Author:
Richard Wysk
Subject:
Engineering, Manufacturing
Material Type:
Textbook
Level:
Community College / Lower Division, College / Upper Division, Graduate / Professional
Tags:
  • Design Analysis
  • Engineer
  • Engineer Design Process
  • Industrial
  • Manufacture Process
  • Manufacturing and Product Development
  • SLAM
  • License:
    Creative Commons Attribution Non-Commercial
    Language:
    English
    Media Formats:
    eBook, Text/HTML

    Traditional Manufacturing Processes - Chapters

    Traditional Manufacturing Processes - Chapters

    Overview

    The engineer of the year 2020 and beyond will require an increasingly broad set of technical and business skills. Today's technical environment already spans from product development to design to planning for manufacture to manufacture to qualification to marketing and to maintenance of a product. In the future, engineers will also address business requirements to include: marketing, capital equipment justification and procurement, pricing and capitalization. In general, engineers of the future will provide many of the business and technical integration requirements linking engineering and business.  Our focus and presentation of the technologies of engineering will strongly be skewed toward how these activities fit into the manufacturing of a product but also with emphasis of design and planning for manufacturing.  Integration (both functional where design is linked to manufacturing and informational where data is available to everybody) is key to future engineering success.  Our presentation of materials in this repository will be directed toward this vision.

    Chapter 1 Engineering a product

    This chapter provides a general perspective of engineering and the manufacturing life cycle engineering for a typical "durable good" product.  A durable good is a product that is intended for multiple uses and extended service.  Examples of durable goods are automobiles, aircraft, machine tools and coffee makers to name a few.  In the chapter, we describe how product engineering and process engineering affect the factories of today (and of our future) noting the technologies and operations that the current generation of product/ manufacturing/industrial engineers will experience. Manufacturing of the future, like manufacturing of the present and past, will span a broad gamut of activities that will increasingly depend on electronic communication systems. This connectivity will link manufacturers (designers, planners and product on personnel), customers and suppliers so that information processing will become increasingly responsive and effective.

     

    Title of work:  Engineering a Product

     

    Type of material:  Chapter

     

    Principle author(s):  Richard A. Wysk

    Editor(s):  Julie Talbot, Joseph McConnell

    Prerequisite material:  Sophomore engineering understand – Fundamentals of materials, Engineering mechanics, Calculus 1 and 2

     

    Purpose: This material is to introduce the process of how products are engineered.  This chapter introduces the concepts of Product Engineering (Design), Process Engineering (how an engineered product might be manufactured) and Production Engineering (the steps and equipment needed to execute a method of manufacturing).

     

    Use:  This material is Open source educational material.  These materials may be adopted for any learning (non-commercial) activities.  Future contributors may use these materials as foundation for their new methods or materials.  This “Open use” is predicated on the improved/extended material being returned to the SLAM repository so that the material will continue to grow.

    Section 1 Powerpoint Presentation -- Engineering a product

    The attached is a generic slide presentation for "Engineering a product".  This presentation can be copied and improved.  If you add or edit slides, please redeposit them into the SLAM repository so that all materials can be kept up to date.

    Chapter 2 Product specification

    SLAM Data Sheet

     

    Title of work:  Engineering Specification and Qualification

     

    Type of material:  Chapter

     

    Principle author(s):  Richard A. Wysk

    Editor(s):  Joseph McConnell, Julie Talbot

     

    Prerequisite material:  Sophomore engineering understand – Fundamentals of materials, Engineering mechanics, Calculus 1 and 2

     

    Purpose: This material is intended to introduce the process of how products are engineered.  This chapter illustrates Product Engineering (Design) activities and the phases of product engineering, A transition into Process Engineering (how an engineered product might be manufactured) is provided and the concept that nothing can be manufactured perfectly is introduced.  The concept of tolerance is introduced for geometric design and the reader is introduced to ASME Y14.5 product design standards and interpretation.  and Production Engineering (the steps and equipment needed to execute a method of manufacturing).

     

    Use:  This material is Open source educational material.  These materials may be adopted for any learning (non-commercial) activities.  Future contributors may use these materials as foundation for their new methods or materials.  This “Open use” is predicated on the improved/extended material being returned to the SLAM repository so that the material will continue to grow.

    Chapter 3 - Process Planning and Economics of Manufacturing

    The importance of integrating product design and process design cannot be over emphasized. However, even once a design has been finalized, today's manufacturing industries must be willing to accommodate their customers by allowing for last‑minute engineering design changes without affecting their shipping schedule or altering their product quality.

    Chapter 4 - Materials Properties and Behaviors

    Part I of this text deals with materials- their structure, properties, heat treating, and applications.  The presentation is intended as a review of these topics and as such looks primarily at the information needed to understand how to design products and process materials effectively.

    Chapter 5 - Polymer Processes

    We have learned that plastics are important polymers. In this text, the term plastics has been applied to those synthetic non metallic materials that can be made sufficiently fluid to be shaped readily by casting, molding or extruding and that may be hardened subsequently to preserve the desired shape.

    Chapter 6 - Fundamentals of Machining

    In many cases, products from primary processes including: castings, forgings, bar stock and plates must undergo further refinements in size and surface finish to meet their design specifications.  To meet precise tolerances, we must remove small amounts of material.  We generally use machine tools for these operations, and metals are often the material chosen for the product design because of their mechanical properties and ease of shaping.  In the United States, material removal is big business.

    Chapter 7 - Production Processes

    In this chapter we will study basic machining operations including: machine tools, cutting tool geometries, capabilities, and how to plan for these operations.  One way to think about the variety of processes and tools presented in this chapter is to consider that an industrial or manufacturing engineer is frequently faced with the challenge of taking a material in its initial state (perhaps as a casting or forging), and selecting the individual operations (and order) necessary to have it eventually correspond with the final specification for that part.

    Chapter 8 - Sheet Metal Processes

    In sheet processes, we are working with metal in sheet form and are transforming it geometrically by both cutting (blanking or punching) and forming processes. Thus, the input material is either formed geometry or sheared to some required configuration.  The input metal can be both formed and sheared to the required specifications.

    Chapter 9 - Chipless Manufacturing

    Material removal from ductile materials can be accomplished by using a tool that is harder than the  depends upon chemical dissolution. The first group consists of electric discharge machining (EDM), electrochemi¬cal machining (ECM), electron beam machining (EBM), laser beam machin-ing (LBM), and ultrasonic machining (USM). The second includes chemical milling. These processes are useful for machining hard materials because they depend on the physical and chemical properties of a material not its mechanical properties. The designation chipless machining has been chosen deliberately because the methods used are in direct contrast to chip producing methods of machining.

    Chapter 10 - Process Engineering

    Process Engineering is squeezed in between Product Engineering and Production Engineering, and serves to define how a product will be produced.  Our discussion will focus on mechanical components, but all products (electrical, chemical, food, etc.) go through the same process engineering cycle.  Unfortunately, the technological details for the type of product dictate much concerning how the product will be produced, and discussing all products and processes is far beyond the scope of this book and chapter so we will illustrate the process engineering process for mechanical metal components.