KỸ THUẬT CHẾ TẠO

(Manufacturing Technology)
C O U R S E T I T L E : M AT E R I A L S P R O C E S S I N G T E C H N O L O G Y
C O U R S E N U M B E R . : M AT E 2 3 0 5 3 0
L E C T U R E R : X U A N T I E N VO

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Đề cương chi tiết
Mô tả môn học (Course Description)
1. Môn học cung cấp các kiến thức kỹ thuật cơ sở về kỹ thuật cơ khí từ giai đoạn
đầu đến cuối của quá trình chế tạo các chi tiết.
2. Môn học trang bị cho sinh viên kỹ thuật nhưng không chuyên về công nghệ
chế tạo máy có khả năng tính toán, thiết kế quy trình công nghệ chế tạo cơ khí
nhằm đáp ứng các yêu cầu về kỹ thuật và kinh tế.
3. Môn học giúp người học có kiến thức và kỹ năng để chọn lựa được phương án
vật liệu, chế tạo phôi và gia công tối phù hợp khi đi vào thức tế sản xuất cơ
khí.

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COURSE SYLLABUS
This course is intendedly designed to provide basic knowledge about engineering
concepts in field of mechanical processing.
The course help learners knowledge and skills to select suitable materials, metal
and machining processing as they are getting into the working world of
mechanical engineering
The course equips also students, who study engineering program but just related
to mechanical engineering:
 understanding of engineering manufacture
 ability of calculating and proper materials as well as manufacturing process
selection in order to fulfill economic demands and technological requirements.

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Đề cương chi tiết
Môn học bao gồm các nội dung:

lựa chọn vật liệu

phương pháp tạo phôi

quy trình gia công

kiểm tra đánh giá sản phẩm

tạo mẫu nhanh

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COURSE SYLLABUS
The course is divided into following sections:
+ Materials selection
+ Metal processing
+ Machining process
+ Products testing and evaluating
+ Rapid prototyping

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Reference books/ Learning materials
1. Lecture notes.
2. Nguyễn Tiến Đào, Công nghệ chế tạo phôi, NXB Khoa học và Kỹ thuật, 2008
3. Nguyễn Thúc Hà, Bùi Văn Hạnh, Giáo trình Công nghệ hàn, NXB giáo dục, 2008
4. Nguyễn Mậu Đằng, Công nghệ tạo hình kim loại tấm, Nhà xuất bản khoa học kỹ
thuật, 2006
5. Vukota Boljanovic, Sheet Metal Forming Processes and Die Design, Industrial Press,
2005
6. T. Altan, G. Ngaile, and G. Shen, Cold and Hot Forging: Fundamentals and
Applications, ASM international, 2004
7. P Rao, Manufacturing Technology: Foundry, Forming And Welding, Tata McGraw.
Hill, 2008
8. H.N.Gupta, Manufacturing process, New age international publishes, 2009
9. Ammen, The complete handbook of sand casting, MrGraw- Hill,
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Extras
Unified CAD, CAM, and PCB software
Get access to Fusion 360 for personal use, including standard features for home-
based, non-commercial projects.
Fusion 360 for Personal Use | Fusion 360 | Autodesk
https://www.autodesk.com/products/fusion-360/personal
Fusion 360 Blog - Product updates, tips, tutorials and community news. (autodes
k.com
)
https://www.autodesk.com/products/fusion-360/blog#mechanical-engineering

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Part I:
General introduction to manufacturing processing
What is manufacturing?
The importance of materials in manufacture
Manufacturing procedures
Manufacturing systems
Trends in manufacturing

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Part I:
General introduction to manufacturing processing
-Manufacturing is the transformation
of materials into items of greater value
by means of one or more processing
and/or assembly operations.
-The key point is that manufacturing
adds value to the material by changing
its shape or properties, or by
combining it with other materials that
have been similarly altered.
-The material has been made more
valuable through the manufacturing
operations performed on it.
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Part I:
General introduction to manufacturing processing
-“manufacture”: manu (meaning “by hand”) and factum
(meaning “made”).
-Manufacturing is the process of converting (either by
manual labor or by machines) raw materials into
finished products, especially in large quantities.
-Manufacturing is concerned with making products.
-A manufactured product may itself be used to make
other products
Manufacturing covers a wide variety of processes and products.
It involves the production of many different types of goods that range from food
to microcircuits to airplanes to health care equipment

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Part I:
General introduction to manufacturing processing
A manufactured item typically starts
with raw materials which are then
subjected to a sequence of processes
to make individual products, it has a
certain value.

