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Manufacturing technology Introduction

Manufacturing technology Introduction. Technology II – Jan Tomíček. Manufacturing. Important part of World economy. Allmost all products are manufactured. Demands are increasing New issues – energy efficiency, waste, etical issues. Changes in the world of goods manufacturing.

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Manufacturing technology Introduction

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  1. Manufacturing technologyIntroduction Technology II – Jan Tomíček

  2. Manufacturing • Important part of World economy. Allmost all products are manufactured. • Demands are increasing • New issues – energy efficiency, waste, etical issues

  3. Changes in theworldofgoodsmanufacturing • Worldwidecompetetion • New materials • Advancedtechnologies • New manufacturingsystems • Enviromentalissues

  4. 1. WorldWideCompetetion • Global business • Market = Wholeworld • Everybodycanmake business – • knowledge vs. capital • customization vs. massproduction • Productplacement vs. variability

  5. 2. New materials • Demandsfromcustomers • Smoothsurface on plasticparts • Transparencyofplastic • Shiny metal look etc. • New developedmaterialswithbetterproperties • Heatresistantmaterials • Highstrengthmaterials • Specialmaterials

  6. 3. Advancedtechnologies • Complexproducts • Combinedprinciples • Mechanicalprinciples • Electrical • Electronical • Combination • Water, steam, electricity,

  7. 4. New manufacturingsystems • Manufacturingsystem • Manufacturingstrategies • Management

  8. 5. Enviromentalissue • Lowenergyandmaterialconsumption • Utilizationofhumanlabor, heavywork • Healtandsecurityissues • Ethicalproblems

  9. ProductLifeCycle

  10. TIME Cost Per unit SATURATION Annualsales per model

  11. Priceoftheproduct? • Whatisthebestpriceoftheproduct? Smallest, affordable, highest, psychologicallyfriendly, discounted?? Productioncosts!

  12. Manufacturingcosts • Methods: • Casting, foundry, moulding • Formingofmetalforming • Machining(materialremoval) • Surfacetreatments(finishing) • Heattreatment • Joiningandassembling • Machiningisapprox 40% ofmanufacturingcosts TECHNOLOGY II

  13. Machining • Chipremovalprocess – Materialisremoved in formof chips from a pieceofrawmaterial to archive thedesiredshape. • Material(chips) are removed by a toolfromtheblank • Thisprocessiscalled „Chipforming“

  14. ADVANTAGES • variety of work materials • variety of part shapes and geometric features • dimensional accuracy • good surface finishes DISADVANTAGES • wasteful of material • time consuming

  15. Materialutilization

  16. A CUTTING TOOL • single-point tool (a) • multiple cutting edge tool (b)

  17. Chipformingprinciple • Continuous vs. discontinuouschip Forcestressworkhardeningsaturation(fullyhardenedmaterial)shearconinuouschip

  18. CHIP FORMATION(orthogonal cutting schema) • the tool is forced into the material • plastic deformation→ hardening of the material • shear deformation – shear plane (angle φ)

  19. CHIP FORMATION

  20. Secondarydeformationzone

  21. Chipbreakers • Preventingthebuilt-upedge • Groove type - premanufactured • Obstruction type

  22. ChipandTool geometry • Tool – rake & faceangle

  23. Chipthickness • Chipthickness ratio

  24. CUTTING CONDITIONS • cutting speedvc [m.s-1]; [m.min-1] • feedf[mm.rev-1]; [m.min-1] • depth of cutd = ap[mm]

  25. Chiptypes

  26. Chipbreakingdiagramme

  27. Chipbreakingdiagramme

  28. Chip volume ratio • Calculation W = • Value 3-400 • Large volume of chips

  29. Chips removal • Chips mustberemoved • Fromthecut – gravity, liquid, airetc. • Fromthemachine – liquid, automatic, manually • Fromthe workshop – conveyors, carriages • Fromfactory – • recycling

  30. What to thinkabout? • Nexttime – resistanceofmaterial, cuttingforces, heatandtemperature

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