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Manufacturing

V
Venkatesh Vadithya

The document discusses various manufacturing processes used to convert raw materials into products. It begins by contrasting prototypes, which are one-offs, from products which need to be manufactured at scale. It emphasizes designing for manufacturability and considering factors like cost, quality and repeatability when scaling production. The rest of the document then provides detailed descriptions and examples of many common manufacturing processes, grouping them into categories like subtractive processes, additive processes, continuous processes and net shape forming. Specific processes discussed include casting, machining, welding, injection molding, thermoforming and more.

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Manufacturing Processes
Context: Prototype vs. Product Toy RC car Product 5,000 $5-10 Little Automobile Product 10,000 $10,000+ Very little ME72 Device Prototype Quantity 1 $200 in parts + your effort Mfg. cost Variability Can be a lot
Prototype -> Product Prototypes are one-offs Products are to be manufactured What if someone wanted you to make 1,000 of your device for $50 each? What would you change? How do you make it to meet scale, cost, and repeatability? Better, faster, cheaper Manufacturing Processes What processes should you use? Design for manufacturability How do you design so it is easily made/assembled?
METAL CASTING AND POWDER PROCESSES CASTING CASTING OF INGOTS CONTINUOUS CASTING SAND CASTING SHELL MOLDING SLURRY MOLDING INVESTMENT CASTING (LOW-WAX PROCESS) EVAPORATIVE CASTING DIE CASTING (GRAVITY-FEED, PRESSURIZED) CENTRIFUGAL CASTING SQUEEZE CASTING RHEOCASTING CRYSTAL GROWING CRYSTAL-PULLING ZONE MELTING Electro forming Plasma Spraying POWDER METALLURGY PRESSING ISOSTATIC PRESSING SINTERING JOINING PROCESSES MECHANICAL JOINING BOLTS, SCREWS, RIVETS SOLID-STATE WELDING DIFFUSION, FORGING, FRICTION, DEFORMATION LIQUID STATE WELDING RESISTANCE WELDING ARC WELDING THERMAL WELDING HIGH-ENERGY BEAM WELDING ELECTRONIC BEAM, LASER LIQUID-SOLID STATE BONDING BRAZING SOLDERING ADHESIVE BONDING PLASTICS AND COMPOSITES JOINING (MECHANICAL, HEATING, SOLVENTS, ULTRASONICS) MACHINING PROCESSES SINGLE POINT MACHINING TURNING BORING FACING FORMING SHAPING,PLANNING MULTIPOINT MACHINING DRILLING MILLING SAWING, FILING BROACHING, THREAD CUTTING, GRINDING SURFACE GRINDING CYLINDRICAL GRINDING CENTERLESS GRINDING INTERNAL GRINDING FORM GRINDING ABRASIVE WIRE CUTTING HONING LAPPING ULTRASONIC MACHINING BUFFING, POLISHING BURNISHING TUMBLING GRIT BLASTING CHEMICAL MACHINING ENGRAVING CHEMICAL MILLING CHEMICAL BLANKING ELECTROCHEMICAL MACHINING ELECTRICAL DISCHARGE MACHINING LASTER MACHINING ELECTRON BEAM MACHINING PLASMA-ARC CUTTING FLAME CUTTING, WATER JET CUTTING DEFORMATION PROCESSES OPEN-DIE FORGING IMPRESSION-DIE FORGING CLOSED-DIE FORGING PRECISION OR FLASHLESS FORGING COINING HEADING, PIERCING, HUBBING, COGGING, FULLERING, EDGING, ROLL FORGING, SKEW ROLLING ROLLING FLAT, RING, THREAD, GEAR, PIERCING EXTRUSION DIRECT, INDIRECT HYDROSTATIC, IMPACT, BACKWARD DRAWING ROD & WIRE, FLAT STRIP, TUBES SWAGING SHEARING BENDING PRESS-BRAKE FORMING, ROLL FORMING TUBE FORMING BEADING, FLANGING, HEMMING, SEAMING STRECH FORMING BULGING DEEP DRAWING PRESS FORMING RUBBER FORMING SPINNING EXPLOSIVE FORMING ELECTROHYDRAULIC FORMING MAGNETIC-PULSE FORMING SUPERPLASTIC FORMING Source: Gutowski Manufacturing process (page 1)
