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授課教師：楊宏智教授
MANUFACTURING ENGINEERING TECHNOLOGY
GENERAL INTRODUCTION
1
MANUFACTURING ENGINEERING
TECHNOLOGY
機械製造
楊宏智（台大機械系教授）
2
CHAPTER OUTLINE
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2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
What Is Manufacturing?
Product Design and Concurrent Engineering
Design for Manufacture, Assembly, Disassembly, and Service
Green Design and Manufacturing
Selection of Materials
Selection of Manufacturing Processes
Computer-integrated Manufacturing
Quality Assurance and Total Quality Management
Lean Production and Agile Manufacturing
Manufacturing Costs and Global Competition
General Trends in Manufacturing
3
WHAT IS MANUFACTURING?
 Application of physical and chemical processes to
alter the geometry, properties, and/or appearance of
a starting material to make parts or products.
4
MANUFACTURING - ECONOMIC
 Transformation of materials into items of greater
value by one or more processing and/or assembly
operations.
5
ECONOMIC IMPORTANCE
U.S. Economy
Sector:
%GDP
Agriculture and natural resources
5
Construction and public utilities
5
Manufacturing
15
Service industries
75
100
6
WHAT IS MANUFACTURING?
Products around us consist of numerous individual
pieces that shall be built and assembled:
Clip – one part
Lawn mower – 300 parts
Grand piano – 12,000 parts
Automobile – 15,000 parts
Boeing 747-400 – 6 million parts
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WHAT IS MANUFACTURING?
EXAMPLE 1.1
Paper Clips

Functional and Service Requirement
-Clamping forces (stiffness,strength- permanent deformation; material select: shape and size)
-Corrosion resistance

Style and Cost
-Metallic or plastic? What shape (round or else)? It’s dia? Surface finish?

Production Consideration
-How to shape (hand or machine)? Batch quantity
-Bending without cracking or breaking
-Easily cut without causing excessive wear on tooling
-Produce smooth edge on the wire (burs not desire)
8
What Is Manufacturing?
9
WHAT IS MANUFACTURING?
Example 1.2
Incandescent Light Bulbs
• Component of a common incandescent light bulb
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MANUFACTURING STEPS IN MAKING AN
INCANDESCENT LIGHT BULB (PROD. RATE >1000/MIN)
Filament manufacturing: Tungsten powder (sintering) –
Ingot (swaging) –Rods (drawing)- thin Wire (60W,
0.045 mm dia)
Wire dia. 1%less causes 25% life shortage (heated to
2200 to 3000 C)
Bulb vacuumed or filled w N2 or Argon gas (water drop
causes 0.5m blackened); coil spacing accuracy (heat
concentration); position accuracy – heat deflection
disk, and lead-in wire (Fe+Ni w Cu coating)= glass
thermal expansion coefficient
11
PRODUCT DESIGN AND CONCURRENT ENGINEERING
The Design Process
• Design and manufacturing
activities take place
sequentially
12
PRODUCT DESIGN AND CONCURRENT ENGINEERING
The Design Process
•
It would be more desirable to:
1. Use a different material
2. Use the same material but in a different condition
3. Modify the design of a component
Concurrent Engineering
•
Also called simultaneous engineering
•
From the earliest stages of product design and engineering, all
are simultaneous
13
PRODUCT DESIGN AND CONCURRENT ENGINEERING
Market
Concurrent Engineering
•
Any iterations will require a
smaller effort and less wasted
time would occur
Specification
Concept design
Detail design
Sell
Manufacture
14
PRODUCT DESIGN AND CONCURRENT ENGINEERING
Life Cycle
• Life cycle of a new product consists of:
1. Product start-up
2. Rapid growth of the product in the marketplace
3. Product maturity
4. Decline
•
Life-cycle engineering requires that the entire life of a
product be considered
15
PRODUCT DESIGN AND CONCURRENT ENGINEERING
Role of Computers in Product Design
•
Product models are simplified through computeraided design (CAD) and computer-aided
engineering (CAE) techniques
•
CAD systems are capable of rapid and complete
analysis of designs
•
This is the process known as paperless design
•
Performance of structures can be analysed
16
PRODUCT DESIGN AND CONCURRENT ENGINEERING
Role of Computers in Product Design (Con’t)
•
Computer-aided manufacturing involves all phases
of manufacturing
•
Performing tasks such as:
1. Programming for numerical control machines