Manufacturing engineers design the

processes and systems to make
products with the required
functionality, high quality, at the
lowest price, and in ways that are
environmentally friendly
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Part I: General introduction to manufacturing processing
Manufacturing Processes

as an economic process

as a technical process

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Part I: General introduction to manufacturing processing
Manufacturing Processes
A manufacturing process is a
designed procedure that results in
physical and/or chemical changes to a
starting work material with the
intention of increasing the value of
that material.
A manufacturing process is usually
carried out as a unit operation, which
means that it is a single step in the
sequence of steps required to
transform the starting material into a
final product.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
Manufacturing operations can be divided into two basic types:
(1) processing operations
(2) assembly operations

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Part I:
General introduction to manufacturing processing
A processing operation transforms a
work material from one state of
completion to a more advanced state
that is closer to the final desired
product.
It adds value by changing the
geometry, properties, or appearance of
the starting material.
Processing operations are performed on
discrete work parts, but certain
processing operations are also
applicable to assembled items.
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Part I: General introduction to manufacturing processing
Manufacturing Processes
An assembly operation joins two or
more components to create a new
entity, called an assembly,
subassembly, or some other term that
refers to the joining process

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Manufacturing Processes

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Part I: General introduction to manufacturing processing
Manufacturing Processes
A processing operation uses energy to
alter a work part’s shape, physical
properties, or appearance to add value to
the material.
The forms of energy include mechanical,
thermal, electrical, and chemical.
The energy is applied in a controlled way
by means of machinery and tooling, as
well as human energy Material is fed into the process, energy
is applied by the machinery and tooling
to transform the material, and the
completed work part exits the process.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
More than one processing operation is usually required to transform the starting
material into final form. The operations are performed in the particular sequence
required to achieve the geometry and condition defined by the design
specification.
Three categories of processing operations are distinguished:
(1) shaping operations,
(2) property-enhancing operations,
(3) surface processing operations.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
(1) Shaping operations alter the geometry of the starting work material by
various methods. Common shaping processes include casting, forging, and
machining.
(2) Property-enhancing operations add value to the material by improving its
physical properties without changing its shape. Heat treatment is the most
common example.
(3) Surface processing operations are performed to clean, treat, coat, or deposit
material onto the exterior surface of the work.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
Shaping Processes: Most shape processing operations apply heat, mechanical
force or a combination of these to effect a change in geometry of the work
material.
There are various ways to classify the shaping processes such as classification
based on the state of the starting material, by which there are four categories:
(1) solidification processes;
(2) particulate processing;
(3) deformation processes;
(4) material removal processes.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
SOLIDIFICATION PROCESSES PARTICULATE PROCESSING
Processes, in which the starting Processes, in which the starting
material is a heated liquid or semifluid material is a powder, and the powders
that cools and solidifies to form the are formed and heated into the desired
part geometry; geometry

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Part I: General introduction to manufacturing processing
Manufacturing Processes
DEFORMATION PROCESSES MATERIAL REMOVAL PROCESSES
The processes, in which the starting The processes, in which the starting
material is a ductile solid (commonly material is a solid (ductile or brittle),
metal) that is deformed to shape the from which material is removed so that
part. the resulting part has the desired
geometry

The starting work part is shaped by the

application of forces that exceed the yield
strength of the material
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Part I: General introduction to manufacturing processing
Manufacturing Processes
-These certain described processes are known as traditional processes.
-Nontraditional processes, in which another energy source for material
removal such as lasers, electron beams, chemical erosion, electric discharges,
and electrochemical energy used to remove material instead of using cutting or
grinding tools.
-It is desirable to minimize waste and scrap in converting a starting work part
into its subsequent geometry.
-Material removal processes (e.g., machining) tend to be wasteful of material,
simply by the way they work. The material removed from the starting shape is
waste, at least in terms of the unit operation. Other processes, such as certain
casting and molding operations, often convert close to 100% of the starting
material into final product.
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Part I: General introduction to manufacturing processing
Manufacturing Processes
Property-Enhancing Processes The second major type of part processing is
performed to improve mechanical or physical properties of the work material.
These processes do not alter the shape of the part, except unintentionally in some
cases. The most important property-enhancing processes involve heat
treatments, which include various annealing and strengthening processes for
metals and glasses.
Sintering of powdered metals is also a heat treatment that strengthens a pressed
powder metal work part. Its counterpart in ceramics is called firing.

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Part I: General introduction to manufacturing processing
Manufacturing Processes

Property-Enhancing Processes

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Activities
Please visit the web adress: https://fractory.com/heat-treatment-methods/ and….

