Pertemuan Ke-2 Sistem Manufaktur

7/24/2019 Pertemuan Ke-2 Sistem Manufaktur

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Manufacture

Manufacture

Mata Kuliah :

Proses Produksi


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Manufacture

What is Manufacture Process of transforming raw material into useful

products The combining of basic parts into more complex

products The finishing of products, ready for sale Manufacturing is the process of converting raw

materials into products. Manufacturing is synonymous with production.

process of adding value to raw materials or otherproducts.

Products may be either discrete or continuous.


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Manufacture

Materials in an Automotive

Engine

!igure ".# $ection of an automotive engine % the &uratec '%( % showing various

components and the materials used in making them. $ource: )ourtesy of !ord

Motor )ompany. "llustration by &avid Kimball.


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Manufacture

Components in Products* $ome products are a single

components +nail, bolt, fork, coat

hanger, etc.

* $ome products are assemblies ofmany components +ball point pens,

automobiles, washing machines, etc.

* ll components are manufactured.

* Manufacturing means, literally, -Made

by Hand.


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Manufacture

Manufacturing Trends Products must meet specifications, design

re/uirements, 0 regulatory standards.

Product must be economic and environmentally

friendly. 1uality must be built into the design.

Methods must be flexible.

Technologies employed in materials, methods, and

computer integration must constantly evolve. Manufacturers must listen to customer feedback.

Productivity must be constantly improved.


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Manufacture

Brief History of Manufacture

BCE!2 34445)6: )asting, hammering, stone

tools

3444%74445)6: casting with lost wax,stamping, soldering

7444%84445)6: 5ron9e, wire drawing,sheet formation, riveting, bra9ing

8444%#5)6: )ast iron, $teel, coins,welding


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Manufacture


CE! #%#44: blast furnaces, forging armour

and steel swords,

#44%#;44: cast iron cannon, waterpower for metalworking

#;44%#


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Manufacture


"#$$s! #=44%#=84: oxyacetylene welding, high speed machining,

5akelite #=84%#=34: die casting, tungsten carbide tools, mass

production, plastics #=34%#=4: high precision lost wax, steel extrusion,

powder metals #=4%#=(4: chemical machining, automatic control #=(4%#=;4: single crystal turbine blades, numerical

control #=;4%8444: vacuum casting, rapid solidification, rapid

prototyping, etc>?


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Manufacture

History of Manufacturing until "%$$!


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Manufacture

History of Manufacturing "%$$&"#'$!


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Manufacture

History of Manufacturing "#'$&($$$s!


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Manufacture

Materials )election for Paper Clips

!igure ".8 6xamples of the wide variety of materials and geometries for paper clips.

1uestions for consideration:

* @hat material properties are

re/uiredA

* @hat manufacturing attributes arere/uiredA

* @ould the material and processing

strategy change if the desired

/uantity was #4,444 vs. # million

per dayA


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Manufacture

E*amples+ " Paper clip Paper clip

$ingle part

!unction: clamp

sheets of paper

)haracteristic:stiffness, elastic

Material selectionA

Production methodA


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Manufacture

Manufacture of ,ight Bul-s

!igure ".7a )omponents of a commonincandescent light bulb. Source: )ourtesy

of Beneral 6lectric )ompany.

!igure ".7b Manufacturing steps inmaking an incandescent light bulb.

Source: )ourtesy of Beneral 6lectric

)ompany.


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Manufacture

E*amples+ ( Car engine 6ngine block

$mall +2#44 number ofindividual parts

!unction: contain highpressures, resist hightemperatures, contain

pistons

)haracteristics: smooth

cylinders, strong Production methodsA

!inishingA


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Manufacture

E*ample .+ /as tur-ine aero

engine


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Manufacture

Why study Manufacture0

Manufacturing core to economic activity?s a designer: understand the limitations

available Tolerances

Production rates

6conomic issues

"n general: develop analytic skills,specifically for process oriented tasks


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Manufacture

1esign 2ssues

&esigner must consider: @hat processes are availableCrelevant for the

productA

@hat tolerances can be achieved, and arethese sufficientA

re there any design features that need to beincorporated +eg webbing, round edges, etcA

)an the expected production rate be metA

Dow will the product be assembledA


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Manufacture

Product 1esign 3 Concurrent

Engineering

;4E to


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Manufacture

!igure ".3 +a )hart showing the

various steps involved in design

and manufacturing a product.

&epending on the complexity of

the product and the type ofmaterials used, the time span

between the original concept and

the marketing of the product may

range from a few months to many

years.

+b )hart showing general

product flow in concurrentengineering, from market analysis

to selling the product. Source:

fter $. Pugh, Total Design.

ddison%@esley, #==#.

Product 1esign

Process


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Manufacture

Product ,ife Cycle

Time

Introduction

Growth

Maturity

Saturation

Decline

Demand


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Manufacture

1f*

&esign for x

Manufacturability or ssembly

Method of product design considering the mosteconomical method of manufacture for a given

producer.