MICROELECTRONICS PROCESSING CRYSTAL GROWTH CZOCHRALSKI CRYSTAL GROWTH FLOAT-ZONE CRYSTAL GROWTH WAFER PROCESSING SLICING, ETCHING, POLISHINNG SURFACE PROCESSES CHEMICAL VAPOR DEPOSITION (CVD) EPITAXIAL FILM GROWTH POLY CRYSTALLINE FILM GROWTH S102 FILMS OTHER (DIELECTRICS, METALS) OXIDATION ION IMPLANTATION PHYSICAL VAPOR DEPOSITION SPUTTERING EVAPORATION LITHOGRAPHY PHOTORESIST ELECTRON BEAM, X-RAY, ION BEAM LITHOGRAPHY WET ETCHING CHEMICAL DRY ETCHING PLASMA SPUTTER REACTIVE ION PACKAGING DICING DIE ATTACHMENT WIRE BONDING ENCAPSULATION POLYMER PROCESSES EXTRUSION FIBER SPINNING CALANDERING FILM BLOWING COATING (MELTS, SOLUTION, PLASMA, ELECTROSTATIC, PLASTISOL, UV CURABLE) BLOW MOLDING INJECTION MOLDING REACTION INJECTION MOLDING (RIM) COMPRESSION MOLDING TRANSFER MOLDING CASTING THERMOFORMING ROTATIONAL MOLDING SOLID STATE FORMING MACHINING ETCHING SOLVENT PROCESSING FOAMING BONDING IMPREGNATING PAINTING COMPOSITES PROCESSES (POLYMER COMPOSITES) PULTRUSION FILAMENT WINDING PULL FORMING BRAIDING AUTOCLAVE MOLDING COMPRESSION MOLDING (SMC) RESIN TRANSFER MOLDING AUTOCOMP MOLDING HAND LAY-UP SPRAY-UP AUTOMATIC TAPE LAY-UP STAMPING DIAPHGRAM FORMING INJECTION MOLDING (FILLED THERMOPLASTICS, BMC) REINFORCED REACTION INJECTION MOLDING (RRIM) (METAL MATRIX COMPOSITES) HOT PRESSURE BONDING HOT ISOSTATIC PRESSING LIQUID METAL INFILTRATION ELECTRODEPOSITION PLASMA SPRAY DEPOSITION CERAMICS PROCESSES POWER PROCESSES CONSOLIDATION SINTERING MELT PROCESSES CRYSTALLINE MATERIALS (SILICON) GLASSES DRAWING, CASTING, BLOWING, TEMPERING (OPTICAL & STRUCTURAL FILTERS) COATING SOL-GEL CERAMICS PROCESSING Source: Gutowski Manufacturing process (page 2)
Materials used in a car Source: K. H. Grote
Effect of manufacturing on geometry Source: Magrab
Performance measures What makes a good manufacturing process? Rate Material flow through system Time Order to receipt Setup time + part process time Cost Material + Labor + Tooling + Equipment Quality Deviation from target Source: Gutowski
Manufacturing processes 1. Subtractive Material removal 2. Additive Material addition, often in layers 3. Continuous Continuous output (wire, rod) 4. Net shape Output is the same as (or near) final shape Source: Gutowski
1. Subtractive Processes Machining Turning milling boring grinding Non-traditional machining Chemical milling Waterjet machining Micro-electronics processes etching processes using either masks or beam
Milling Basic Types of Milling Cutters and Operations Source: K. H. Grote and Kalpakjian
Non-traditional machining Laser machining Waterjet machining Source: K. H. Grote
2. Additive Processes Joining Welding, soldering, adhering Rapid Prototyping/Layered manufacturing Stereolithography, 3D printing Composites
Welding Shielded Metal-Arc Welding Process. 50% of all industrial welding employs this. Source: K. H. Grote
Stereolithography (SLA) Photopolymers are exposed by laser and cured from a liquid to a solid. Source: http://cybercut.berkeley.edu/mas2/html/processes/stereolith/more.html
3D printing Thin layer of powder spread over surface Like an ink-jet printer, binder material selectively joins particles to form the object Source: http://web.mit.edu/tdp/www/whatis3dp.html