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Part I: General introduction to manufacturing processing
Manufacturing Processes
Manufacturing processes:
Modern manufacturing can be
divided into the following four
main categories:
1. subtractive,
2. additive,
3. continuous,
4. net shape

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 Part I: General introduction to manufacturing processing
Manufacturing Processes

Subtractive Processes

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Part I: General introduction to manufacturing processing
Manufacturing Processes
The subtractive process involves
material removal via machining (e.g.,
turning, milling, boring, grinding,
cutting, and etching).
The three principal machining
processes are classified as turning,
drilling, and milling.

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Part I: General introduction to manufacturing processing
Manufacturing Processes

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Part I: General introduction to manufacturing processing
Manufacturing Processes
Turning is a process that uses a lathe
to produce “solids of revolution.”
The lathe can be operated by a person
or a computer. A lathe that is controlled
by a computer is known as a CNC
(computer numerical control) machine.
CNC commonly is used with many
other types of machine tools besides
the lathe.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
In a turning operation, the part is rotated (i.e.,
turned) while it is being machined.
Turning produces straight, conical, curved, or
grooved workpieces such as shafts, spindles,
pins, and so forth.
The majority of turning operations involve the
use of a single point cutting tool

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Part I: General introduction to manufacturing processing
Manufacturing Processes
-Drilling is the process of using a cutting tool
called a drill bit to produce round holes in
materials such as wood or metal.
-The common twist drill (the one sold in hardware
stores) has a point angle of 118 degrees. This
angle works well for a wide array of drilling
operations.
-A steeper point angle (say, 90 degrees) works well
for plastics and other soft materials.
-A shallower point angle (say 150 degrees) is
suited for drilling steels and other tough materials.
-Drills with no point angle are used in situations
where a blind, or flat-bottomed hole is required.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
-Milling is carried out on a machine tool called a
“milling machine” that is used for the shaping of
metal and other solid materials.
-Often the movement is achieved by moving the
workpiece while the cutter rotates in one place.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
- It has a cutting tool that rotates
about the spindle axis similar to a
drill. However, a drill moves along
only one axis, but on a milling
machine the cutter and workpiece
move relative to each other,
generating a tool path along which
material is removed along three
axes.
- Milling machines may be manually
operated, mechanically automated,
or digitally automated via CNC
(computer numerical control).

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Part I: General introduction to manufacturing processing
Manufacturing Processes
Additive Processes:
-The additive process is where material is
added such as in joining, soldering, and
gluing), rapid prototyping, stereolithography,
3D printing, and the application of composite
layers of resin and fiber.
-Additive machining processes add material to
a base object to create complex shapes.
-This is far less expensive than cutting an
intricate product from a solid block of material
by the subtractive process.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
Continuous Processes:
In the continuous process the product is
produced continuously, such as in the
extrusion of metals and plastics, and the
pultrusion of composites.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
-Extrusion is a continuous process of manufacture
used to create objects of a fixed cross-sectional
profile by pushing or drawing material through a
die of the desired crosssection.
In extrusion, a bar or metal or other material is
forced from an enclosed cavity through a die
orifice by a force applied by a ram

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Part I: General introduction to manufacturing processing
Manufacturing Processes
The extruded product has the desired
reduced cross-sectional area, and also has a
good surface finish so that further
machining is not needed.

Extrusion products include rods

and tubes with varying degrees
of complexity in cross-section

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Part I: General introduction to manufacturing processing
Manufacturing Processes
-Pultrusion is a similar continuous process
of manufacturing materials with constant
cross-section except the material is pulled
through a process or a die to its final shape.
-Pultrusion is the only continuous
manufacturing process available for
obtaining high quality composite profile,
with good mechanical properties.
-Pultruded products normally are
composed of high performance glass or
carbon fibers embedded in a polymer
matrix.
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Part I: General introduction to manufacturing processing
Manufacturing Processes
-Net Shape Processes: net shape process
occurs when the output is at or near its
final shape, such as stamping, forging,
casting, injection molding, blow molding,
and thermoforming.
-Stamping is a metalworking process in
which sheet metal is formed into a desired
shape by pressing or punching it on a
machine press.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
-Stamping can be a single stage operation where only
one stroke of the press produces the desired form, or
could occur through a series of these stages
The most common stamping operations are piercing,
bending, deep drawing, embossing, and extrusion.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
-Casting is a manufacturing process by which a
liquid material is poured into a mold containing a
cavity of the desired shape, and then allowed to
solidify.
-The mold is then opened to complete the
process. The casting process is subdivided into
two distinct subgroups: expendable and
nonexpendable mold casting.
-Casting most often is used for making complex
shapes that would be otherwise difficult or
uneconomical to make by other machining
methods.
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Part I: General introduction to manufacturing processing
Manufacturing Processes
-Injection molding is a manufacturing process used
to make parts by injecting molten plastic at high
pressure into a mold. Injection molding is used
widely for manufacturing a variety of parts, from
the smallest gears to entire automotive body panels.
-Blow molding is a manufacturing process in which
hollow plastic parts are formed. The blow molding
process begins with melting the plastic and forming
it into a tube-like piece with a hole in one end into
which air can be injected. It is then clamped into a
mold and air pressure pushes the plastic into the
mold. Once the plastic has cooled and hardened the
mold opens up and the part is ejected. Plastic soda
bottles are made this way.

