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01 Intro and Dimensions

The document provides an overview of manufacturing processes and related concepts. It discusses three categories of engineering materials - metals, polymers, and ceramics - as well as composites. It describes two main types of manufacturing processes: shaping operations which change the geometry of materials, and assembly operations which join components. Key dimensions and tolerances that define manufactured parts are also outlined. Measurement instruments and characterizing surface texture are additionally summarized.

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QiYun Liang
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33 views

01 Intro and Dimensions

The document provides an overview of manufacturing processes and related concepts. It discusses three categories of engineering materials - metals, polymers, and ceramics - as well as composites. It describes two main types of manufacturing processes: shaping operations which change the geometry of materials, and assembly operations which join components. Key dimensions and tolerances that define manufactured parts are also outlined. Measurement instruments and characterizing surface texture are additionally summarized.

Uploaded by

QiYun Liang
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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LIANG QIYUN

MA2004 MANUFACTURING PROCESSES

01 Introduction and Dimensions


Manufacturing
Technical process: Application of physical and chemical processes to alter geometry, properties
and/or appearance of a given starting material to make parts or products.

Economic process: Transformation of materials into items of greater value by means of one or more
processing and/or assembly operations.

Engineering Materials: (3 Basic Categories)


1. Metals (usually alloys)
a. Ferrous (based on iron)
b. Nonferrous
2. Polymers (formed of repeating structural units called mers)
a. Thermoplastic polymers subjected to multiple heating and cooling without
altering molecular structure
b. Thermosetting polymers molecules chemically transform into rigid structure
during curing
c. Elastomers show significant elastic behaviour
3. Ceramics
a. Crystalline Ceramics ordered molecular structure (include traditional ceramics)
b. Glasses mostly based on silica (SiO2)

Composites Mixture of the 3 basic types. (e.g. Metal-Ceramic, Ceramic-Polymer, Metal-Polymer)

Manufacturing Processes: (2 Categories)


Shaping Operations Change geometry of starting material
o Solidification processes Starting material is heated liquid/semi-fluid
o Particulate processing Starting material consists of powders pressed + sintered
o Deformation processes Starting material is a ductile solid (commonly metal)
o Material removal processes ductile or brittle solid excess material removed
Minimum Waste Processes: Near net shape process (little waste of starting
material and minimum machining required)
Assembly Operations Join two or more components to create a new entity
o Joining Processes Create a permanent joint (e.g. welding, brazing, soldering,
adhesive bonding)
o Mechanical Assembly fastening by mechanical methods (e.g. threaded fasteners,
press fitting, expansion fits)

Trends in Manufacturing
Environmentally Conscious Manufacturing
Microfabrication and Nanotechnology (Micro and Nanometer range)
Additive Manufacturing (Built layer by layer involving CAD models)
LIANG QIYUN
MA2004 MANUFACTURING PROCESSES

Dimensions and Tolerances


Factors that determine manufactured products performance

Dimensions: Linear or angular sizes of a component specified on part drawing. Basic/Nominal size

Tolerances: Allowable variations from specified part dimensions

Bilateral Tolerance Variation permitted in +ve and -ve direections from nominal direction.
Unilateral Tolerance Variation permitted in only one direction (either +ve or -ve)
Limit Dimensions Maximum and minimum dimensions/material conditions allowed.

Measurement
Provides numerical value of quantity of interest, within certain limits of accuracy and precision.

Systematic Errors (+ve or -ve deviations that are consistent throughout measurements)
Random Errors (Random. Affects precision (reproducibility))
Accuracy (degree to which measured value agrees with true value of quantity of interest)
Precision (degree of repeatability in measurement process)
Resolution (smallest discrimination that instrument can show)

Types of Measuring Instruments:


Precision Gage Blocks (usually square or rectangular blocks)
o Standards against which other dimensional measuring instruments/gages are
compared. Dimensionally accurate, parallel and polished to mirror finish.
Measuring instruments for linear dimensions (graduated and non-graduated devices)
Comparative Instruments (mechanical gages designed to mechanically magnify deviation)
Fixed Gages (Go/No-Go Gages One gage limit allows part to be inserted while the other
limit does not. Inspects the dimension at the maximum and minimum dimension allowed)
o Snap Gage (checking outside dimension e.g. diameter of a part)
o Plug Gage (checking internal dimension e.g. diameter of a hole)
Angular Measurements (Sine bar)
Electronic Gages (convert linear displacement
into electrical signal)

Surfaces
(Processing cost increases with better surface finishing)

Nominal Surface designers intended surface contour of part, defined by lines in engineering
drawing
LIANG QIYUN
MA2004 MANUFACTURING PROCESSES

Surface Texture Topography & geometry (Deviation from nominal surface)


o Roughness (small, finely spaced deviations from nominal surface)
Measured via: Subjective comparison (fingernail test),
Stylus electronic instruments, Optical Techniques
Surface Roughness Equation: RA (average roughness)
y = vertical deviation from nominal surface
Lm = specified distance over which surface deviations are measured
Problem: WAVINESS may get included, LAY unaccounted for
Cutoff Length used as filter to separate waviness from roughness
deviation
o Sampling distance along surface. Typical
Cutoff Length = 0.8mm. Lm normally set at 5 * Length_Cutoff
= 5*0.8 = 4.0mm
Measuring Stylus should travel perpendicular to the LAY direction
o Waviness (deviations of much larger spacing. Roughness superimposed on it.)
o Lay (pattern/direction resulting from mechanical process that produced it)
o Flaws (irregularities on surface e.g. cracks, scratches, inclusions, craters etc)
Surface Integrity Material characteristics immediately beneath surface and changes in it
o Possible metallurgical changes in altered layer that can affect material mechanical
properties (grain size, residual stress)

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