Tài liệu 01 introduction

ADVANCED MANUFACTURING ENGINEERING 1: Introduction to Manufacturing Engineering December 2016 Module Schedule Day Monday Date Topic 12/12/2016 Introduction to Manufacturing Engineering Health and Safety for Engineering Students Mechanical Behaviour Properties of Tuesday 13/12/2016 Materials Wednesday 14/12/2016 Casting Processes and Equipment Thursday 15/12/2016 Metal Forming Processes Friday 16/12/2016 Forging processes Monday 19/12/2016 Rolling, Extrusion, Drawing Processes Tuesday 20/12/2016 Extrusion and drawing Sheet metal forming Wednesday 21/12/2016 Advanced Machining Processes Thursday 22/12/2016 Non-conventional machining processes Joining processes Friday 23/12/2016 Revision, project presentation Activity Type Notes Lecture Lecture Lecture/Exercise Lecture Lecture/Exercise Lecture/Exercise Project brief Lecture/Exercise Lecture/Exercise Lecture/Exercise Lecture Lab Lecture Lecture/Exercise Project presentation Module Assessment Assignments/project Class participation Final exam : : : 20.0 10.0 70. 0 Total marks : 100.0 4 Introduction  The word manufacturing is derived from the Latin “manu factus”, meaning made by hand.  Manufacturing involves making products from raw materials by various processes or operations.  Manufacturing is generally a complex activity, involving people who have a broad range of disciplines and skills with a wide variety of machinery, equipment, tooling with various levels of automation, including computers, robots, and material-handling equipment. 5 What is Manufacturing? • Manufacturing: is a set of correlated operations and activities which includes product design, material selection, planning, production, inspection, management, and marketing of the products, for the manufacturing industries. • Manufacturing is the process of converting raw materials into products. 6 History • The earliest-known stone tools, found in the Olduvai Gorge in what is now Kenya, date from about 2.5m years ago (mya). STONE AGE 7 History • These Oldowan tools (Fig.1) are used for pounding, chopping, cutting and scraping, and made by chipping material away from a found stone ‘core’ to make it more useful — a process we call subtraction. • Subtraction techniques have played a major role in the history of manufacture and continue to do so today, with machining, laser and water jet cutting. History of machine tools 4000 BC: first wooden drilling machine 1452-1519: first deep hole drilling machine was built by Leonardo da Vinci First wooden lathe machine In 1840, the first engine lathe was introduced A completely automatic turret lathe was invented by Spencer in 1896 Wooden planer machine (1855) 8 9 History • The earliest known ceramics (fired clay) are figurines dating from the Gravettian period, about 28,000 ya. • Moulding techniques like pottery always involve an (shapeless) material, a shapegiving step (with hands, a mould or extrusion die for amorphous example) and subsequent conversion to a solid state. • Metal casting which dates from at least 4,800 ya and thermoplastic injection moulding are both also examples of the moulding technique. 10 History BRONZE AND IRON AGE 11 History • The third basic object-making process is forming, where solid material in sheet or billet form is pressed or drawn into the desired shape. • Uses a combination of mechanical force, heat or chemical hardening, often with a tool being employed to define the shape. • Forming probably began at least 8,000 ya with the working of gold or copper (Fig.4), which exist naturally in their elemental state. 12 Summary • These three techniques; – subtraction, – moulding – forming • have dominated object making throughout manufacturing’s long history and are in use today for the majority of part production. 13 Rapid Prototyping • A NEW WAY – Layer Manufacture – Solid Free Form Manufacturing (SFFM), Rapid Prototyping • Many different processes http://youtu.be/flPVHmkosh0 (2min) • All same principle of operation • Design in 3D Computer Aided design system • Export geometry file as a triangle .STL file • Slice in thin vertical sections for slice to build • Build one layer on top of previous layer until part manufactured. 14 Manufacturing activities must be responsive to demands and trends • A product must fully meet design requirements and specifications. • A product must be manufactured by the most economical methods in order to minimise costs. • Quality must be built into the product at each stage, from design to assembly, rather than relying on quality testing after the product is made. • In a highly competitive environment, production methods must be sufficiently flexible so as to respond to changing market demands, types of products, production rates, production quantities, and on-time delivery to the customer. 15 Product cycle Product design and concurrent engineering Product design and concurrent engineering • Concurrent or simultaneous engineering is a systematic approach integrating design and manufacture of products. • It optimizes all elements involved in the life cycle of the product. Design for Manufacture, Assembly, Disassembly & Service • Design for manufacture (DFM) integrates product design process with materials, manufacturing methods, process planning, assembly, testing, and quality assurance. • • •Assembly is an important phase of the overall manufacturing operation. Environmentally Conscious Design, Sustainable Manufacturing & Product Life Cycle • Design for recycling (DFR) and Design for the environment (DFE) anticipates the negative environmental impact during initial stages of design. • The basic guidelines for sustainable manufacturing are: • 1.Reducing waste of materials • 2.Reducing use of hazardous materials • 3.Proper disposal of all waste • 4.Improvements in waste treatment and in recycling 20 Manufacturing activities must be responsive to demands and trends  New developments in materials, production methods, and computer integration of both technological and managerial activities in a manufacturing organization must constantly be evaluated with a view to their timely and economic implementation.  Manufacturing activities must be viewed as a large system, each part of which is interrelated to others. Such systems can be modelled in order to study the effect of factors such as changes in market demands, product design, material and various other costs, and production methods on product quality and cost.  The manufacturing organization must constantly strive for higher productivity, defined as the optimum use of all its resources: materials, machines, energy, capital, labour and technology.