From: http://web.mit.edu/tdp/www/applications.html
Composites Hand lay-up of layers of resin and fiber. Lightweight & strong, but process is labor intensive. Source: http://www.saint-gobain-vetrotex.com.br/process_handlay.htm#01
3. Continuous Processes Extrusion of metals Plastic Extrusion Pultrusion of composites
Metal extrusion Direct extrusion Indirect Hydrostatic Source: K. H. Grote and Kalpakjian
Plastic extrusion Source: http://www.telfordsmith.com.au/products/
Pultrusion For composites Fiber reinforcing material is pulled through resin bath and into a die. Source: http://users.techline.com/lord/manu.html
4. Net Shape forming Solids Metal Forming stamping, forging Powders Liquids Casting Injection Molding, thermoforming, blow molding Mixtures Infiltration Viscoelastics Tolerances not as tight
Drawing and stretching Sheet metal From: http://www.tms.org/pubs/journals/JOM/9911/Hosford-9911-figure1.html
Forging Metal workpiece pressed under great pressure into high strength parts Closed die forging workpiece From: http://www.forging.org/facts/idproc.htm
Investment/lost wax Casting A wax pattern is surrounded with investment material (sand), baked out, then metal is poured in the cavity. 1. Create wax pattern 2. Assemble patterns 3. Apply investment 4. Dewax 5. Fill shell 6. Knockout 7. Cutoff 8. Finished castings From: http://www.hitchiner.com/home.html
Compression Molding Rubber trivet Source: Byars 1998
1. Compression molding machine 2. Slabs of HTV silicone rubber 3. Trim excess 4. Finished trivets
Injection Molding From: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm
Injection molding example Cutlery made of biodegradable starch Source: Byars 1998
1. Starch 2. Pellets are formed 3. Injection molded forks on stem 4. Decomposing cutlery
Thermoforming Very inexpensive for low volumes Plastic sheet From: http://www.kenplas.com/topic/thermoforming.aspx Pattern

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Manufacturing

  • 2. Context: Prototype vs. Product Toy RC car Product 5,000 $5-10 Little Automobile Product 10,000 $10,000+ Very little ME72 Device Prototype Quantity 1 $200 in parts + your effort Mfg. cost Variability Can be a lot
  • 3. Prototype -> Product Prototypes are one-offs Products are to be manufactured What if someone wanted you to make 1,000 of your device for $50 each? What would you change? How do you make it to meet scale, cost, and repeatability? Better, faster, cheaper Manufacturing Processes What processes should you use? Design for manufacturability How do you design so it is easily made/assembled?
  • 4. METAL CASTING AND POWDER PROCESSES CASTING CASTING OF INGOTS CONTINUOUS CASTING SAND CASTING SHELL MOLDING SLURRY MOLDING INVESTMENT CASTING (LOW-WAX PROCESS) EVAPORATIVE CASTING DIE CASTING (GRAVITY-FEED, PRESSURIZED) CENTRIFUGAL CASTING SQUEEZE CASTING RHEOCASTING CRYSTAL GROWING CRYSTAL-PULLING ZONE MELTING Electro forming Plasma Spraying POWDER METALLURGY PRESSING ISOSTATIC PRESSING SINTERING JOINING PROCESSES MECHANICAL JOINING BOLTS, SCREWS, RIVETS SOLID-STATE WELDING DIFFUSION, FORGING, FRICTION, DEFORMATION LIQUID STATE WELDING RESISTANCE WELDING ARC WELDING THERMAL WELDING HIGH-ENERGY BEAM WELDING ELECTRONIC BEAM, LASER LIQUID-SOLID STATE BONDING