2. Designing tools, dies, moulds, fixtures, and workholding devices
3. Maintaining quality control
17
PRODUCT DESIGN AND CONCURRENT ENGINEERING
Prototypes
•
A prototype is a physical model of an individual
component or product
•
Rapid prototyping use CAD/CAM and various
specialized technologies
•
Prototypes developed can review for
possible modifications to the original
design, materials, or production methods
18
PRODUCT DESIGN AND CONCURRENT ENGINEERING
Virtual Prototyping
•
It is a software-based method that uses advanced
graphics and virtual-reality environments
•
To allow designers to view and examine a part in detail
•
Also known as simulation-based design
19
DESIGN FOR MANUFACTURE, ASSEMBLY, DISASSEMBLY, AND
SERVICE
•
Design for manufacture (DFM) integrate the design
process with production methods, materials, process
planning, assembly, testing, and quality assurance
•
Design for assembly (DFA), Design for manufacture
and assembly (DFMA), and Design for disassembly
(DFD) are all important for manufacturing
•
Assembly requires a consideration of the ease, speed,
and cost of individual components of a product
20
GREEN DESIGN AND MANUFACTURING
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Manufacturing operations produce waste like:
Chips from machining and trimmed materials
Slag from foundries and welding
Additives in sand used in sand-casting
Hazardous waste and toxic materials
Lubricants and coolants
Liquids from heat treating
Solvents from cleaning operations
Smoke and pollutants from furnaces
21
GREEN DESIGN AND MANUFACTURING
•
Environmentally conscious design and manufacturing
considers all possible adverse environmental impacts of
materials, processes, operations and products
•
Design for recycling (DFR) - two basic activities
1) Biological cycle
- Organic materials degrade and lead to new soil that sustain
life
2) Industrial cycle
- Product that can be recycled and reused continuously
22
GREEN DESIGN AND MANUFACTURING
Cradle-to-cradle Production emphasizes:
1. Sustainable and efficient manufacturing activities
2. Waste-free production
3. Using recyclable and nonhazardous materials
4. Reducing energy consumption
5. Using renewable energy
6. Maintaining ecosystems
7. Using available materials and energy sources
8. Exploring the reuse and recycling of materials
23
GREEN DESIGN AND MANUFACTURING
Guidelines for Green Design and Manufacturing
1. Reduce waste of materials
2. Reduce hazardous materials products and processes
3. Investigate environmental-friendly manufacturing
technologies
4. Improvements in methods of recycling and reusing
5. Minimize energy use
6. Encourage recycling
24
SELECTION OF MATERIALS
•
1.
2.
3.
4.
5.
6.
7.
General types of materials used:
Ferrous metals
Nonferrous metals
Plastics (polymers)
Ceramics, glasses
Composite materials
Nanomaterials
Shape-memory alloys, amorphous alloys,
semiconductors and superconductors
25
SELECTION OF MATERIALS
Properties of Materials
1. Mechanical properties
2. Physical properties
3. Chemical properties
4. Manufacturing properties
5. Appearance
General Manufacturing Characteristics of Various Materials
Alloy
Castability
Weldability
Machinability
Aluminium
E
F
E-G
Copper
G-F
F
G-F
Gray cast iron
E
D
G
White cast iron
G
VP
VP
Nickel
F
F
F
Steels
F
E
F
Zinc
E
D
E
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SELECTION OF MATERIALS
Availability
•
If materials are not available in the desired quantities,
shapes, dimensions, and surface texture, substitute
materials can be considered
•
Reliability of supply is important in order to meet
production schedules
•
A country’s self-reliance on resources is a political goal
27
SELECTION OF MATERIALS
Service Life
•
A shortened service life of a product is due to:
1. Improper selection of materials
2. Improper selection of production methods
3. Insufficient control of processing variables
4. Defective parts or manufacturing-induced defects
5. Poor maintenance
6. Improper use of the product
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SELECTION OF MATERIALS
Material Substitution in Products
•
We would want to consider the following substitutions:
1. Metal vs. wooden handle for a hammer
2. Aluminium vs. cast-iron lawn chair
3. Aluminium vs. copper wire
