Chapter 1. Introduction

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M2794.001800 M A T E R I A L A N D M A N U F A C T U R I N G P R O C E S S E S

Chapter 1. Introduction

Prof. Sung-Hoon Ahn ( )

School of Mechanical and Aerospace Engineering Seoul National University

September 2, 2014

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Creation of Adam

 Michelangelo Buonarroti (1508-1516)

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3

(FIB) Focused Ion Beam

Manufacturing

Size of typical parts and the capabilities of manufacturing processes

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Manufacturing

 Manufacturing ( , , )

• Latin: manus (hand) + factus (make)

 “To make by hands or, especially by machinery, often on a large scale and with division of labor”

(Webster Dictionary)

 ( ) :

(Yahoo dictionary)

 ː ( ) :

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5

Importance of manufacturing

2014 2013

Gross Domestic Products

(GDP) Total Employees

Manufacturing industry:

(14.3%)

Others:

(19.8%)

Service Industry:

(65.8%)

출처 : Statistics Korea (http://www.kosis.kr)

Manufacturing industry:

(34%) Others:

(28%) Service Industry:

(38%)

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 Textbook

 Schedule

 Homework

 Exam

 Term project

 Website

 http://fab.snu.ac.kr

 http://etl.snu.ac.kr

 TAs

(Bldg. 301-1405/ 880-9073/ jamaisvu444@gmail.com)

Syllabus

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7

Textbook

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Textbook

Ch 1. Introduction

Ch 2. Fundamentals of the Mechanical Behavior of Materials Ch 3. Structure and Manufacturing Properties of Metals

Ch 4. Surfaces, Tribology, Dimensional Characteristics, Inspection, and Product Quality Assurance Ch 5. Metal-Casting Processes and Equipment; Heat Treatment

Ch 6. Bulk Deformation Processes Ch 7. Sheet-Metal Forming Processes Ch 8. Material-Removal Processes: Cutting

Ch 9. Material Removal Processes: Abrasive, Chemical, Electrical, and High-Energy Beams

Ch 10. Properties and Processing of Polymers and Reinforced Plastics; Rapid Prototyping and Rapid Tooling

Ch 11. Properties and Processing of Metal Powders, Ceramics, Glasses, Composites, and Superconductors

Ch 12. Joining and Fastening Processes

 Chapters to be covered

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9

Schedule

화목 1.5-1.5 at 301-118

Week Sun Mon Tue Wed Thu Fri Sat Day Chap. 진도 HW

31 1 2 3 4 5 6 2 1 Introduction

4 1 Introduction

7 8 9 10 11 12 13 9 휴강 추석

11 2 Fundamentals of the mechanical behavior of materials

14 15 16 17 18 19 20 16 2 Fundamentals of the mechanical behavior of materials Ch.02

18 3 Structure and manufacturing properties of metals

21 22 23 24 25 26 27 23 3 Structure and manufacturing properties of metals

25 4 Surfaces/dimensional characteristics/inspection/QA Ch.03~04

28 29 30 1 2 3 4 30 5 Metal casting process and equipment

2 5 Metal casting process and equipment Ch.05

5 6 7 8 9 10 11 7 6 Bulk/sheet metal forming processes

9 휴강 한글날

12 13 14 15 16 17 18 14 6 Bulk/sheet metal forming processes Ch.06

16 7 Sheet-metal forming processes

Meeting Team meeting with professor

19 20 21 22 23 24 25 21 7 Sheet-metal forming processes Ch. 07

23 휴강 자율학습일

26 27 28 29 30 31 1 28 중간고사

30 중간발표

2 3 4 5 6 7 8 4 8 Material removing process-cutting

6 8 Material removing process-cutting Ch. 08

9 10 11 12 13 14 15 11 9 Material removal process-abrasive/chemical/electrical/high-energy beams

13 9 Material removal process-abrasive/chemical/electrical/high-energy beams

16 17 18 19 20 21 22 18 9 Material removal process-abrasive/chemical/electrical/high-energy beams