BRAZING SOLDERING ADHESIVE BONDING PLASTICS AND COMPOSITES JOINING (MECHANICAL, HEATING, SOLVENTS, ULTRASONICS) MACHINING PROCESSES SINGLE POINT MACHINING TURNING BORING FACING FORMING SHAPING,PLANNING MULTIPOINT MACHINING DRILLING MILLING SAWING, FILING BROACHING, THREAD CUTTING, GRINDING SURFACE GRINDING CYLINDRICAL GRINDING CENTERLESS GRINDING INTERNAL GRINDING FORM GRINDING ABRASIVE WIRE CUTTING HONING LAPPING ULTRASONIC MACHINING BUFFING, POLISHING BURNISHING TUMBLING GRIT BLASTING CHEMICAL MACHINING ENGRAVING CHEMICAL MILLING CHEMICAL BLANKING ELECTROCHEMICAL MACHINING ELECTRICAL DISCHARGE MACHINING LASTER MACHINING ELECTRON BEAM MACHINING PLASMA-ARC CUTTING FLAME CUTTING, WATER JET CUTTING DEFORMATION PROCESSES OPEN-DIE FORGING IMPRESSION-DIE FORGING CLOSED-DIE FORGING PRECISION OR FLASHLESS FORGING COINING HEADING, PIERCING, HUBBING, COGGING, FULLERING, EDGING, ROLL FORGING, SKEW ROLLING ROLLING FLAT, RING, THREAD, GEAR, PIERCING EXTRUSION DIRECT, INDIRECT HYDROSTATIC, IMPACT, BACKWARD DRAWING ROD & WIRE, FLAT STRIP, TUBES SWAGING SHEARING BENDING PRESS-BRAKE FORMING, ROLL FORMING TUBE FORMING BEADING, FLANGING, HEMMING, SEAMING STRECH FORMING BULGING DEEP DRAWING PRESS FORMING RUBBER FORMING SPINNING EXPLOSIVE FORMING ELECTROHYDRAULIC FORMING MAGNETIC-PULSE FORMING SUPERPLASTIC FORMING Source: Gutowski Manufacturing process (page 1)
  • 5. MICROELECTRONICS PROCESSING CRYSTAL GROWTH CZOCHRALSKI CRYSTAL GROWTH FLOAT-ZONE CRYSTAL GROWTH WAFER PROCESSING SLICING, ETCHING, POLISHINNG SURFACE PROCESSES CHEMICAL VAPOR DEPOSITION (CVD) EPITAXIAL FILM GROWTH POLY CRYSTALLINE FILM GROWTH S102 FILMS OTHER (DIELECTRICS, METALS) OXIDATION ION IMPLANTATION PHYSICAL VAPOR DEPOSITION SPUTTERING EVAPORATION LITHOGRAPHY PHOTORESIST ELECTRON BEAM, X-RAY, ION BEAM LITHOGRAPHY WET ETCHING CHEMICAL DRY ETCHING PLASMA SPUTTER REACTIVE ION PACKAGING DICING DIE ATTACHMENT WIRE BONDING ENCAPSULATION POLYMER PROCESSES EXTRUSION FIBER SPINNING CALANDERING FILM BLOWING COATING (MELTS, SOLUTION, PLASMA, ELECTROSTATIC, PLASTISOL, UV CURABLE) BLOW MOLDING INJECTION MOLDING REACTION INJECTION MOLDING (RIM) COMPRESSION MOLDING TRANSFER MOLDING CASTING THERMOFORMING ROTATIONAL MOLDING SOLID STATE FORMING MACHINING ETCHING SOLVENT PROCESSING FOAMING BONDING IMPREGNATING PAINTING COMPOSITES PROCESSES (POLYMER COMPOSITES) PULTRUSION FILAMENT WINDING PULL FORMING BRAIDING AUTOCLAVE MOLDING COMPRESSION MOLDING (SMC) RESIN TRANSFER MOLDING AUTOCOMP MOLDING HAND LAY-UP SPRAY-UP AUTOMATIC TAPE LAY-UP STAMPING DIAPHGRAM FORMING INJECTION MOLDING (FILLED THERMOPLASTICS, BMC) REINFORCED REACTION INJECTION MOLDING (RRIM) (METAL MATRIX COMPOSITES) HOT PRESSURE BONDING HOT ISOSTATIC PRESSING LIQUID METAL INFILTRATION ELECTRODEPOSITION PLASMA SPRAY DEPOSITION CERAMICS PROCESSES POWER PROCESSES CONSOLIDATION SINTERING MELT PROCESSES CRYSTALLINE MATERIALS (SILICON) GLASSES DRAWING, CASTING, BLOWING, TEMPERING (OPTICAL & STRUCTURAL FILTERS) COATING SOL-GEL CERAMICS PROCESSING Source: Gutowski Manufacturing process (page 2)
  • 6. Materials used in a car Source: K. H. Grote
  • 7. Effect of manufacturing on geometry Source: Magrab
  • 8. Performance measures What makes a good manufacturing process? Rate Material flow through system Time Order to receipt Setup time + part process time Cost Material + Labor + Tooling + Equipment Quality Deviation from target Source: Gutowski
