Advanced Manufacturing Choices

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Advanced Manufacturing Choices

• MAE 165-265
• Spring 2014, Dr. Marc Madou
• Class 1

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Advanced Manufacturing Choices

• Manufacturing processes can be organized by
  considering the type of energy required to shape
  the work-piece. In this course, sources of
  energy considered for manufacturing are
• Mechanical energy such as in cutting and shaping
• Electrical energy
• Heat energy such as in laser cutting,
• Chemical energy such as in electro chemical
  machining.
• Categorizing is often not that simple (e.g.,
  chemical and thermal). It is easier to categorize
  in the case of subtractive than in the case of
  additive manufacturing.

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Advanced Manufacturing Choices

• Students, guided by product specifications and a
  design will be able to decide
• 1) When to apply mechanical machining vs.
  lithography based machining,
• 2) What type of mechanical machining and what
  type of lithography based machining to apply,
• 3) When to employ bottom-up vs. top-down
  manufacturing,
• 4) When to choose serial, batch or continuous
  manufacturing and
• 5) What rapid prototyping method to select.
• A logical decision tree will be presented to sort
  out the machining options.
• Examples will include a variety of products
  ranging in size from nanometers to centimeters.

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Advanced Manufacturing Choices

• The size of things

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Advanced Manufacturing Choices

• Syllabus Topics
• Serial, batch and continuous manufacturing
  processes.
• Relative tolerances vs. absolute machining
  tolerances.
• Principles of manufacturing processes I.
  Mechanical energy e.g., Cutting, Shaping,
  Forging, Ultrasonic Machining, Sputtering.
• Principles of manufacturing processes II.
  Electrical energy e.g., Electron Discharge
  Machining (EDM)
• Principles of manufacturing processes III. Heat
  energy e.g. , Laser machining, plastic molding.

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Advanced Manufacturing Choices

• Principles of manufacturing processes IV.
  Chemical energy Electrochemical Machining (ECM),
  Chemical Machining
• Next generation lithography tools,
• 8. Nanomachining tools.
• 9. Top-down vs. bottom-up machining.
• 10. Rapid prototyping, layered manufacturing.
• 11. Matching manufacturing processes to product
  specification and design.
• 12. Manufacturing process decision tree.

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Class 1

• Definition of manufacturing
• Serial, batch and continuous manufacturing
  processes.
• Relative tolerances vs. absolute machining
  tolerances.

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Definition of Manufacturing

• Manufacturing is the use of machines, tools and
  labor to make things for use or sale. The term
  may refer to a range of human activity, from
  handicraft to high tech, but is most commonly
  applied to industrial production, in which raw
  materials are transformed into finished goods on
  a large scale. Such finished goods may be used
  for manufacturing other, more complex products,
  such as household appliances or automobiles, or
  sold to wholesalers, who in turn sell them to
  retailers, who then sell them to end users - the
  "consumers". Wikipedia

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Serial, batch and continuous manufacturing
processes.

• Single unit production or serial production
• The primary characteristic of batch production is
  that a group of identical components are
  completed at a workstation before they move to
  the next one (e.g., IC fabrication).
• Continuous production is a method used to
  manufacture, produce, or process materials
  without interruption

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Serial, batch and continuous manufacturing
processes.
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Serial, batch and continuous manufacturing
processes.
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Relative tolerances vs. absolute machining
tolerances.

• A dimension is a numerical value expressed in
  appropriate units of measure and used to define
  size, location, orientation, form or other
  geometric characteristics of a part.
• A tolerance is the acceptable variation of
  feature from the specified dimension
• Relative tolerance tolerance on dimension over
  dimension

Dimension with Limit Tolerance
Dimension with Plus-Minus Tolerance
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Relative tolerances vs. absolute machining
tolerances.
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Relative tolerances vs. absolute machining
tolerances.

• Lithography (e.g. Si-micromachining) is excellent
  for small absolute tolerances
• For relative tolerances, ultra-fine diamond
  milling is better
• In some cases we might want to keep our
  micromachine somewhat larger to optimize relative
  tolerances

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Relative tolerances vs. absolute machining
tolerances.

• The total amount by which a given dimension may
  vary, or the difference between the limits -
  ANSI Y14.5M-1982(R1988) Standard R1.4
• Nominal tolerances for steel (see figure)
• Tighter tolerances gt increase cost