&esign for Maintenance

&esign for disassembly

&esign for service


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Manufacture

4edesign of Parts

!igure ". Gedesign of parts to facilitate assembly. Source: Geprinted

from B. 5oothroyd and P. &ewhurst, Product Design for Assembly, #=


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Manufacture

Material selection

Harge range of materials to select from

Ieed criteria for basing selection eg mechanical,environmental, economic, machinability, etc

)learly, material selection and process

selection are dependent on each other

This course will focus on Metals and Plastics+so leaving ceramics, silicon, wood, etc out


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Manufacture

)election of Materials

Engineering Materials

Metals Plastics CeramicsComposites

FerrousNonferrousAmorphousThermoplasticsThermosetsElastomers

Steels

tainless Steels

ool & Die Steels

Cast Irons

Aluminum

Copper

Titanium

Tungsten

Others

Acrylics

AS

Nylons

Polyethylenes

P!C

Others

Epo"ies

Phenolics

Polymi#es

Others

$u%%ers

Silicones

Polyurethanes

O"i#es

Nitri#es

Car%i#es

lasses

lass Ceramics

raphite

Diamon#

$einforce# Plastics

Metal'Matri"

Ceramic'matri"

(aminates


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Manufacture

)election of Materialseha)ior & Manu'facturing Propertiesof MaterialsStructure of

MaterialsMechanicalProperties

Physical &ChemicalProperties

PropertyMo#ificationtomic %on#s* Metallic+

o)alent+ an# Ionic

CrystallineAmorphous

Partly Crystalline

Polymer Chains

Strength

DuctilityElasticity

,ar#ness

Fatigue

CreepToughness

Fracture

Density

Melting PointSpecific ,eat

Thermal Con#ucti)ity

Thermal E"pansion

Electrical Con#ucti)ityMagnetic Properties

O"i#ation

Corrosion

,eat Treatment

Precipitation ,ar#eningAnnealing

Tempering

Surface Treatment

Alloying$einforcements

Composites

(aminations

Fillers


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Manufacture


Properties

Mechanical Properties

Physical Properties )hemical Properties

Manufacturing Properties


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Manufacture


)ost and vailability

ppearance

$ervice Hife

&isposal Properties

Gecyclability

$pecies Hife

Darmful nature of the material Geduction in waste generation +Geusability


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Manufacture

Manufacturing Characteristics

of Alloys


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Manufacture

Base-all Bat Cross&sections

!igure ".( )ross%sections ofbaseball

bats made of aluminum +top portion

and composite material +bottom

portion.


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Manufacture

Manufacturing

Processes+ Casting

!igure ".;a $chematic illustration of various

casting processes


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Manufacture

Manufacturing Processes+ 5orming

and )haping

!igure ".;b $chematic illustration of various bulk deformation processes


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Manufacture

Manufacturing

Processes+ 5orming

and )haping

!igure ".;c $chematic illustration of various sheet metal forming processes


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Manufacture

Manufacturing

Processes+ 5orming and

)haping

!igure ".;d $chematic illustration of

various polymer processing methods


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Manufacture

Manufacturing

Processes+

Machining

!igure #.;e $chematic illustrations of various

machining and finishing processes.


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Manufacture

Manufacturing

Processes+ 6oining

!igure ".;f $chematic illustration of

various Joining processes


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Manufacture

)and Casting

5asically: Pour molten metal into a mould cavity

s metal free9es +solidifies, takes on form ofcavity

Moulds can take on complex shapes Harge parts can be cast

&efects mainly occur due to coolingprocess


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Manufacture

)and Casting illustration!

"mportant aspects:

!luid flows

)ooling rates

Mould design


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Manufacture

Plastic 2n7ection Moulding

$imilar to $and )asting +uses mould to

obtain forms

&ifferences: Properties of polymers v metals

Digh pressures in mould

)omparatively easy to handle

)ost considerations are more complex


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Manufacture

Plastic 2n7ection Moulding illus!


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Manufacture

4olling

5asically: Geducing the thickness of a workpiecethrough

applying pressure via rolls

$imilar to rolling dough with a rolling pin?ccounts for the about =4E of all metal Harge range of thicknesses: luminium foil: 4.44


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Manufacture

4olling illustration!


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Manufacture

5orging

$imilarity to rolling: 5oth involve reformation of workpiece through

application of force

&ifferences: !orging produced discreteproducts as

opposed to continuous

Metal flow can be controlled: )an produce parts for high stress

concentration applications: eg gears, shafts


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Manufacture

5orging illustrations!


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Manufacture

Cutting and Machining

)utting and Machining processes removematerialfrom a workpiece

&esign issues:

)utting tool must be able to access area to removematerial

Mechanics: Plastic behaviour of metal

6conomics: Tool life

$etting up the machine


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Manufacture

Cutting and Machining illus!


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Manufacture

Metal 5inishing

Gaising standards:

"n general, a manufacturing process can onlyproduce products to a certain tolerance

To improve, an additional finishingprocesswill usually be re/uired

Main methods:

Material removal: grinding, honing, lapping

Material addition: electroplating, coating


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Manufacture

Metal 5inishing illustration!


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Manufacture

6oining

ll previous processes have been for single

parts

Most products contain several parts

Ieed to Join these parts

Three Joining methods will be considered:

@elding

dhesive bonding

Mechanical fastening


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6oining illustrations!

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