Manufacturing Processes

Introduction

Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 What is Manufacturing?
• Manufacturing is the process of converting raw materials
into products.
• Nations with largest GDP growth concentrated on high value-
added products, such as automobiles and machinery.

Powder Manufactu Bread

ring?
Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 What did we make?

Paper  Mask Paper+Bamboo  Kite Pet bottle  Rocket

Who to make it?

Manufacturing Process

Introduction
ManufacturingChopstick
Processes  Gun Paper+Bamboo  Airplane
© Pearson & MIT & GNU Su-Jin Kim
 Materials

The types of materials generally used in manufacturing:

1. Ferrous metals : Steels
2. Nonferrous metals and alloys : Aluminium, copper
3. Plastics
4. Ceramics
5. Composite materials
6. Silicon

Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Metals
• Iron (Fe): Cast iron, Steel, Carbon steel, High strength
steel, Stainless steel, Tool steel
• POSCO: [Link] -> Products and Technology

• Copper (Cu), Brass (Cu+Zn,Zinc), Bronze (Cu+Sn,Tin)

• Aluminum (Al), Duralumin (Al+Cu+Mg+Mn)
• Lead, Titanium, Nickel, (Zinc), Gold, Silver

Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Polymer (Plastic)
• Thermoplastics: Nylon, Polyethylene, Polystyrene, Vinyl
• Thermosets: Epoxy, Phenolic, Polyester
• Elastomer: Rubber

Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Ceramics
Ceramics
• Clay, Glass (SiO2), Diamond (C), Alumina (Al2O3),
Semiconductor (Si+P+?)

Powder metals

Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Composite
• Reinforced plastics, Concrete (Cement + Sand), Concrete-
steel wire, Wood, Polywood, Polymer matrix
• FRP, Glass reinforced plastic, Carbon reinforced plastic

Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Material property
• Melting temperature, Density (Specific weight)
• Harness, Toughness (Ductile-Brittle), Strength
• Chemical stability (Corrosion), Electric property
Properties
• Recycle, Price Metal Plastic Ceramic
Melting temperature 1,000℃ 200℃ 3,000℃
Strength 200GPa 10GPa -300GPa, +50GPa
Toughness Ductile Ductile Brittle
Hardness High Low Very High
T. E. conductivity High Low Low
Stiffness (=E) High Low High

Chemical stability Mid High Very high

Density High Low High

Introduction
ManufacturingPrice
Processes High Low High
© Pearson & MIT & GNU Su-Jin Kim
 Material & Process
Materials Process Products
Machining Axis
Metals Forming Crank arm
Casting Engine housing
Plastics Injection molding Toy

Ceramic Powder forming

Welding Ship
Joining processes
Mechanical assembly Car
Silicon Deposition, Etching Memory
Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Manufacturing Process

Market & Conceptual Design for

Specification Design Manufacture

Unit
UnitManufacturing
Manufacturing
•Machining
Assembly
Assemblyand
and
Product •Injection molding
Joining
Joining
Sell •Welding •Casting
•Bolting •Stamping
•Bonding •Chemical vapor deposition
Introduction •Soldering
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Manufacturing Attributes for
Decision Making
1. Cost
2. Quality
3. Flexibility
4. Rate

Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Machining (Cutting)
1. Cost: Expensive $100(Cylinder)-$10,000(Mold)
2. Quality: Very high, precise
3. Flexibility: Any shape cut by tool, Small production
4. Rate: Slow

Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Forming (Metal squeezing)
1. Cost: Cheap, $0.1 - $100, Expensive equipments, over
$100,000
2. Quality: Reasonable
3. Flexibility: Shapes limited constant cross-section, Mass
production
4. Rate: Fast (cycle time in sec), high volume

Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Casting
1. Cost: Expensive $100 - $10,000
2. Quality: Requires post finishing (except Die casting)
3. Flexibility: Very flexible, Good for large parts
4. Rate: Very slow

16V engine block Machine tool surface

plate
Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Plastics Injection
1. Cost: Cheap, $0.1 , Expensive mold, over $10,000
2. Quality: Very high
3. Flexibility: Opening for ejection , Mass production
4. Rate: Very fast

Introduction
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim
 Welding
1. Cost: Cheap, but expensive labor
2. Quality: Wide range
3. Flexibility: Manual vs automated
4. Rate: Slow in general

Introduction
Manufacturing Processes Very Large Crude Carrier (VLCC)
© Pearson & MIT & GNU Su-Jin Kim
 Thinfilm fabrication
1. Cost: Very expensive equipments, $Millions
2. Quality: Very high, Nanometer pattern
3. Flexibility: Any shape in 2-D
4. Rate: Slow

300mm dual stage lithography

system capable of 110nm
Introduction resolution
Manufacturing Processes
© Pearson & MIT & GNU Su-Jin Kim