that certain manufacturing processes will be used ● Manufacturing engineer responsibilities ➢ Select and coordinate speci c processes and equipment ➢ Supervise and manage their use ● Industrial (Manufacturing) engineer ➢ Manufacturing systems layout ● Materials engineers ➢ Specify ideal materials ➢ Develop new and better materials
3 Major Changes in the World of Goods Manufacturing ● Worldwide or global competition ● Advanced technology ● New manufacturing systems structure, strategies, and management Changing World Competition ● Globalization has impacted manufacturing ➢ Worldwide competition for global products and their manufacture ➢ High tech manufacturing for advanced technology ➢ New manufacturing systems, designs, and management Manufacturing Systems Designs ● Job shop is characterized by large varieties of components, general-purpose machines, and a functional layout. ➢ Machines are collected by function. ➢ Material is moved from machine to machine in carts or containers and is called the lot or batch. ➢ To be the least cost-efficient of all the systems because of its design ● Flow shop are characterized by larger designs volumes of the same part or assembly, special-purpose machines and equipment, less variety, less exibility, and more mechanization. ➢ Common light bulb ➢ A transfer line producing an engine block ➢ If interrupted, the line manufactures large lots but is periodically "changed over" to run a similar but different component. ● Linked-cell shop is composed of manufacturing and subassembly cells connected to nal assembly (linked) using a unique form of inventory and information control called Kanban. ➢ Used in lean production systems where manufacturing processes and subassemblies are restructured into U-shaped cells so they can operate on a one-piece- ow basis, like nal assembly. ● Project shop is characterized by the immobility of the item being manufactured. ➢ In the construction industry, bridges and roads ➢ In the manufacture of goods, large airplanes, ships, large machine tools, and locomotives ➢ Workers, machines, and materials come to the site ➢ Job shop usually supplies parts and subassemblies to the project shop in small lots. ● Continuous process are used to manufacture liquids, oils, gases, and powders. ➢ Usually large plants producing goods for other producers or mass-producing canned or bottled goods for consumers. Other Manufacturing Operations ● Testing ● Transportation ● Automation ● Removal of material waste ● Packaging ● Storage Characteristics of Process Technology ● Mechanics (static or dynamic) ● Economics or costs ● Time Spans ● Constraints ● Uncertainties and process reliability ● Skills ● Flexibility ● Process capability New Manufacturing Systems ● Toyota Production System ➢ Lean manufacturing system ➢ 100% good units ow without interruption ➢ Integrated quality control ▷ Responsibility for quality is given to manufacturing ➢ Constant quality improvement World Class Manufacturing (WCM) ● A concept of continual rapid improvement ● Everything we do, it should be viewed as a process-→there is always a better way.
What is Metal Forming?? ● Metal forming involves using mechanical, thermal or chemical methods to shape metals into different sizes and forms. Its main purpose is to create functional and useful products from raw materials like sheets, bars, or rods. ● Deformation results from the use of a tool, usually called a die in metal forming, which applies stresses that exceed the yield strength of the metal. ● This process can be classi ed into two basic categories: bulk deformation processes and sheet metalworking. Die - it is a special tool for forming metallic material, which uses the up-and-down movement of press machine. Advantages ● Cost-effectiveness ● Improved strength and durability ● Enhanced surface nish Disadvantages ● Limited to speci c materials ● High equipment costs ● Environmental concerns Bulk Deformation ● Bulk deformation is a manufacturing process in which a large amount of material is deformed through compressive or tensile forces, resulting in a change in shape or dimensions. ● A process where it re nes the starting shapes, sometimes improving mechanical properties, and always adding commercial value. ● Bulk deformation processes are performed as cold, warm, and hot working operations. ● There are several types of bulk deformation processes, including rolling, forging, extrusion, and drawing , among others. Types of Bulk Deformation ● Rolling ● Forging ● Extrusion ● Drawing Rolling Process ● Rolling is a deformation process in which the thickness of the work is reduced by compressive forces exerted by two opposing rolls. ● The rolls rotate to pull and simultaneously squeeze the work between them ● Most rolling processes are very capital intensive, requiring massive pieces of equipment, called rolling mills,to perform them. ● Most rolling is carried out by hot working, called hot rolling, owing to the large amount of deformation required.