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Part I: General introduction to manufacturing processing
Manufacturing Processes
Thermoforming is a manufacturing
process used with plastic sheets.
Plastic sheets or film is converted
into a finished part by heating it in
an oven to its forming temperature,
then stretching it on a mold and
cooled.
A thermoform machine typically
utilizes vacuum to draw the plastic
onto the mold in the forming
process

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Part I: General introduction to manufacturing processing

Manufacturing Procedures

What makes a good

manufacturing process?

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Part I: General introduction to manufacturing processing
Production systems
To operate effectively, a manufacturing
firm must have systems that allow it to
efficiently accomplish its type of
production. Production systems consist
of people, equipment, and procedures
designed for the combination of
materials and processes that constitute a
firm’s manufacturing operations.
Production systems can be divided into
two categories:
(1) production facilities
(2) manufacturing support systems

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Part I: General introduction to manufacturing
processing
Production systems
MANUFACTURING SUPPORT
PRODUCTION FACILITIES
SYSTEMS
Production facilities refer to the Manufacturing support systems are
physical equipment and the the procedures used by the company to
arrangement of equipment in the manage production and solve the
factory. technical and logistics problems
encountered in ordering materials,
moving work through the factory, and
ensuring that products meet quality
standards.

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Part I: General introduction to manufacturing
processing
Production systems
-Production facilities consist of the
factory and the production, material
handling, and other equipment in the
factory.
-The equipment comes in direct
physical contact with the parts and/or
assemblies as they are being made.
-The facilities “touch” the product.

Facilities also include the way the equipment is arranged in the factory—the
plant layout. The equipment is usually organized into logical groupings.

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Part I: General introduction to manufacturing processing
Production systems
Automated production line, or a machine cell consisting of an industrial robot
and two machine tools are called as manufacturing systems.

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Part I: General introduction to manufacturing processing
Production systems
Three different types of
facilities are required for each product layout
of the three ranges of annual
production quantities:
-Low-Quantity Production,
fixed-position layout
-Medium Quantity Production
-High Production

cellular layout
process layout
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Part I: General introduction to manufacturing processing
Production systems
Low-Quantity Production:
-In the low-quantity range (1–100 units/year),
the term job shop is often used to describe the
type of production facility.
-A job shop makes low quantities of specialized
and customized products.
-The products are typically complex, such as
space capsules, prototype aircraft, and special
machinery.
-The equipment in a job shop is general
purpose, and the labor force is highly skilled.
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Part I: General introduction to manufacturing processing
Production systems
-A job shop must be designed for
maximum flexibility to deal with the
wide product variations encountered
(hard product variety).
-If the product is large and heavy, and
therefore difficult to move, it typically
remains in a single location during its
fabrication or assembly.
-Workers and processing equipment are
brought to the product, rather than This type of layout is referred to
moving the product to the equipment.
as a fixed-position layout

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Part I: General introduction to manufacturing processing
Production systems
-In a pure situation, the product remains
in a single location during its entire
production. Examples of such products
include ships, aircraft, locomotives, and
heavy machinery.
-In actual practice, these items are usually
built in large modules at single locations,
and then the completed modules are
brought together for final assembly using
large-capacity cranes.

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Part I: General introduction to manufacturing processing
Production systems
The individual components of these large
products are often made in factories in
which the equipment is arranged
according to function or type.
This arrangement is called a process
layout.

