IEEM 215 Manufacturing Processes.ppt

IEEM 215: Manufacturing Processes Introduction and Agenda Materials Properties - helps to determine how to make things with it - helps to determine the processing conditions - helps and constrains process optimization Processes - forming, cutting, non-traditional, joining, surface treatments, electronics components, … Process Planning Process Economics and Optimization Product design and Fabrication CNC programming Process Evaluation and Quality control Outcome(s) 1.0 1.1 2.0 2.1 7.0 3.0 3.1 4.0 6.0, 6.1 5.0, 8.0, 8.1 5.0 9.0 A bottle of Watson’s water (~HK$6) Four components (bottle, cap, label, water) - How are each of these manufactured? - What does the equipment cost? Motivation (1) Motivation (2) Approx. 15 components - How do we select the best material for each component? - How are each of these manufactured? Stapler (~HK$ 45) Car: ~ 15,000 parts; Boeing 747 plane: ~6 million parts Intel core 2 duo processor: 65 nm feature size, 291 million transistors Materials Nanomaterials, shape-memory alloys, superconductors, … Ferrous metals: carbon-, alloy-, stainless-, tool-and-die steels Non-ferrous metals: aluminum, magnesium, copper, nickel, titanium, superalloys, refractory metals, beryllium, zirconium, low-melting alloys, gold, silver, platinum, … Plastics: thermoplastics (acrylic, nylon, polyethylene, ABS,…) thermosets (epoxies, Polymides, Phenolics, …) elastomers (rubbers, silicones, polyurethanes, …) Ceramics, Glasses, Graphite, Diamond, Cubic Boron Nitride Composites: reinforced plastics, metal-, ceramic matrix composites Properties of materials Mechanical properties of materials Strength, Toughness, Hardness, Ductility, Elasticity, Fatigue and Creep Chemical properties Oxidation, Corrosion, Flammability, Toxicity, … Physical properties Density, Specific heat, Melting and boiling point, Thermal expansion