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04chapter3 - Manufacturing Engineering Engineering Chapter...

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Unformatted text preview: Manufacturing Engineering Engineering Chapter 3 – ISE 105 Manufacturing Engineering Manufacturing Designing the production process for a product Functions: – Manufacturability – Selecting the processes, and setting the parameters – Designing work­holding devices – Estimating the cost of manufacturing – Assuring the quality of the product Chapter three discusses some of the Introduction Introduction Manufacturing Engineering ­ primary areas of manufacturing engineering. includes all considerations pertaining to the process of production. The rate of technological change in manufacturing engineering is phenomenal. It is important to understand the basics of manufacturing engineering. Manufacturing Engineering Manufacturing Engineering Evaluating the manufacturability of the product Selecting processes and setting process parameters Designing work­holding devices to secure and control the position of the work­piece Estimating the cost of manufacturing the part Assuring the quality of the part produced. Product-Production Design Interaction Product-Production Product design requires that a person develop and evaluate the ability of the part to perform its intended function. Manufacturing engineering develops and evaluates the cost of producing the part. Ideally, a manufacturing engineer and an industrial engineer should work with the product designer from the beginning to ensure producibility. Employee participation is also important since no one knows the details of the job better than the person doing it. Process Engineering Process engineering is concerned with the design of the actual process to be used in the manufacture of the product. In designing the process to be used, a six­ step sequence should be undertaken. 1. 2. 3. 4. 5. 6. Defining the product structure and specifications (B.O.M.) Assessing each component’s manufacturability Determining the different processes capable to manufacturing the component (Relationship of cost and tolerance.) Evaluating the cost of each of the alternative processes (Make vs. Buy) Determining the sequence in which the operations are to be performed and tooling requirements. (Taylor’s tool life equation) Documenting the process. Six-Step Sequence Six-Step Industrial Metal Processes Industrial There is a wide variety of processes available to the manufacturing engineer to transform materials into the desired size and shape. Majority of the processes are for non­metallic materials. Chapter 3 limits the discussion to those used for the production of metal parts. Processes for Production of Metal Parts Processes Refining and alloying of the metal Casting – All metals generally begin with ore in its natural state – Tensile strength, Hardness, Impact resistance, Malleability, Fatigue resistance, Corrosion resistance – Alloys are combination of two or more metals to obtain better properties – Sand casting, die casting, gravity casting, centrifugal casting, lost­ wax casting, etc. – Rolling, Wire drawing, Forging, Extrusion, Bending, Drawing and Stretching. – Shearing, Turning, Drilling, Shaping and Planing, Milling, Broaching, Sawing, Grinding Forming – Hot and/or Cold Metal cutting Processes for Production of Metal Parts Processes Welding – Bonding two pieces of the same metal – Electric Arc, Resistance welding (spot and seam welding), Beam welding (electron beam and laser), Thermit welding, Pressure welding (friction welding), Gas welding, Brazing and Soldering (filler material melting point lower than the metals welded) – Process of bringing together various parts and subassemblies to complete a product – Honing, Lapping, Polishing, Buffing, Brushing, and Tumbling Assembly Finishing Ancillary Functions Ancillary The production or manufacturing engineer performs other functions other than the process selection. Some of these are tool, fixture, and jig design, cost estimating, maintenance systems design, and packaging systems design. Many of the above are not taught in schools due to breadth and complexity and almost all are learned on the job, as for example, considerations for tool design: – End cutting edge angle, side cutting edge angle, side rake angle, side relief angle, end relief angle, back rake angle, lip angle, nose angle, etc. Computer Applications Computer Computers have changed the nature of production processes in many ways. It is often helpful to use a computer to set the parameters of the production process. The future is bright and unlimited for computer usage in manufacturing engineering. ...
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