Industrial & Manufacturing Engineering Department IME 144 INTRODUCTION TO DESIGN & MANUFACTURING Lecture #01 Course Introduction, Manufacturing, Engineering Drawings, & Basic Measurement Tools! Week #1 Industrial & Manufacturing Engineering Department IME 144 Class Overview & Syllabus • Lecture & Lab Overview • Office Hours • Lab Manual Info • Assignment Overview 1 Industrial & Manufacturing Engineering Department Manufacturing • Textbook Definition of manufacturing • The application of physical and chemical processes to alter the geometry, properties, and or appearance of a given material to make parts or products; manufacturing also includes the joining of multiple parts to make assembled cars, planes, food, etc products. • Economic Viewpoint: • The transformation of materials into items of greater value by means of one or more processing or assembly operations. Industrial & Manufacturing Engineering Department Manufacturing Industries • ________________ primary • Those that cultivate and exploit natural resources pull materials from the Earth secondary • ________________ • Convert primary industry outputs into products tertiary • ________________ • Service sector of the economy 3 Industrial & Manufacturing Engineering Department Manufacturing • ________________ Products discrete • Individual Items Industrial & Manufacturing Engineering Department Manufacturing continuous • ________________ Products (not in units) 4 Industrial & Manufacturing Engineering Department Manufacturing Processes • In order to convert raw materials into products four different activities must occur in the factory: processing • ________________ and Assembly Operations material handling • ________________ <-- flow/movement of inspection • ________________ and stuff thru the "factory" Testing coordination • ________________ and Control Industrial & Manufacturing Engineering Department Processing Operations • Use ________________, thermal electrical or mechanical chemical energy to add value to a material • Solidification process • Deformation process • Particulate processing • Material removal process 5 Industrial & Manufacturing Engineering Department MFG Processes • Casting Processes • Expendable Mold & Permanent Mold • Bulk Deformation Processes • Rolling, Forging, Extrusion, Joining Processes Fusion Welding, Other Welding, Fastening & Bonding Machining Processes Focus of IME 144 & Drawing • Sheetmetal Forming Processes • Shearing, Bending, Drawing, & Forming • Manufacturing processes decisions are driven by engineering drawings and economics! • Polymer Processing Processes • Thermoplastics, Thermosets, RP Methods Industrial & Manufacturing Engineering Department Machining Processes machining • ________________ is a group of processes that consist of the removal of material and modification of the surfaces of a work piece. • Parts created with casting, forming, and shaping sometimes require machining. • Secondary & Finishing Mfg Processes 6 Industrial & Manufacturing Engineering Department Machining Operations • Machining is the process of removing unwanted material from a work piece in the form of chips ________________. • Often called metal cutting or metal removal. • The US spends more than $60 billion dollars each year performing machining operations. U.S. machining industry valued around $40 billion dollars Industrial & Manufacturing Engineering Department Machining Material Removal Processes https://www.youtube.com/watch?v=dsSo5qOGk6c https://www.youtube.com/watch?v=A49l8ljcPis 7 Industrial & Manufacturing Engineering Department Machining • Tolerances can be in the ten thousandths of an inch. (.0001) • Machining is the most important of the basic manufacturing processes. • Machining produces chips using a few different chip formation processes. turning • ________________ milling • ________________ • ________________ drilling • ________________ sawing • ________________ broaching Industrial & Manufacturing Engineering Department Inspection and Testing • Purpose of testing is to ensure that the product meets all of the established design standards and specifications. • Tolerances • Quality Control & (SPC) • Where do we get the inspection data (tolerances) from? 8 Industrial & Manufacturing Engineering Department Manufacturing Processes & Engineering Drawings (How are they related?) Industrial & Manufacturing Engineering Department Multiview Drawing The majority of engineered parts require the specification of measurements, sizes, and allowable errors of features on the parts. Engineers need to be able to specify part sizes so that everything fits together and functions as intended. 