The lathes are in one department,

the milling machines are in another
department

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Part I: General introduction to manufacturing processing
Production systems
In the process layout, different parts,
each requiring a different operation
sequence, are routed through the
departments in the particular order
needed for their processing, usually in
batches.
The process layout is noted for its
flexibility; it can accommodate a great
variety of operation sequences for
different part configurations. Its
disadvantage is that the machinery and
methods to produce a part are not
designed for high efficiency.
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Part I: General introduction to manufacturing processing
Production systems
Medium Quantity Production
In the medium-quantity range (100–10,000 units annually), two different types of
facility are distinguished, depending on product variety: batch process and
cellular manufacturing.

cellular layout

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Part I: General introduction to manufacturing
processing
Production systems
BATCH PROCESS CELLULAR MANUFACTURING
-When product variety is hard, the usual -When product variety is soft, the
approach is batch production, in which cellular layout is an alternative
a batch of one product is made, after approach to medium-range production.
which the manufacturing equipment is -It is often possible to configure the
changed over to produce a batch of the
manufacturing system so that groups of
next product, and so on.
similar products can be made on the
-The production rate of the same equipment without significant lost
equipment is greater than the time because of setup. The extensive
demand rate for any single product changeovers between one product style
type, and so the same equipment can and the next may not be necessary.
be shared among multiple products
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Part I: General introduction to manufacturing
processing
Production systems
BATCH PROCESS CELLULAR MANUFACTURING
-The changeover between production runs -The processing or assembly of
takes time—time to change tooling and set
up the machinery. This setup time is lost
different parts or products is
production time, and this is a disadvantage accomplished in cells consisting of
of batch manufacturing several workstations or machines.
-Batch production is commonly used for -Each cell is designed to produce a
make-to-stock situations, in which itemslimited variety of part configurations;
are manufactured to replenish inventory that is, the cell specializes in the
that has been gradually depleted by production of a given set of similar
demand. parts, according to the principles of
-The equipment is usually arranged in a group technology
process layout

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Part I: General introduction to manufacturing processing
Production systems
High Production
 The high-quantity range (10,000 to millions of units per year) is referred to as
mass production.
 The situation is characterized by a high demand rate for the product, and the
manufacturing system is dedicated to the production of that single item. Two
categories of mass production can be distinguished: quantity production and
flow line production.

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Part I: General introduction to manufacturing processing
Production systems
QUANTITY PRODUCTION FLOW LINE PRODUCTION
-involves multiple pieces of equipment or
-involves the mass production of single workstations arranged in sequence, the work
parts on single pieces of equipment. units are physically moved through the
sequence to complete the product.
-It typically involves standard machines
(e.g., stamping presses) equipped with -The workstations and equipment are designed
specifically for the product to maximize
special tooling (e.g., dies and material efficiency. The layout is called a product
handling devices), in effect dedicating layout, and the workstations are arranged into
the equipment to the production of one one long line or into a series of connected line
part type. segments.
-Typical layouts used in quantity -The work is usually moved between stations
by mechanized conveyor. At each station, a
production are the process layout and small amount of the total work is completed on
cellular layout. each unit of product
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Part I: General introduction to manufacturing
processing
Production systems

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Part I: General introduction to manufacturing
processing
Recent Developments in Manufacturing
-Microelectronics involves electronic
devices that are fabricated on a
microscopic scale. Examples include
integrated circuits, which consist of
components such as transistors, diodes, and
resistors that have been fabricated and
electrically connected on a small flat chip,
usually made of silicon.
-The remarkable feature about today’s
microelectronics devices is the huge
number of components that can be
contained onto the chip

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Part I: General introduction to manufacturing processing
Recent Developments in Manufacturing
Computerization of Manufacturing
 The first digital computers date from the mid-1940s, but
their applications in manufacturing came quite a few years
later.
 In the mid-1960s direct numerical control was developed,
in which mainframe computers were employed to remotely
control machine tools in factories.
 As computer technology developed, enabled by advances in
microelectronics, the cost of computers and data processing
was reduced, leading to the widespread use of personal
computers, not only in the office but also in the factory for
tasks ranging from control of individual equipment on the
shop floor to control of the information required to manage
the entire enterprise
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Part I: General introduction to manufacturing
processing
Recent Developments in Manufacturing
 The Internet has allowed manufacturing companies to communicate among their
own geographically distributed plants and offices, and it has also provided access
to customers and suppliers around the world

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Part I: General introduction to manufacturing processing
Recent Developments in Manufacturing
 Flexible Manufacturing: computerization
has enabled manufacturing companies to
develop systems that are able to cope with
product variations

 Flexible manufacturing system is an

industrial procedure that enables to use
equipment for more than one thing.
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Part I: General introduction to manufacturing
processing
Recent Developments in Manufacturing
-Mass customization involves a
production system that is capable of
producing individualized products for
each customer.
-The customer specifies the model and
options, and the product is made to
those specifications.

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Part I: General introduction to manufacturing processing
Recent Developments in Manufacturing
-In Microfabrication and Nanotechnology, materials and products whose
dimensions are sometimes so small that they cannot be seen by the naked eye. In
extreme cases, the items cannot even be seen under an optical microscope.
-Products that are so miniaturized require special fabrication technologies.