4. Plastic vs. steel car bumper
5. Plastic vs. metal toy
6. Alloy steel vs. titanium submarine hull
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SELECTION OF MATERIALS
Example 1.2
Baseball Bats
•
Cross sections of baseball
bats made of aluminium and
composite material
30
SELECTION OF MATERIALS
Example 1.3
U.S. Pennies
•
Materials used undergone changes throughout history
due to periodic material shortages and the cost of
appropriate raw materials
1793-1837
100% copper
1837-1857
95% copper, 5% tin and zinc
1857-1863
88% copper, 12% nickel
1864-1962
95% copper, 5% tin and zinc
1943(WW II year)
Steel, plated with zinc
1962-1982
95% copper, 5% zinc
1982-present
97.5% zinc, plated with copper
31
SELECTION OF MANUFACTURING PROCESSES
•
Some examples of manufacturing methods are:
1. Casting
2. Forming and shaping
3. Machining
4. Joining
5. Finishing
6. Microfabrication and nanofabrication
32
SELECTION OF MANUFACTURING PROCESSES
Casting processes
Expendable
pattern and
mold and
other
Expendable mold,
Permanent pattern
Bulk-deformation processes
Permanent
mold
Rolling
Forging
Extrusion and
drawing
33
SELECTION OF MANUFACTURING PROCESSES
Sheet-metal-forming processes
Shearing
Bending and drawing
Polymer-processing processes
Forming
Thermoplastics
Thermosets
Rapid prototyping
34
SELECTION OF MANUFACTURING PROCESSES
Machining and finishing
processes
Machining
Advanced Machining
Joining processes
Finishing
Fusion
welding
Other
welding
Fastening and
bonding
35
SELECTION OF MANUFACTURING PROCESSES
Process Selection
•
Selection of process depends on geometric features of
the parts and workpiece material and properties
•
Some mechanical tools are
being replaced by laser cutting
•
Size of manufactured products
are getting smaller such as
microscopic gears
36
SELECTION OF MANUFACTURING PROCESSES
Net-shape and Near-net-shape Manufacturing
•
Part is made in only one operation to the final desired
dimensions, tolerances and surface finish
•
Difference between the two is the degree of how close
the product is to its final dimensional characteristics
•
Examples of net-shape manufacturing are precision
casting, forging, forming sheet metal, powder
metallurgy, injection molding of metal powders and
injection molding of plastics
37
SELECTION OF MANUFACTURING PROCESSES
Ultraprecision Manufacturing
• Advantages are dimensional accuracies and mirror-like
surfaces on metals
Types of Production
• Job shops: less than 100
• Small-batch production: 10 to 100
• Batch production: 100 and 5000
• Mass production: over 100,000
38
SELECTION OF MANUFACTURING PROCESSES
Example 1.4
Saltshaker and Pepper Mill
•
The two metal pieces for the
pepper mill are made by
powder-metallurgy techniques
39
COMPUTER-INTEGRATED MANUFACTURING
•
Computer-integrated manufacturing (CIM) integrates
computer graphics, computer-aided modelling, and
computer-aided design and manufacturing activities
•
Capable of making possible
1. Responsiveness to rapid changes
2. Better use of materials, machinery, and personnel
3. Reduction in inventory
4. Better control of production
and management
40
COMPUTER-INTEGRATED MANUFACTURING
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Various elements in CIM include:
Computer numerical control (CNC)
Adaptive control (AC)
Industrial robots
Automated materials handling
Automated assembly systems
Computer-aided process planning (CAPP)
Group technology (GT)
Just-in-time production (JIT)
Cellular manufacturing (CM)
Flexible manufacturing systems (FMS)
Expert systems (ES)
Artificial intelligence (AI)
Artificial neural networks (ANN)
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COMPUTER-INTEGRATED MANUFACTURING
圖
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COMPUTER-INTEGRATED MANUFACTURING
Example 1.5
Mold for Making Sunglasses Frames
•
Machining a mold cavity for making sunglasses
•
Computer model of the sunglasses as designed and
viewed on the monitor
•
Machining of the die cavity using a computer numericalcontrol milling machine
43
QUALITY ASSURANCE AND TOTAL QUALITY
MANAGEMENT
•
Product quality influences customer satisfaction
•
Quality must be built into the product from its initial design
•
Quality assurance and total quality management (TQM) are