Rolling mills compress metal into a uniform thickness, bend it into custom shapes, and create custom-sized stripping. Three intermediate shapes in Rolling process Before achieving its nal shape, the material undergoing the rolling process goes through various intermediate shapes. Those shapes are the ff:
- Bloom - The rst shape that a piece of metal takes on in a rolling process is called a bloom and has a square cross section 150 mm 150 mm (6 in 6 in) or larger.
- Billet - Bloom is cut into a smaller piece, more manageable pieces called billets it is a square with dimensions 40 mm (1.5in) on a side or larger.
- Slab - Once the billets have been formed, they are typically reheated and rolled further to create a slab shape. it has a rectangular cross section with a width of 250 mm (10 in) or more and thickness 40 mm (1.5 in) or more. Steps in a Rolling process
- The work starts out as a cast steel ingot that has just solidi ed.
- While it is still hot, the ingot is placed in a furnace where it remains for many hours until it has reached a uniform temperature
- The ingot is moved to the rolling mill, where it is rolled into one of three intermediate shapes called blooms, billets, or slabs.
- A slab is rolled from an ingot or a bloom
- These intermediate shapes are subsequently rolled into nal product shapes. DIfferent types of Rolling process ● Hot Rolling ● Cold Rolling ● Ring Rolling ● Thread Rolling ● Pro le Rolling Forging Process ● Forging is a deformation process in which the work is compressed between two dies, using either impact or gradual pressure to form the part ● Either impact or gradual pressure is used in forging ● A forging machine that applies an impact load is called a forging hammer ● A forging machine that applies gradual pressure is called a forging press. ● Forging is carried out in many different ways. One way to classify the operations is by working temperature. ● It is the oldest of the metal forming operations, dating back to perhaps 5000 BCE ● Today, forging is an important industrial process used to make a variety of high-strength components for automotive, aerospace, and other applications.
Process of Open-Die forging
- Heating the metal : The rst step in open-die forging is to heat the metal to a temperature that makes it malleable and easier to shape.
- Placing the metal between the dies: Once the metal has been heated, it is placed between two at or slightly concave dies.
- Hammering or pressing the metal : The next step is to hammer or press the metal between the dies.
- Reheating and further shaping (optional): Depending on the complexity of the nal product, the metal may need to be reheated and shaped multiple times using different sets of dies.
- Finishing : Once the forging is complete, the product may require additional processing to achieve its nal shape and nish. This can include machining, grinding, polishing, or other nishing techniques. Products of Open-die forging ● Shafts ● Blocks ● Rings ● Disks ● Bars ● Flanges ● Cylinder liners ● Couplings ● Valve bodies ● Fittings Impression-die forging ● also known as closed-die forging or precision forging the ● die surfaces contain a shape or impression that is imparted to the work during compression ● In this type of operation, a portion of the work metal ows beyond the die impression to form ash ● The metal lls the die and takes on the shape of the cavity ● This process is often used to create complex shapes with tight tolerances Process of Impression-die forging
- Preparation of raw material : Preparing the raw material needed which is a metal billet or ingot then it is heated to make it malleable and easier to shape.
- Placing the material in dies : The heated billet is placed between two dies that contains the desired shape.
- Forging the material : The dies are then closed, and the material is forged into the shape of the impression.
- Reheating and repeating : Depending on the complexity of the nal product, the material may need to be reheated and shaped multiple times using different sets of dies.
- Finishing : Once the forging is complete, the product may require additional processing to achieve its nal shape and nish. Products of Impression-die forging ● Gears ● Connectingrods ● Crankshaftsed ● Turbineblades ● Flanges ● Axles ● Valves Flashless forging ● also known as precision ashless forging or true closed-die forging , is a process in which heated metal is shaped by pressing it into a die that has a speci c shape, without the use of ash or excess material. ● The die is closed and does not have any other opening. ● Flashless forging and impression forging both need special tools and equipment and can make accurate and smooth parts. But, ashless forging is better for making complicated parts with detailed shapes and precise measurements. Products of Flashless forging ● Bolts and screws ● Gear blanks ● Wheel hubs ● Shackle Pins ● Nuts ● Splines ● Spindles
