Review for Exam #1
ISE316
Fall 2010
Readings
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Chapter 1 -- What is manufacturing?
Chapter 2 -- The nature of materials
Chapter 3 -- Mechanics of materials
Chapter 2 and 3 of supplement -Dimensioning and tolerancing
• Chapter 21 – Theory of machining
• Chapter 22 – Fundamentals of machining
Chapter 1 -- What is manufacturing?
• Importance of manufacturing
Manufacturing Is Important
Economically
Manufacturing is a means by
which a nation creates
material wealth
• In the U.S. manufacturing
constitutes ~ 20% of GNP
• Government is as much of
GNP as manufacturing, but
it creates no wealth
U.S. economy:
Sector
% of
GNP
Manufacturing
20%
Agriculture, minerals, etc.
5%
Construction & utilities
5%
Service – retail,
transportation, banking,
communication,
education, and
government
70%
IE 316 Manufacturing Engineering I - Processes
Manufacturing is Important
Historically
• Historically,word “manufacture” was first
coined around 1567 A.D.
• Most modern manufacturing is
accomplished by automated and
computer-controlled machinery that is
manually supervised
IE 316 Manufacturing
Engineering I - Processes
Manufacturing is the application of physical and
chemical processes to alter the geometry,
properties, and/or appearance of a given starting
material to make parts or products; manufacturing
also includes assembly of multiple parts to make
products
• Manufacturing is almost always carried out as a
sequence of operations
Figure 1.1 (a)
Manufacturing
as a technical
process
IE 316 Manufacturing Engineering I - Processes
Traditional Engineering
Engineering
Mechanics of Materials
Fundamentals of Mechanics
Figure 3.2 - Typical progress of a tensile test: (1) beginning of test, no load;
(2) uniform elongation and reduction of cross-sectional area; (3)
continued elongation, maximum load reached; (4) necking begins, load
begins to decrease; and (5) fracture. If pieces are put back together as in
(6), final length can be measured
ISE 316 - Manufacturing
Processes Engineering
Engineering Stress
Defined as force divided by original area:
e 
F
Ao
where e = engineering stress, F = applied force, and Ao = original area of
test specimen
ISE 316 - Manufacturing
Processes Engineering
Engineering Strain
Defined at any point in the test as
e
L  Lo
Lo
where e = engineering strain; L = length at any point during elongation; and Lo
= original gage length
ISE 316 - Manufacturing
Processes Engineering
Figure 3.3 - Typical engineering stress-strain plot
in a tensile test of a metal
ISE 316 - Manufacturing
Processes Engineering
Two Regions of Stress-Strain Curve
• The two regions indicate two distinct forms of
behavior:
1. Elastic region – prior to yielding of the material
2. Plastic region – after yielding of the material
ISE 316 - Manufacturing
Processes Engineering
Dimensioning and tolerancing
• Traditional dimensional specification
– Datums
– Tolerance stacking
• ASME Y14.5 standards
– Form geometry
– Material conditions
• Inspection
Machining
• Principles of metal cutting
• Basic geometry of cutting
– Chip formation
– Shear
– MRR
• Turning/lathe operations
– Cutting geometries
– Time
• Milling and drilling
• Principles of process planning
ISE316
Test #2 review
Chapters covered
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Chapter 23 – Tool technology and tool life
Chapter 24 -- Machining economics
Chapter 19 – Metal Forming
Chapter 20 – Sheet metal working
Exam format
• Chapters 23 and 24 will be covered on
Tuesday November 16
• Chapters 19 and 20 will be covered on
Thursday November 18
Let’s play ISE316 Jeopardy/Jeopardy -1
Topic – Tool technology
• He developed the first tool life equation
• Who is Fredrick Taylor?
Topic – Tool technology
• Primary independent variable/parameter for
tool life
• What is cutting velocity?
Topic – Machining economics
• T/Tm in the machine economics equation
• What is the fraction of the tool used in a
single operation?
Topic – Metal forming
• This process produces steel plate and sheet
above recrystalization temperature
• What is Hot working
Topic – Metal forming
• The process used to produce the structure
frame pieces for aluminum screen doors
• What is extrusion?
Team Jeopardy-1
• In this portion of the review a question will be
asked to the entire team. When the team has
the answer, they will chime in to be
recognized first with the answer and then the
method used to get the answer.
Topic – Tool technology
• In a turning process where a 2” diameter bar is turned
to 1.75”, find the following
– Depth of cut
• For the processing, each part is 6 inches long and
turned for half the part length and then cut off at the 6
inch mark and then collected via a conveyor in the bed
of the lathe.
– How long does the turning operation take if the velocity is
300 fpm and the feed is .008 in/rev?
• The cut off operation occurs with a velocity of 250 fpm
and a feed rate of 5 ipm.
– How long does the cut off process take?
Topic – Tool technology
• For the turning operation previously described
(V= 300 fpm, f = 0.008 ipr) the tool life realized
for the process was 55 minutes. The operator
changed the velocity to 400 fpm and the tool
life changed to 35 minutes. What is the tool
life equation for the tool?
Topic – Tool economics
• If the time required to change the tool is 5
minutes, what is the optimum velocity?
Topic – Machining economics
• If 500 parts are to be made in batches of 50,
how expensive is the part? Cmo = $35/hr; Tl/ul
= .1 min; Process engineering time for the
part was 8 hours; engineering time is $150/hr;
batch set-up time is 2 hours
Topic – Sheet metal working
• A 1.0 in wide 90o corner bracket made of
0.125 inch Cold Rolled steel is to be made in
large quantities. The finished bracket will be 2
inches long on either side and will have 2 ¼
inch holes equally spaced on the flat surface.
– How long should the blanks be cut?
Topic – Sheet metal working
• What tonnage press is required to make the
brackets?
• What tooling is required?
And finally, …
• Nano-technology and nano-manufacturing
– Chapters 36 and 37 from the book
– Powerpoint slides