تصنيع

• Casting

  • Fundamental of metal casting
  • Casting process, sand mold casting
  • Metal mold casting
• Forging

  • Hot working
  • Cold working
  • Mechanism and industrial applications of each process
• Welding

  • Gas welding
  • Arc welding
  • Tig welding
  • Mig welding
  • Resistance welding
  • Thermit welding
  • Laser welding
  • Plasma Welding
• Machine cutting process


  • Theory of cutting
  • Conventional process (milling Machine, lath Machine, shaper Machine, drilling Machine)
• Powder Metallurgy
• Numerical control machines


  • CNC Machines
• Text Book: Manufacturing Engineering and Technology (Fourth Edition) By: Serope Kalpakjian Steven R. Schmid
• References


  • Fundamentals of Modern Manufacturing By: Mikell P. Groover
  • Introduction to basic Manufacturing processes and Workshop Technology By : Rajender Singh
• Manufacturing process


  The steps through which raw material are transformed into final product
• Technical manufacturing


  The application of physical and chemical processes to alter the geometry, properties and appearance of a given starting material to make parts or products including assembly of multiple parts
• Economically Manufacturing


  The transformation of material into items of greater value by means of one or more processing and assembly operations
• Manufacturing activities


  • Product design
  • Machinery and tooling
  • Materials
  • Purchasing
  • Manufacturing
  • Production control
  • Supporting
  • Marketing
  • Sales
  • Shipping
  • Customer services
• Production Quantity


  • Low production (Q < 100)
  • Medium production (100 < Q < 10000)
  • High production (10000 < Q)
• Toyota was the world's first automobile manufacturer to produce more than 10 million vehicles per year which it has done since 2012
• In 1924, Sakichi Toyoda invented the Toyoda Model G Automatic Loom. The principle of jidoka, which means the machine stops itself when a problem occurs
• Manufacturing activities must be responsive to

  • Design requirement and product specification
  • Environmentally friendly
  • Quality
  • Flexible
  • Material, Production methods and Computer integration
  • System
  • Manufacturing organization must constantly strive for higher levels of quality and productivity
• Questions during design and manufacturing paper clips

  • What type material would you choose to make this product?
  • Does it have to be metallic or it can be non-metallic? (such as plastic)
  • If we choose metal, what kind of metal?
  • If the material that you have start with is wire? What should be its diameter?
  • Should be it round or have some other cross section?
  • Is wire surface finish and appearance important?
  • How we take a piece of wire and shape it into a paper clip? Would you do it by hand or by machine?
  • Would you have to manufacture from 100- 1000000 paper clips, do you buy it or rent it?
• Stiffness


  A measure of how much it deflects under a given force
• During manufacturing paper clips, there are some important considerations should be consider

  • Corrosion of material
  • Finalizing the design and select suitable material which is commercially available
  • Cost of material
  • Bending of material without cracking or breaking
  • Can the wire easy cut from long piece without excising wear on cutting tool
  • Machining , what is the economical method of manufacturing this product? This depend on production rate and Market competitive (national and inter nation market)
• Casting is basically involves pouring metal into a mold cavity where upon solidification, it takes the shape of the cavity
• Reasons casting processes are most often selected over other manufacturing methods

  • Castings are producing complex shapes with internal cavities or hollow section
  • It can produce very large parts
  • It can utilize work piece materials that are difficult or uneconomical to process by other means
  • Casting is competitive with other processes (net –shape manufacturing technologies)
• Net-shape and near net-shape manufacturing

  A part is made in only one operation at or close to the FINAL desired dimensions, tolerances, and surface finish
• The casting process basically involves

  • Pouring molten metal into a mold patterned after the part to be manufactured
  • Allowing it to cool
  • Removing the metal from the mold
• Important considerations in casting operation

  • The flow of molten metal into the mold cavity
  • The solidification and cooling of the metal in mold
  • The influence of the type of mold material
• Pure metals

  It solidifies at constant temperature
• Alloys

  The solidification begins when temperature drops below the liquidus TL
• Freezing range

  The width of the mushy zone, where both liquidus and solid phases are present, It is an important factor during solidification. This zone is described in terms of a temperature difference, as TL - Ts
• Freezing range

  • Short freezing range (< 50°C) for example (ferrous casting)
  • Long freezing range (> 110°C) for example (Aluminum and Magnesium)
• Slow cooling rate (on the order of 102 K/s)

  Long local solidification time, Coarse dentric structure with large spacing between the dentric
• Faster cooling rates (on the order 104 K/s)

  Short local solidification time, the structure becomes finer with small dentric arm spacing
• Higher cooling rates (on the order of 106 to 108 K/s)

  The structures developed are amorphous
• The basic casting system

  • Sprue
  • Runner
  • Risers
  • Gate
• Sprue

  A vertical channel through which the molten metal flows downward in the mold
• Runner

  Channels that carry the molten metal from sprue to the mold cavity, or connect the sprue to the gate
• Risers

  Serve as reservoirs to supply the molten metal necessary to prevent shrinkage during solidification
• Gate

  That portion of the runner through which the molten metal enters the mold cavity
• Function of gating system in sand casting

  • Trap contaminants (such as oxides and other inclusion) in the molten metal
  • Avoids or minimizes problems (such as premature cooling, turbulence and gas entrapment)
• Bernoulli's Theorem

  Based on the principle of conservation of energy, h + p/ρg + v2/2g = constant
• For two different elevations

  h1 + p1/ρg + v12/2g = h2 + p2/ρg + v22/2g + f
• Continuity

  Rate of flow is constant, Q = A1V1 = A2V2