  • 9. Manufacturing processes 1. Subtractive Material removal 2. Additive Material addition, often in layers 3. Continuous Continuous output (wire, rod) 4. Net shape Output is the same as (or near) final shape Source: Gutowski
  • 10. 1. Subtractive Processes Machining Turning milling boring grinding Non-traditional machining Chemical milling Waterjet machining Micro-electronics processes etching processes using either masks or beam
  • 11. Milling Basic Types of Milling Cutters and Operations Source: K. H. Grote and Kalpakjian
  • 12. Non-traditional machining Laser machining Waterjet machining Source: K. H. Grote
  • 13. 2. Additive Processes Joining Welding, soldering, adhering Rapid Prototyping/Layered manufacturing Stereolithography, 3D printing Composites
  • 14. Welding Shielded Metal-Arc Welding Process. 50% of all industrial welding employs this. Source: K. H. Grote
  • 15. Stereolithography (SLA) Photopolymers are exposed by laser and cured from a liquid to a solid. Source: http://cybercut.berkeley.edu/mas2/html/processes/stereolith/more.html
  • 16. 3D printing Thin layer of powder spread over surface Like an ink-jet printer, binder material selectively joins particles to form the object Source: http://web.mit.edu/tdp/www/whatis3dp.html
  • 18. Composites Hand lay-up of layers of resin and fiber. Lightweight & strong, but process is labor intensive. Source: http://www.saint-gobain-vetrotex.com.br/process_handlay.htm#01
  • 19. 3. Continuous Processes Extrusion of metals Plastic Extrusion Pultrusion of composites
  • 20. Metal extrusion Direct extrusion Indirect Hydrostatic Source: K. H. Grote and Kalpakjian
  • 21. Plastic extrusion Source: http://www.telfordsmith.com.au/products/
  • 22. Pultrusion For composites Fiber reinforcing material is pulled through resin bath and into a die. Source: http://users.techline.com/lord/manu.html
  • 23. 4. Net Shape forming Solids Metal Forming stamping, forging Powders Liquids Casting Injection Molding, thermoforming, blow molding Mixtures Infiltration Viscoelastics Tolerances not as tight
  • 24. Drawing and stretching Sheet metal From: http://www.tms.org/pubs/journals/JOM/9911/Hosford-9911-figure1.html
  • 25. Forging Metal workpiece pressed under great pressure into high strength parts Closed die forging workpiece From: http://www.forging.org/facts/idproc.htm
  • 26. Investment/lost wax Casting A wax pattern is surrounded with investment material (sand), baked out, then metal is poured in the cavity. 1. Create wax pattern 2. Assemble patterns 3. Apply investment 4. Dewax 5. Fill shell 6. Knockout 7. Cutoff 8. Finished castings From: http://www.hitchiner.com/home.html
  • 27. Compression Molding Rubber trivet Source: Byars 1998
  • 28. 1. Compression molding machine 2. Slabs of HTV silicone rubber 3. Trim excess 4. Finished trivets
  • 29. Injection Molding From: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm
  • 30. Injection molding example Cutlery made of biodegradable starch Source: Byars 1998
  • 31. 1. Starch 2. Pellets are formed 3. Injection molded forks on stem 4. Decomposing cutlery
  • 32. Thermoforming Very inexpensive for low volumes Plastic sheet From: http://www.kenplas.com/topic/thermoforming.aspx Pattern