Transcript Environmentally Conscious Design & Manufacturing ME592E-1

Environmentally Conscious
Design & Manufacturing
Class 5: Manufacturing
Prof. S. M. Pandit
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000
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Manufacturing
Agenda
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What is a Manufacturing Enterprise?
Systems View - Manufacturing
Manufacturing Processes
Modeling
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000
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Manufacturing Enterprise
Marketing
Product Design
Manufacturing Enterprise
Finance
Manufacturing
Management
Technology
Environmentally Conscious Design & Manufacturing (ME592)
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Manufacturing Enterprise
- Product Design
Product Design
Traditional
 Functional Requirements
 Cost, Time & Material constraints
 Design tools for CAE
(Integrated CAD - CAM +..
Research Areas
 Computer Aided Design Tools
 Environmentally-Friendly Product
Design and Packaging
Stereolithography:
 Human Machine Interface
http://www.nitc.qub.ac.uk/divs/pddc.htm
 Rapid Prototyping
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Manufacturing Enterprise
- Product Design
CAD
• Drafting function
• Divide into elements
• Optimize storage and processing
• Finite element / Finite difference analysis
2D .. 2.5D .. 3D
Solid Stress / Thermal / Fluid Flow
Material Properties -- Isotropic
Anisotropic
Environmentally Conscious Design & Manufacturing (ME592)
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Manufacturing Enterprise
- Manufacturing
Manufacturing
Traditional
 Machining
Single and multi-point cutting
 Joining, Forming, Casting ..
 Metrology
Non-Traditional
 Laser Cutting
 Abrasive jet machining
 Electrochemical machining
 Explosive deformation and joining
 Hydroforming
Laser Cutting
http://www.servicemetal.com
Environmentally Conscious Design & Manufacturing (ME592)
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Manufacturing Enterprise
- Manufacturing
CAM
- Data transfer (integrated CAD - CAM)
- Machine tool controller (language)
- Program entry / debugging / dry run
- Tool wear / breakage
- Dimensional accuracy
Temperature effects
Elastic deformation
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000
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Manufacturing Enterprise
- Manufacturing
CNC
information
flow
http://www.ab.com/cnc
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Systems View
Drafting
Finite-Element Analysis
Computational Fluid Dynamics
Kinematic / Dynamic Analysis
Design Visualization and Animation
CAM
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000
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Manufacturing Processes
• Solidification
• Forming Processes
• Particulate Processing
• Material Removal
• Joining
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Manufacturing Processes
Solidification Processes
Melting
Furnace
(Metals: 800 C to 3000 C)
- Alloying
- Phase stability
- Inclusions and impurities
(chemical metallurgy)
- Stirring and agitation
- Buoyancy and surface tension
driven flow
- Bubbles in the melt
{Chemical and Physical Metallurgy}
Environmentally Conscious Design & Manufacturing (ME592)
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Manufacturing Processes
- Solidification 1
Sand Casting
Sand Core
Sprue
Riser
Parting Line
Environmentally Conscious Design & Manufacturing (ME592)
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Manufacturing Processes
- Solidification 2
Solidification
Time - temperature - composition
Quenching (conduction heat transfer)
- Simple analysis: Lumped parameter
transient temperature profiles
T( ) - T
e
T0 - T
(
hAs
)
VC p
‘T’ is a function of time, , the initial temperature, T0 , and the
ambient temperature, T . ‘h’, As , r, V, and Cp are the convective heat
transfer coefficient, Surface area, density, Volume, and specific heat
capacity, respectively.
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000
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Manufacturing Processes
- Forming
Molding
Injection
Blow
Extrusion
Rolling
Forging
• Polymer processing
• Cost advantages
• Rheological properties and
temperature dependent
properties
• Temperature & pressure
• Influence on grain structure
• Diffusion processes
• Directional properties
Reference: Physical Metallurgy by Dieter
Environmentally Conscious Design & Manufacturing (ME592)
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Manufacturing Processes
- Powder Metallurgy
Powder
production
Blending
Compaction
Sintering
Creating a “die compaction tool”
1) Develop a user-friendly software
simulation model
2) Develop the required material models
and incorporate them into the
software,
3) Determine the material properties
necessary to verify and implement the
model,
4) Verify model output through
experimental techniques, and
5) Demonstrate the applicability of the
process model.
Environmentally Conscious Design & Manufacturing (ME592)
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Machining - 1
Metal removal
Turning, Milling, Drilling:
Primary Inputs:
Electrical Energy
Cutting fluid
Primary Outputs: Finished products
Spent cutting fluid
Others: Lubricants, oils, machined chips, tool debris, heat
Environmentally Conscious Design & Manufacturing (ME592)
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Machining - 2
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Machining - 3
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Machining - 4
Radial drilling
machine
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Machining - 5
Metal removal
Electro discharge / Electro-chemical /
Primary Inputs:
Electrical Energy
Cutting fluid / Electrolytes
Primary Outputs: Finished products
Spent cutting fluid / Electrolyte
Others: Lubricants, oils, work-piece debris, tool debris, heat,
Metal vapor, Metallic compounds, ...
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Machining - 6
Electrochemical
machining of
blades
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Machining - 7
Abrasive jet
machining schematic
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000
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Machining - 8
Metal removal - no ‘tooling’
Electron beam, Laser, Abrasive jet, Water jet
Primary Inputs:
Electrical Energy
Fluids & abrasives
Primary Outputs: Finished products
Spent fluid & abrasives
Others: Heat, Metal vapor, Metallic compounds, ...
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 15, 2000
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Machining - 9
Electron - beam machining:
• Intense energy densities
• Non - contact
• Clean
http://www.llnl.gov/IPandC/op96/09/9c-com.html
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