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Part I: General introduction to manufacturing processing
Recent Developments in Manufacturing
MICROFABRICATION NANOTECHNOLOGY
-Microfabrication refers to the -Nanotechnology refers to materials
processes needed to make parts and and products whose feature sizes are in
products whose features sizes are in the the nanometer scale (1 nm = m = mm
micrometer range (1 m = mm = m). = m), a scale that approaches the size
-Examples include ink-jet printing of atoms and molecules.
heads, compact discs (CDs and DVDs), -Ultra-thin coatings for catalytic
and microsensors used in automotive converters, flat screen TV monitors,
applications (e.g., air-bag deployment and cancer drugs are examples of
sensors). products based on nanotechnology.

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Part I: General introduction to manufacturing processing
Recent Developments in Manufacturing
Lean Production and Six Sigma:
-These are two programs aimed at improving efficiency and quality in
manufacturing.
-They address demands by customers for products they buy to be both low in cost
and high in quality.
-Lean production and Six Sigma are being widely adopted by companies.

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Part I: General introduction to manufacturing processing
Recent Developments in Manufacturing
-Lean production is based on the Toyota Production System developed by Toyota
Motors in Japan.
-Its origins date from the 1950s and 1960s when Toyota began using
unconventional approaches to improve quality, reduce inventories, and increase
flexibility in its operations.
-Lean production can be defined simply as “doing more work with fewer
resources.” It means that fewer workers and less equipment are used to
accomplish more production in less time, and yet achieve higher quality in the
final product. The underlying objective of lean production is the elimination of
various forms of waste, such as producing defective parts, excessive inventories,
and workers waiting

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Part I: General introduction to manufacturing processing
Recent Developments in Manufacturing
- Six Sigma was started in the 1980s at Motorola Corporation in the United
States.
- The objective was to reduce variability in the company’s processes and products
to increase customer satisfaction.
- Today, Six Sigma can be defined as “a quality-focused program that utilizes
worker teams to accomplish projects aimed at improving an organization’s
operational performance.

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Activities (personal)
Please search Lean tools and choose or pick one of them up to give
more detailed information about it. (You can finish this task at home
and show me next week) (you can bring 1 or 2 pages about LEAN
tools to class)

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Recent Developments in Manufacturing
Globalization and Outsourcing
- The world is becoming more and more integrated, creating an international
economy in which barriers once established by national boundaries have been
reduced or eliminated. This has enabled a freer flow of goods and services,
capital, technology, and people among regions and countries.
- Globalization is the term that describes this trend, which was recognized in the
late 1980s and is now a dominant economic reality. Of interest here is that once
underdeveloped nations such as China, India, and Mexico have developed their
manufacturing infrastructures and technologies to a level such that they are now
important producers in the global economy.

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Recent Developments in Manufacturing
- Developing countries, such as China, India, Mexico and also Vietnam, have
young and large populations, and therefore large workforces, and low labor costs.
Meanwhile, hourly wages in developed countries such as Japan, Korea, United
States, Canada are significantly higher than in these countries, making it difficult
for domestic companies to compete in many products that require high labor
content. Examples include garments, furniture, toys, and electronic consumer
products.
- The result has been a loss of manufacturing jobs in developed countries and a
gain of related work to developing countries. However, the rising of protectism
after the Trump’s victory in the USA´ election 2016 is the best example and
prevents the globalization.

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Recent Developments in Manufacturing
- Outsourcing is closely related to globalization.
- In manufacturing, outsourcing refers to the use of outside contractors to
perform work that was traditionally accomplished in-house.
- Outsourcing can be done in several ways, including the use of local suppliers. In
this case the jobs remain in the United States. Alternatively, U.S. companies can
outsource to foreign countries, so that parts and products once made in the
United States are now made outside the country. In this case U.S. jobs are
displaced.
- Two possibilities can be distinguished: (1) offshore outsourcing, which refers to
production in China or other overseas locations and transporting the items by
cargo ship to the United States, and (2) near-shore outsourcing, which means
the items are made in Canada, Mexico, or Central America and shipped by rail or
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Recent Developments in Manufacturing
- Outsourcing has resulted in the growth of contract manufacturers, companies
that specialize in producing parts, subassemblies, and/or products for other
companies.
- Contract manufacturers have developed expertise and efficiencies in certain
manufacturing operations, which means they can likely produce the contracted
items at prices that are lower than the production costs of the customer company
if it were the producer.