the responsibility of everyone involved in the design and
manufacture of products and their components
•
Product integrity define the degree to which a product
1. Functions reliably
2. Suits its intended purposes
3. Can be maintained with relative ease
44
QUALITY ASSURANCE AND TOTAL QUALITY
MANAGEMENT
Average Life Expectancy of Various Products
Type of product
Life expectancy(years)
U.S. dollar bill
1.5
Personal computer
2
Car battery
4
Hair dryer
5
Automobile
8
Dishwasher
10
Kitchen disposal unit
10
Vacuum cleaner
10
Water heater(gas)
12
Clothes dryer(gas)
13
Clothes washer
13
Air-conditionimg unit(central)
15
Manufacturing cell
15
Refrigerator
17
Furnace(gas)
18
Machinery
30
Nuclear reactor
40
Relative Cost of Repair at Various Stages of Product Development
Sale
Stage
Relative cost of repair
When part is being made
1
Subassembly of the product
10
Assembly of the product
100
Product at the dealership
1000
Product at the customer
10000
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QUALITY ASSURANCE AND TOTAL QUALITY
MANAGEMENT
•
•
At six sigma, defective parts are reduced to only 3.4 per million
parts made.
Level reached only through manufacturing process capabilities to
reduce variability in product quality
Quality Standards
•
Global manufacturing and competitiveness
lead to international quality control methods
•
Thus the establishment of ISO 9000
and QS 9000 standards
46
QUALITY ASSURANCE AND TOTAL QUALITY
MANAGEMENT
Human-factors Engineering
•
Human-factors approach results in ergonomics design
•
Defined as the study of a workplace and the design of
machinery and equipment
Product Liability
•
Involved with product design, manufacture and marketing
•
Product’s malfunction or failure can cause bodily injury or
even death
47
LEAN PRODUCTION AND AGILE MANUFACTURING
•
Lean production involves a thorough assessment of
each activity of a company
•
Lean production focuses on:
1. Efficiency and effectiveness of each and every
manufacturing operation,
2. Efficiency of the machinery and equipment used
3. Activities of the personnel involved in each operation
48
LEAN PRODUCTION AND AGILE MANUFACTURING
Agile Manufacturing
•
Agile manufacturing is ensuring agility and flexibility
•
Methodologies of both lean and agile production require
that a manufacturer benchmarks its operations
49
MANUFACTURING COSTS AND GLOBAL COMPETITION
•
Manufacturing cost is about 40% of its selling price
•
Total cost of manufacturing a product consists of:
1. Materials
2. Tooling
3. Fixed Costs
4. Capital
5. Labour
50
GENERAL TRENDS IN MANUFACTURING
Global manufacturing trends
1. Product variety and complexity continue to increase
2. Product life cycles are becoming shorter
3. Markets have become multinational
4. Market conditions fluctuate widely
5. Customers are demanding
51
GENERAL TRENDS IN MANUFACTURING
Materials
6. Material composition, purity, and defects
7. Selection of materials for improved recyclability
8. Developments in nano-technology for materials
9. Testing methods and equipment
10. Increasing control over the thermal treatment
11. Higher strength-to-weight and stiffness-to-weight ratios
52
GENERAL TRENDS IN MANUFACTURING
Manufacturing operations
12. Predictive models of the effects of material processing
parameters
13. Ultraprecision manufacturing
14. Computer simulation and modelling
15. Rapid-prototyping technologies
16. Optimization of manufacturing processes
53
GENERAL TRENDS IN MANUFACTURING
Manufacturing systems
17. Computer software and hardware
18. Control systems and automated inspection
19. Lean production and information technology
Goals in manufacturing
20. View manufacturing activities not as individual
21. Meet all design requirements, product specifications
22. Build quality into the product
23. Economical and environmentally friendly (green) manufacturing methods
54
GENERAL TRENDS IN MANUFACTURING
Goals in manufacturing
24. Evaluate advances in materials, production methods,
and computer integration
25. Adopt flexible production methods
26. Achieving higher levels of productivity
27. Continuous improvement of a company’s products
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參考影片
•
http://www.youtube.com/watch?v=XSojNSwAb7I
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