Lecture 9 - Manufacturing in EngineeringSlide 2© 2006 Baylor UniversityEGR 1301IntroductionDr. Carolyn SkurlaSpeakingSlide 3© 2006 Baylor UniversityEGR 1301Process Selection• Choice depends on:– The material from which the component is to be made.– The size, shape, and dimension tolerances for the component.– The number of components to be manufactured.Slide 4© 2006 Baylor UniversityEGR 1301Process Selection• Each process is characterized by:– The materials it can handle.– The shapes it can make and the dimension tolerances it can achieve.– The complexity and size of the shape it can make.– The effect the process has on the material’s properties.Lecture 9 - Manufacturing in EngineeringSlide 5© 2006 Baylor UniversityEGR 1301Process Selection• Finding the ______________ between design requirements and process attributes– Iterative procedure– Interaction between function, material, shape, and process are taken into account.Slide 6© 2006 Baylor UniversityEGR 1301Raw MaterialCasting MethodsGravity,Pressure, Die CastingPressureMoldingPolymerMolding,GlassMoldingDeformationProcessingRoll,Forge,Draw, PressPowderMethodsSinter, Slipcast,Hot IsostaticPressureSpecialMethodsLay-UpCVD,ElectroformMachiningCut, Turn, Plane,Drill, GrindHeat TreatQuench, Temper Steels,Age-Harden Al-AlloysJoiningBolt, Rivet, Weld,Braze, AdhesiveFinishPolish, Plate,Anodize, PaintClass of Manufacturing ProcessesSlide 7© 2006 Baylor UniversityEGR 1301Casting Methods• Sand castingSources: http://www.imp.mtu.edu/index.htmlhttp://www.dansworkshop.com/Sand%20castings%20and%20patterns.shtmlMaterials Science: A Multimedia Approach, John C. RussLecture 9 - Manufacturing in EngineeringSlide 8© 2006 Baylor UniversityEGR 1301Casting Methods• Die castingSource: Materials Selection in Mechanical Design, Michael F AshbySlide 9© 2006 Baylor UniversityEGR 1301Casting Methods• So, which one do we choose?– It dependsSource:Materials Selection in Mechanical Design, Michael F AshbySlide 10© 2006 Baylor UniversityEGR 1301Pressure Molding• Compression molding• Transfer moldingSource:Materials Selection in Mechanical Design, Michael F AshbyLecture 9 - Manufacturing in EngineeringSlide 11© 2006 Baylor UniversityEGR 1301Pressure Molding• Blow moldingSource: Materials Selection in Mechanical Design, Michael F AshbyMaterials Science: A Multimedia Approach, John C. Russ Slide 12© 2006 Baylor UniversityEGR 1301Pressure Molding• Injection molding– > 50% of polymer components are manufactured by this methodSource: http://www-materials.eng.cam.ac.uk/mpsite/process_encyc/default.htmlMaterials Selection in Mechanical Design, Michael F AshbySlide 13© 2006 Baylor UniversityEGR 1301DeformationProcessing• Rolling– Cold rolling– Warm rolling– Hot rollingSources: Materials Science: A Multimedia Approach, John C. RussLecture 9 - Manufacturing in EngineeringSlide 14© 2006 Baylor UniversityEGR 1301DeformationProcessing• Forging–Example Æ Closed-die forging• A heated blank is placed between 2 halves of a die• A single compressive stroke squeezes the blank into the die to form the part. Sources: http://www-materials.eng.cam.ac.uk/mpsite/process_encyc/default.htmlMaterials Selection in Mechanical Design, Michael F AshbySlide 15© 2006 Baylor UniversityEGR 1301DeformationProcessing– Closed-die forging (cont)• Once the die halves have separated, the part can be ejected immediately using an ejector pin. • The waste material, called flash, is removed later.Source: http://www-materials.eng.cam.ac.uk/mpsite/process_encyc/default.htmlSlide 16© 2006 Baylor UniversityEGR 1301Deformation Processing• ExtrusionSource: http://www.aec.org/cyberg/process.html#a1Materials Selection in Mechanical Design, Michael F AshbyLecture 9 - Manufacturing in EngineeringSlide 17© 2006 Baylor UniversityEGR 1301Powder Methods• Powder sintering• Hot isostatic pressing (HIPing)Source:Materials Selection in Mechanical Design, Michael F AshbySlide 18© 2006 Baylor UniversityEGR 1301Machining• Cutting• Turning• Drilling• Milling• GrindingSource:Materials Selection in Mechanical Design, Michael F AshbySlide 19© 2006 Baylor UniversityEGR 1301Joining & Fastening• Welding• Mechanical joiningSource: http://www-materials.eng.cam.ac.uk/mpsite/process_encyc/default.htmlMaterials Selection in Mechanical Design, Michael F AshbyManufacturing ProcessRelative Tooling CostsRelative Equipment CostsRelative Labor Costs Materials ShapesSurface FinishEconomic Batch Sizes Examples Additional CommentsSand CastingDie CastingCompression moldingTransfer moldingBlow moldingInjection moldingRollingForgingExtrusionPowder sinteringMachiningJoiningFasteningManufacturing Methods Sample Problem Based on your notes from Lecture 9, match the following items to be manufactured with the manufacturing process. Note some methods may be used more than once and some possibly not at all!! ______ 500 items of steel; complex shape; rough surface finish acceptable A. Die casting ______ Aluminum for window frames B. Blow molding ______ 50,000 large gears of steel; simple shape; good surface finish required C. Rolling ______ 25,000 items of aluminum; simple shape; good surface finish required D. Sand casting ______ Structural I-beams of steel E. Forging ______ 10,000 ceramic components F. Injection molding ______ 100,000 plastic bottles G. Extrusion ______ Copper pipes for household plumbing H. Powder sintering ______ 100,000 small, plastic gears for a toy; good surface finish required, simple