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Recent Developments in Manufacturing
- Contract manufacturers include both domestic (U.S.) and foreign companies.
- Reasons why a company might prefer to use the services of a contract
manufacturer include:
(1) the company benefits from cost savings because it does not have to pay the
factory expenses associated with production,
(2) the company can focus its resources on design and marketing of products
rather than manufacturing,
(3) the company may benefit from skills possessed by the contract manufacturer
but not by itself.

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Recent Developments in Manufacturing
- There are risks associated with contract manufacturing by the customer
company. In turning over its product designs it loses control over its intellectual
property, which might result in the contract manufacturer becoming a competitor.
- The distinction between a contract manufacturer and a supplier is perhaps
subtle.
- A supplier is usually thought of as a company that provides materials and
components for a customer who is engaged in production of a product, whereas a
contract manufacturer accomplishes the whole production of the product. It may
use suppliers itself.

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Part I: General introduction to manufacturing processing
Recent Developments in Manufacturing
Environmentally Conscious Manufacturing:
- Environmentally conscious manufacturing refers to programs that seek to
determine the most efficient use of materials and natural resources in production
and minimize the negative consequences on the environment.
- Other terms for these programs include green manufacturing and sustainable
manufacturing.
- Environmentally conscious manufacturing boil down to two basic approaches:
(1) design products that minimize their environmental impact
(2) design processes that are environmentally friendly

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Recent Developments in Manufacturing
Product design is the logical starting point in environmentally conscious
manufacturing. The term design for environment (DFE) is used for the
techniques that attempt to consider environmental impact during product design
prior to production. Considerations in DFE include:
(1) selecting materials that require minimum energy to produce,
(2) selecting processes that minimize waste of materials and energy,
(3) designing parts that can be recycled or reused,
(4) designing products that can be readily disassembled to recover the parts,
(5) designing products that minimize the use of hazardous and toxic materials,
(6) giving attention to how the product will be disposed of at the end of its useful life.

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Recent Developments in Manufacturing
To achieve sustainability, various approaches can be applied to make plant
operations more environmentally friendly. They include:
- adopting good housekeeping practices—keeping the factory clean,
- preventing pollutants from escaping into the environment (rivers and
atmosphere),
- minimizing waste of materials in unit operations,
- recycling rather than discarding waste materials,
- using net shape processes, using renewable energy sources when feasible,
- maintaining production equipment so that it operates at maximum efficiency
- investing in equipment that minimizes power requirements.

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Part I: General introduction to manufacturing processing
Materials in Manufacturing
Most engineering materials
can be classified into one of
four basic categories:
 (1) metals,
 (2) ceramics,
 (3) polymers
 (4) Composites

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Materials in Manufacturing
METALS: used in manufacturing are usually
alloys, which are composed of two or more
elements, with at least one being a metallic
element. Metals and alloys can be divided into
two basic groups:
(1) ferrous,
(2) nonferrous.

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Materials in Manufacturing
-Ferrous metals are based on iron; the
group includes steel and cast iron.
These metals constitute the most
important group commercially, more
than three-fourths of the metal
tonnage throughout the world.
-Pure iron has limited commercial use,
but when alloyed with carbon, iron
has more uses and greater commercial
value than any other metal.
-Alloys of iron and carbon form steel
and cast iron.

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The widespread use of ferrous metals is accounted for by three factors:
(1) iron-containing compounds exist in abundant quantities within the earth’s
crust;
(2) metallic iron and steel alloys may be produced using relatively economical
extraction, refining, alloying, and fabrication techniques;
(3) ferrous alloys are extremely versatile, in that they may be tailored to have a
wide range of mechanical and physical properties.
The principal disadvantage of many ferrous alloys is their susceptibility to
corrosion

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Materials in Manufacturing
-Steel can be defined as an iron–
carbon alloy containing 0.02% to
2.11% carbon.
-It is the most important category
within the ferrous metal group.
-Its composition often includes other
alloying elements as well, such as
manganese, chromium, nickel, and
molybdenum, to enhance the
properties of the metal.

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Materials in Manufacturing
Applications of steel include
construction (bridges, I-beams, and
nails), transportation (trucks, rails, and
rolling stock for railroads), and
consumer products (automobiles and
appliances)

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Materials in Manufacturing
-Cast iron is an alloy of iron and carbon
(2% to 4%) used in casting (primarily
sand casting). Silicon is also present in
the alloy (in amounts from 0.5% to
3%), and other elements are often
added also, to obtain desirable
properties in the cast part.
-Cast iron is available in several
different forms, of which gray cast iron
is the most common; its applications
include blocks and heads for internal
combustion engines
https://www.ductile.org/didata/Section4/4intro.htm

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Materials in Manufacturing
Nonferrous Metals
-Nonferrous metals include the other
metallic elements and their alloys.
-In almost all cases, the alloys are more
important commercially than the pure
metals.
-The nonferrous metals include the pure
metals and alloys of aluminum, copper,
gold, magnesium, nickel, silver, tin,
titanium, zinc, and other metals

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Materials in Manufacturing
CERAMICS
A ceramic is defined as a
compound containing metallic
(or semimetallic) and
nonmetallic elements.
Ceramics include a variety of
traditional and modern
materials.

