美国麻省理工大学：《Engineering Design and Rapid Prototyping》Introduction to Manufacturing

16810(16682) Engineering Design and Rapid prototyping Lecture 6 IGa10 Manufacturing-CAM Instructor(s) Prof. olivier de weck Dr. Il Yong kim January 14, 2004 Massachusetts Institute of Technology

16.810 (16.682) 16.810 (16.682) Engineering Design and Rapid Prototyping Engineering Design and Rapid Prototyping Instructor(s) Lecture 6 Manufacturing - CAM January 14, 2004 Prof. Olivier de Weck Dr. Il Yong Kim

IG a10 Outline Introduction to Manufacturing Parts Fabrication and assembly Metrics: Quality, Rate, Cost, Flexibility Water Jet Cutting Video sequence b777 Manufacturing Role of manufacturing in a real World Context OMax Introduction Computer Aided(assisted )Manufacturing Converting a drawing to CNC Routing Instructions 16.810(16682) Massachusetts Institute of techn

16.810 (16.682) 2 Outline „ Introduction to Manufacturing „ Parts Fabrication and Assembly „ Metrics: Quality, Rate, Cost, Flexibility „ Water Jet Cutting „ Video Sequence B777 Manufacturing „ Role of Manufacturing in a Real World Context „ OMax Introduction „ Computer Aided (Assisted) Manufacturing „ Converting a drawing to CNC Routing Instructions

1G.810 Course Flow Diagram Learning/ Review Problem statement Deliverables Design Intro Hand sketching Design Sketch v1 CAD/CAM/CAE Intro CAd design Drawing v1 FEM/Solid mechanics FEM analysis Overview Analysis output v Manufacturing Produce Part 1 Part v1 Training Due Structural Test Test Wed, Jan 21 xperiment data v1 Training Design Optimization Optimization Design/Analysis output v2 Produce part 2 Part v2 Test Experiment data v2 Final review 16.810(16682)

16.810 (16.682) 3 Course Flow Diagram CAD/CAM/CAE Intro FEM/Solid Mechanics Overview Manufacturing Training Structural Test “Training” Design Optimization Hand sketching CAD design FEM analysis Produce Part 1 Test Produce Part 2 Optimization Problem statement Final Review Test Learning/Review Deliverables Design Sketch v1 Analysis output v1 Part v1 Experiment data v1 Design/Analysis output v2 Part v2 Experiment data v2 Drawing v1 Design Intro Due Wed, Jan 21 Wed, Jan 21

IG A1n Introduction to Manufacturing a Manufacturing is the physica/ realization of the previously designed parts Metrics to assess the" performance"of mfg Quality does it meet specifications? Rate how many units can we produce per unit time? Cost What is the cost per unit? What is the investment cost in machinery tooling? Flexibility what else can be make with our equipment? How long does it take to reconfigure the plant? 16.810(16682) Massachusetts Institute of techn

16.810 (16.682) 4 Introduction to Manufacturing „ Manufacturing is the physical realization of the previously designed parts „ Metrics to assess the “performance” of mfg „ Quality „ does it meet specifications? „ Rate „ how many units can we produce per unit time? „ Cost „ What is the cost per unit? „ What is the investment cost in machinery & tooling? „ Flexibility „ what else can be make with our equipment? „ How long does it take to reconfigure the plant?

IG a0 Life Cycle: Conceive, Design, Implement creativit modeling simulation architecting experiments The Enterprise Beginning trade studies design techniques of Lifecycle optimization(MDo) Conceive manufacturing "process information” Design assembly create integration virtual PDR + CDR SRR Implement iterate Mission a The System Requirements real “um Constraints Customer Architect information Stakeholder Designer to matter' User System Engineer The Environment: technological, economic, political, social, nature 6810(16682) Massachusetts Institute of Technology

16.810 (16.682) 5 Life Cycle: Conceive, Design, Implement 1 Beginning of Lifecycle - Mission - Requirements - Constraints Customer Stakeholder User Architect Designer System Engineer Conceive Design Implement “process information” “turn information to matter” SRR PDR CDR iterate iterate The Environment The Environment: technological, economic, political, social, nature The Enterprise The Enterprise The System creativity architecting trade studies modeling simulation experiments design techniques optimization (MDO) virtual real Manufacturing assembly integration choose create

IG A10 Simple Manufacturing Plant PF≡ Parts Fabricati Raw materials Warehouse focus of this lecture) QA Quality assurance PF1 PFn Energy OA1 QAn Scrap . Emissions Supplied parts SupplierParts Buffer Buffer abor Assembly Money Finished Inspection Goods 16.810(16682) Massachusetts Institute of techno ology it

16.810 (16.682) 6 Simple Manufacturing Plant Warehouse PF1 … PFn QA1 … QAn Parts Buffer Supplier Buffer Assembly Final Inspection Finished Goods PF = Parts Fabrication (focus of this lecture) QA = Quality Assurance Raw Materials Energy Supplied Parts Labor Money Sales Scrap Emissions

IG a10 Raw Materials Material Selection Strength Density Refer to Ashby M F. Materials Selection in Mechanical Design, Oxford; Boston Cost Butterworth-Heinemann 1999 Form Sheet Rods,… 16.810(16682) Massachusetts institute of technol ology it

16.810 (16.682) 7 Raw Materials „ Material Selection „ Strength „ Density „ Cost „ … „ Form „ Sheet „ Rods, ... Refer to Ashby, M.F., Materials Selection in Mechanical Design, Oxford; Boston: Butterworth-Heinemann, 1999

IG a10 Parts Manufacturing example: deck components Rⅰbbed- bulkheads decks a Approximate dimensions 250mm x 350mm x 30mm Wall thickness 2,54m Fundamental Parts Fabrication Techniques Machining -e. g. milling, laser and waterjet cutting Forming-eg deep drawing forging stamping Casting-fll die with liquid material, let cool Injection Molding-mainly polymers Layup-e.g. Pre-preg composite manufacturing Sintering-form parts starting from metal powder 16.810(16682) Massachusetts Institute of techn

16.810 (16.682) 8 Parts Manufacturing „ example: deck components „ Ribbed-bulkheads „ Approximate dimensions „ 250mm x 350mm x 30mm „ Wall thickness = 2.54mm decks „ Fundamental Parts Fabrication Techniques „ Machining – e.g. milling, laser and waterjet cutting ... „ Forming – e.g. deep drawing, forging, stamping „ Casting - fill die with liquid material, let cool „ Injection Molding - mainly polymers „ Layup – e.g. Pre-preg composite manufacturing „ Sintering - form parts starting from metal powder

IGAln Metal Cutting/Removal Techniques New Techniques Laser Cutting Turning on a lathe Milling Planing (mainly for sheet metal) Waterjet Cutting Slotting Drilling Reaming Countersinking Reaming Grinding 16.810(16682) Massachusetts Institute of Technology

16.810 (16.682) 9 Metal Cutting/Removal Techniques Turning on a lathe Milling Planing Drilling Countersinking Slotting Grinding Reaming New Techniques: Laser Cutting (mainly for sheet metal) Waterjet Cutting Reaming

IG A1n Quality: Engineering Tolerances Tolerance -the total amount by which a specified dimension is permitted to vary (ansi y14.5M) a Every component ply within spec adds to the yield(n y 16.810(16682) Massachusetts Institute of techn 10

16.810 (16.682) 10 Quality: Engineering Tolerances „ Tolerance --The total amount by which a specified dimension is permitted to vary (ANSI Y14.5M) „ Every component within spec adds to the yield (Y) q p(q) L U Y y p(y)