9 Industrial & Manufacturing Engineering Department Multiview Drawing This specification must be completed before the parts can be ________________. manufactured Procedures for size specification must be followed to ensure these specifications can be easily interpreted, checked, and controlled for proper function of the parts. Industrial & Manufacturing Engineering Department Multiview Drawing When an engineer is presented with a formal engineering drawing, whether it is a mechanical device or a construction project, that engineer must be able to read all of its contents correctly. Drawings ________________ are legal documents and, as such, are required to contain certain information to ensure that the creators and the receivers interpret them properly. 10 Industrial & Manufacturing Engineering Department Multiview Drawing Guidelines must be followed to ensure that completed drawings are created, updated, and approved in a manner that establishes a line of accountability. Industrial & Manufacturing Engineering Department Creating a Multi View Drawing 1ST ANGLE PROJECTIONS VS. 3RD ANGLE PROJECTIONS ISO VS. ANSI 11 Industrial & Manufacturing Engineering Department Multiview Drawing • Multiview drawings are also called orthographic projection drawings. • Orthographic projection is the process of explaining three-dimensional objects in two-dimensions. • Multiview drawings typically three have ____________ views, but may have as many as four or more for complex objects. • ________ angle projections first are used mainly in Europe. third • ________angle projections are mainly used in the US. Industrial & Manufacturing Engineering Department Orthographic Projection • A Drawing representation of the separate views of an object on a two-dimensional surface. It shows the width, depth and height of an object • There are three principal or coordinate planes of projection that are typically used in orthographic projection • Frontal plane shows front view • Horizontal plane projection is called the top view • Profile plane projections are called the side views 12 Industrial & Manufacturing Engineering Department Creating Dimensions • There are three types of dimensions on engineering drawings: linear dimensions • ________________ angle dimensions • ________________ notes • ________________ Industrial & Manufacturing Engineering Department Dimensioning Fundamentals size • The process of defining the ________, form and location _________ of geometric components on engineering and or architectural drawings. 13 Industrial & Manufacturing Engineering Department Dimensioning Fundamentals • Unidirectional System • All dimension figures are placed to be read from the bottom of the drawing upwards. • All dimensions are ________________. horizontal • This is the recommended ______ ANSI industry standard. Industrial & Manufacturing Engineering Department Dimensioning Fundamentals 14 Industrial & Manufacturing Engineering Department Dimensioning Fundamentals extension lines • ________________ : • Used to indicate the termination of a dimension. • They are usually drawn perpendicular to the dimension line with a visible gap of approximately 1/8 inch beyond the dimension line. • When used to locate a point, they must pass through the point. Industrial & Manufacturing Engineering Department Dimensioning Fundamentals leader lines • ________________: • Thin straight lines that lead from a note or dimension to a feature on the drawing ending in either an arrowhead or dot. • ________________ : arrowheads • Used to terminate leaders that that end at a specific point or outside edge of the part. • The dimension or note end of the leader has a horizontal bar approximately 1/8 inch in length. • The leader angle should be between 45̊ and 60̊ and should never be drawn parallel to extension or dimension lines. 15 Industrial & Manufacturing Engineering Department Dimensioning Fundamentals • ________________ Dimensioning: Chain • Dimensioning a series of features, such as holes, from point to point. • When these dimensions are toleranced, overall variations of the features may occur that exceed the tolerances specified. Industrial & Manufacturing Engineering Department Dimensioning Fundamentals • ________________ Dimensioning: Datum • Also called base line dimensioning, features are dimensioned individually from a datum. • This system of dimensioning avoids accumulation of tolerances from feature to feature. • Where the distance between two features must be closely controlled, without the use of an extremely small tolerance, datum dimensioning should be used. • Used for absolute positioning CNC operations. 16 Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Tolerance Stacking! Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Do not duplicate a dimension! 17 Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Dimensioning _________ & ________! arcs holes From the middle points of the holes Use diameter dimension for full circles Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Dimensioning Holes & Arcs! Don't dimension to "middle of nowhere" 18 Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Dimensioning Holes! counterbore countersink Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Locating Hole Position! Every hole needs x + y dimension and size 19 Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Dimensioning Positive Cylinders & Holes! Place the dimension where you can see the feature best Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Dimensioning Chamfers! Rounded edge = fillet 45 degree edge = chamfer 20 Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Contour Dimensioning! Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Dimensioning Threads! 21 Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Dimensioning Threads! thread callout Industrial & Manufacturing Engineering Department Dimensioning Fundamentals Hidden Do Not Dimension to ____________ Lines! 22 Industrial & Manufacturing Engineering Department Tolerances • Conventional Tolerancing: • The control of dimensions having a range of acceptable sizes that are within a “zone.” • This zone depends on the function of the part. • Design Intent Industrial & Manufacturing Engineering Department Drawing Tolerance Formats for Tolerances! decimal places should match 23 Industrial & Manufacturing Engineering Department Dimensions and Tolerances Nominal Dimension of 2.500 Bilateral Tolerance Unilateral Tolerance Limit Dimensions Figure 5.1 Industrial & Manufacturing Engineering Department Conventional Tolerances 24 Industrial & Manufacturing Engineering Department Working Drawing Sizes • American National Standard (ANSI) • A – 8.50” x 11.00” • B – 11.00” x 17.00” • C – 17.00” x 22.00” • D – 22.00” x 34.00” • E – 34.00” x 44.00” • International Standard (ISO) • A4 – 210mm x 297mm • A3 – 297mm x 420mm • A2 – 420mm x 594mm • A1 – 594mm x 841mm • A0 – 841mm x 1189mm Industrial & Manufacturing Engineering Department Working Drawings 25 Industrial & Manufacturing Engineering Department Working Drawings • Title Block Elements Industrial & Manufacturing Engineering Department Geometric Dimensioning & Tolerancing 26 Industrial & Manufacturing Engineering Department Geometric Dimensioning & Tolerancing Feature control • _______________Frame: • The means by which a geometric tolerance is specified for an individual feature. • The frame is divided into compartments containing, in order from the left, the geometric characteristic symbol ________________ followed by the tolerance. • Where applicable, the tolerance is preceded by the diameter or radius symbol and followed by an appropriate material condition symbol. Industrial & Manufacturing Engineering Department Geometric Dimensioning & Tolerancing 27 Industrial & Manufacturing Engineering Department Working Drawings parallel within 2 thousandths w/respect to A Industrial & Manufacturing Engineering Department Working Drawings circle must be round within 3 thousandths of an inch 28 Industrial & Manufacturing Engineering Department METROLOGY science/study Metrology is the _____________ of measurement. Measurement is a procedure where : • • an unknown quantity is compared to a known standard, using an accepted and consistent system of units. numerical Measurement produces a ________________ value of the quantity of interest, within certain limits of accuracy and precision. Industrial & Manufacturing Engineering Department ACCURACY VS. PRECISION Accuracy ________________ The degree to which the measured value agrees with the true value or against the standard. Instrument must be maintained by proper and regular calibration. ________________ (repeatability) Precision is achieved by selecting the proper instrument technology for the application. Rule of 10 – the measuring device must be ten times more precise than the specified tolerance. 29 Industrial & Manufacturing Engineering Department INSPECTION Inspection involves the use of measurement and gaging techniques to determine whether a product, its components, subassemblies, or starting materials conform to design specifications. 1. ________________ Inspection – dimensions are Variables measured by measuring instruments for length quantities 2. ________________ Inspection – gauged to determine Attributes whether or not parts are within tolerance limits. - (Go / No-Go Gage) – Done quickly at a low cost - Covered Later in Lecture & Lab Industrial & Manufacturing Engineering Department Micrometers • Reading a Micrometer 30 Industrial & Manufacturing Engineering Department Vernier Calipers • Reading a Vernier Caliper http://www.phy.ntnu.edu.tw/ntnujava/viewtopic.php?t=69 Industrial & Manufacturing Engineering Department Dial Calipers • Reading a Dial Caliper http://www.phy.ntnu.edu.tw/ntnujava/viewtopic.php?t=69 https://www.youtube.com/watch?v=1qy3PzrxX4o 31 Industrial & Manufacturing Engineering Department Dial Calipers • Reading a Digital Caliper http://www.phy.ntnu.edu.tw/ntnujava/viewtopic.php?t=69 Industrial & Manufacturing Engineering Department SolidWorks Overview • Canvas Tutorials! • Design Parts • Assemble Parts • Virtually Test Parts • Part Drawings • Program CNC Machines to Make Parts. • Perform First Article Inspection Reports https://www.youtube.com/watch?v=4jbn0ah3u9E&t=14s 32 Industrial & Manufacturing Engineering Department Questions? 33
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