Common objects that are made of ceramic materials: scissors, a

china tea cup, a building brick, a floor tile, and a glass vase.

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Materials in Manufacturing
Traditional ceramics, some of which have been used for thousands of years,
include:
-Clay (abundantly available, consisting of fine particles of hydrous aluminum
silicates and other minerals used in making brick, tile, and pottery);
-Silica Si(the basis for nearly all glass products);
-Alumina ) and silicon carbide (SiC)(two abrasive materials used in grinding).
Modern ceramics include some of the preceding materials, such as alumina,
whose properties are enhanced in various ways through modern processing
methods.

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Materials in Manufacturing
Newer ceramics include: carbides—metal carbides such as tungsten carbide and
titanium carbide, which are widely used as cutting tool materials; and nitrides—
metal and semimetal nitrides such as titanium nitride and boron nitride, used as
cutting tools and grinding abrasives

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Materials in Manufacturing
-A polymer is a compound formed of repeating structural units called mers,
whose atoms share electrons to form very large molecules.
-Polymers usually consist of carbon plus one or more other elements such as
hydrogen, nitrogen, oxygen, and chlorine.
-Polymers are divided into three categories:
(1) thermoplastic polymers,
(2) thermosetting polymers,
(3) elastomers.

Billiard balls that are made of phenol-formaldehyde (Bakelite)

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Materials in Manufacturing
-Thermoplastic polymers can be
subjected to multiple heating and
cooling cycles without substantially
altering the molecular structure of the
polymer.
-Common thermoplastics include
polyethylene, polystyrene, polyvinyl-
chloride, and nylon.

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Materials in Manufacturing
Thermosetting polymers chemically
transform (cure) into a rigid structure
upon cooling from a heated plastic
condition; hence the name
thermosetting.
Members of this type include
phenolics, amino resins, and epoxies.
Although the name “thermosetting” is
used, some of these polymers cure by
mechanisms other than heating

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Materials in Manufacturing
Elastomers, include natural rubber, neoprene, silicone, and polyurethane, are
polymers that exhibit significant elastic behavior; hence the name elastomer.
- continuous tubing is extruded
through an annular die;
- by maintaining a carefully
controlled positive gas pressure
inside the tube
- by drawing the film in the axial
direction as it emerges from the die,
- the material expands around this
trapped air bubble like a balloon.
Fabrication of Elastomers
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Materials in Manufacturing
-Composites do not really constitute a separate category
of materials; they are mixtures of the other three types.
-A composite is a material consisting of two or more
phases that are processed separately and then bonded
together to achieve properties superior to those of its
constituents.
-The term phase refers to a homogeneous mass of
material, such as an aggregation of grains of identical
unit cell structure in a solid metal.
-The usual structure of a composite consists of particles
or fibers of one phase mixed in a second phase, called
the matrix.
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Materials in Manufacturing
Composites are found in nature (e.g.,
wood), and they can be produced
synthetically.
The synthesized type is of greater
interest here, and it includes glass fibers
in a polymer matrix, such as fiber-
reinforced plastic; polymer fibers of one
type in a matrix of a second polymer,
such as an epoxy-Kevlar composite; and
ceramic in a metal matrix, such as a
tungsten carbide in a cobalt binder to
form a cemented carbide cutting tool

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Materials in Manufacturing
-Cemented carbide is a tool material that
has all properties necessary for cutting
tools, including hardness and strength.
-Cemented carbide is made by powdered
tungsten carbide (WC), mixing cobalt (Co)
powder in it as a binder, and sintering the
mixture.
-It can be likened to concrete. Small stones
(tungsten carbide) are surrounded by
cement (cobalt)
Source: http://carbide.mmc.co.jp/permanent/courses/91/index.html

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Materials in Manufacturing
-Properties of a composite depend on its components, the physical shapes of the
components, and the way they are combined to form the final material.
-Some composites combine high strength with light weight and are suited to
applications such as aircraft components, car bodies, boat hulls, tennis rackets,
and fishing rods.
-Other composites are strong, hard, and capable of maintaining these properties at
elevated temperatures, for example, cemented carbide cutting tools.

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