ME 350 Design for Manufacturability

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ME 350 Lecture 1 Chapter 1

• ME 350 Design for Manufacturability
• Instructor Bruce Flachsbart,
• email mems_at_illinois.edu
• office hours Mon 10-11, 1-2,
• Fri 1-2,
• office 221A MEB

Lab TAs Chris Olenek John Scheider
Phillip Poisson Ramin Rasoulian Labs will
meet in 1227 MEL next week, beginning Aug 31st
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Textbooks References
Groover, M. P., Fundamentals of Modern
Manufacturing, Third Edition, John Wiley, 2007
(Available at IUB and Folletts) Make sure you
have the DVD with the book. References
(available at engineering library) 1)
Kalpakjian, S., and Schmid, S.R., Manufacturing
Processes for Engineering Materials, Addison
Wesley, 4th edition, 2003 2) Callister, W. D,
Materials Science and Engineering, Wiley, 2003
3) Devor, Statistical Quality Design Control,
2006
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Grading and Homework Policy

• Grading Homework 25
• Hour Exams 25
• Labs 20
• Final Exam 30
• Grade Distribution A to A- 25-35,
• B to B- 35-45
• C to C- 20-30,
• D to F lt 5
• Homework Policy
• HW turned in by 259 pm in class on the Tuesday
  due.
• HW 10 penalty after 3 pm, 20 after 5 pm, and
  not accepted after 1 pm Wednesday
• Lecture Notes
• Missed lecture material can be gone over during
  office hours

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Three Hour Exams and Final

• In class, close book and notes. Only pencil(s),
  an eraser, and a calculator are allowed at your
  desk. Dates
• Typical problems true/false, short answer, and
  quantitative analysis (equation sheet provided).
• Phone calls or writing after time called will
  cost per minute or phone call.
• Makeup exams with medical excuse only.

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Topics Covered (30 chapters)

• Material properties
• Rapid prototype
• Machining CNC/Abrasive/Nontraditional
• Molding
• Casting
• Composite manufacturing
• Welding/Soldering/Joining
• DFA
• MEMS

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Why Learning Manufacturing?
U.S. economy
Sector of GNP
Manufacturing
Agriculture, minerals, etc.
Construction utilities
Service sector retail, transportation, banking, communication, education, and government

• Manufacturing employs of engineers in the
  U.S. (from US Bureau of Economic Analysis)
• Manufacturing solution should be an integral part
  of product design
• Linking material properties and mechanics to
  production aspects

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Manufacturing History (part 1)

• Late middle ages (1400s) birth of the middle
  class people specialize into professions
• 1439 ?
• 1760-1830 Industrial Revolution typified by the
  
• Manufacturing is moved from home based
  handicraft to assembly in
• The James Watt steam engine replaces water, wind,
  animal power as the primary energy source
• Cotton Processing (Spinning Jenny, Cotton Gin,
  Power Loom) brought about the birth of the
• Iron foundries are built where coke replaces
  charcoal and bar iron enables potting and
  stamping
• The Eli Whitney muskets demonstrate the viability
  of assembly

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Manufacturing History (part 2)

• 1850-1910 Second Industrial Revolution typified
  by
• Mass production of steel enables railroads and
  big machinery
• Canning of foods birth of food processing
• Birth of the chemical industries including
  petroleum refining
• Factories get electrical power enabling longer
  work hours ( also invented)
• Assembly line manufacturing
• The internal combustion engine and the birth of
  the automobile industry ( , 1885)
• Scientific management of manufacturing brings
  about the birth of the field

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Manufacturing History (part 3)

• 1980-present Third Industrial Revolution
  identified by the
• Birth of automation
• Expanse of multinational corporations and
  offshore production
• Forth Industrial Revolution?

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Manufacturable Materials (part 1)

• Metals
• Ferrous (based upon )
• Steel most often an (lt2) alloy, but
  chromium, magnesium, nickel, and molybdenum
  alloys are useful
• Cast iron most often an (2-4) -
  (0-3) alloy
• Nonferrous Alloys (all other metals)
• Al, Cu, Au, Mg, Ni, Si, Sn, Ti, Zn, etc.

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Manufacturable Materials (part 2)

• Plastics
• can be heated multiple times (PE, PS,
  PMMA, etc.)
• cure to a rigid shape (phenolics, epoxies,
  etc.)
• significant elastic behavior (rubber,
  silicone, PU, etc.)

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Manufacturable Materials (part 3)

• Ceramics
• Combination of a metal (or semimetal) inorganic
  nonmetal
• Examples clay, glass, alumina, metal carbides,
  semimetal nitrides
• Two categories glasses (which melt) and
  crystalline ceramics

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Manufacturable Materials (part 4)

• Composites (not really a separate category of
  material)

Nonhomogeneous mixtures of the other three basic
types rather than a unique category. e.g. glass
particles or fibers mixed in a polymer matrix
material, or tungsten carbide in cobalt (metal
binder) to make a cutting tool.
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Figure 1.4 Classification of manufacturing
processes
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Processing Operations

• Increases workparts value by altering
• shape,
• physical property,
• appearance
• Three categories
• Shaping operations (e.g. , etc.)
• Property-enhancing operations (e.g. )
• Surface processing operations (e.g. , etc.)

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Shaping Processes

• Solidification processing
• Starting material is a heated liquid or semifluid
• Particulate processing
• Starting material is a powder
• Deformation processing
• Starting material is a ductile solid (commonly
  metal) that is deformed to form the part
• Material removal processing
• Starting material is a solid from which material
  is removed to form the part
• Traditional techniques (turning, drilling,
  milling) Non-traditional techniques (laser,
  electron beam, chemical erosion, electric
  discharge, and electrochemical)

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Goal of Shaping Operations

• To minimize and in converting a starting
  workpiece into its final part
• Manufacturing processes that convert nearly 100
  of the starting material into product is called

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Property Enhancing Processes

• Processes that do not alter the of the
  workpiece
• Heat treating (e.g. tempering steel)
• Annealing (e.g. to reduce stress in glass)
• Sintering (joins and strengthens powder shaped
  metals and ceramics)

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Surface Processes

• Cleaning
• Both and means to remove dirt, oil, and
  other contaminants
• Surface treatments
• Mechanical (e.g. sand blasting or shot peening)
• Physical (e.g. diffusion, ion implantation)
• Coatings
• e.g. painting, anodizing, electroplating,
  porcelain enameling, thin film deposition, etc.

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Assembly Operations

• Two or more separate parts are joined to form a
  new entity
• Types of assembly operations
• Joining processes create a joint
• Welding, brazing, soldering, and adhesive bonding
• Mechanical assembly fastening by mechanical
  methods
• Threaded fasteners (screws, bolts and nuts)
  press fitting, expansion fits

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What is DFM?

• Design for Manufacturability (DFM) By
  understanding and analyzing the fundamental
  manufacturing processes, reduce the of
  production while achieving optimal product
• Quality and lifetime of the products should not
  be left until the test stage, but actively
  brought into consideration by design, manufacture
  and assembly.
• Rule of 10 order of magnitude increase on the
  cost of repair when changes are made at later
  stages (from parts ? subassembly ? assembly ?
  final product on market ? customer)

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Summary

• Attend lectures, be on time, read chapters, and
  participate.
• We are going to cover a lot of manufacturing
  processes their strengths and weaknesses.
• We are going to cover the tools to understand and
  optimize manufacturing.
• This class is to help you be able to better
  design a product for manufacturing.