20 10 Properties and processing of polymers/reinforced plastics-RP

23 24 25 26 27 28 29 25 10 Properties and processing of polymers/reinforced plastics-RP

27 10 Properties and processing of polymers/reinforced plastics-RP Ch.09~10

Meeting Team meeting with professor

30 1 2 3 4 5 6 2 11 Properties and processing of metal powders/ceramics/glasses/composites

4 12 Joining and fastening processes Ch.11~12

7 8 9 10 11 12 13 9 기말발표

11 기말고사, 과제 제출

14 15 16 17 18 19 20

21 22 23 24 25 26 27

수업일 휴일 성적 제출

마감 Dec

종강

17

수업 2/4선

2 추석 추석 추석

M2794.001800 재료와 제조공정(Material and Manufacturing Processes)

Sep 1

4 3

수업 1/4선 개천절

한글날 Oct

5

7 6

9

자율학습일

8 자율학습일

Nov 10 11

12 수업 3/4선

14 13

16 15

동계 휴가 시작

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Schedule

 Lab tour

 Equipment, facilities in IDIM

 Detail information will be noticed

 Project presentation

 It might take total 120min for mid/final presentations (5min * 20teams)

 Supplementary lecture

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11

Homework



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Exam

 Mid-term + Final exam

 Examples



Determine whether the following statements are true or false.

Mark T if it is true, otherwise F.

a. During tensile test, necking occurs between yield strength and Ultimate Tensile Strength. ( ) b. In general brittle ceramic, fracture occurs at UTS. ( )



Answer the following questions in a couple of sentences.

a. Explain about ‘Hall-Petch Equation.

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13

Exam



(a) Above figure is a general type of mold used for sand casting. Write each name and its function of (A) ~ (D).



(b) Compare the process capability index Cp and Cpk. Explain which index would be more appropriate to describe the process capability. (If necessary, draw the graph.)



(c) Assume that mass of part made from the above sand casting process should be within 15 0.50 kg. It is proposed to use and charts to control this weight. After several subgroups of 10 parts each have been taken, the average of average is 14.88 kg, and the average of range is 1.24 kg. Calculate Cp and Cpk. (Assume normal

distribution.)

(A)

(C)

(D)

(B)

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Term Project

 Topics:

Any topic is possible, but preferred materials and equipment include:

• Composites

• SMA (Shape Memory Alloy)

• IPMC

• NPDS

• RP

• Injection Molding

• SEM

• High speed camera

※ There are additional points for patent, registered program and journal paper.

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Term Project

 Team

 5~6 members in one team

 Each team can use maximum 250,000 won budget

 Presentation

 Mid-term + final presentation

 Team meeting with prof. before presentation

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Term Project

 Examples

 Manufacturing process(2009, 2012)

• Lighting ski pole

• Walking Supporting Device

• Manufacturing CFRP Skate Blade

• LED,

Light Emitting Diode embedded

GFRP,

Glass Fiber Reinforced Plastic

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Options

 Lighting ski pole

 No need to replace batteries.

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– Energy harvesting

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Mechanical-Electric system

관 계 식 비고

진동시스템의 상대적 거리

Mechanical System

Input(y(t))에 따른 output(z(t))의 크기와 위상차

전자기 유도에 의해 발생하는

e.m.f ,

축전기 연결 system

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Drawings

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 High Stiffness

 High Strength

 Low Thermal conductivity

 Low Density

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Appropriate material

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 Polycarbonate

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Process

 Cylinder shape

 Turning operation

 Polycarbonate

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Manufacturing Process Term Project

Final Presentation 5

^th

Team

Walking Supporting Device

For your Happy Silver Life

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?

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Manufacturing Process Term Project

Final Presentation

5

^th

Team

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Anywhere!

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Manufacturing Process Term Project

Final Presentation 5

^th

Team

How it Works

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Normally :

137 ÷ 12 ÷ 0.004 = 286N/m

How it Made

Assume Avg. W : 70kg Assume Leaning : 20%

Set Size : 120 x 100 mm ² Set Number : 12 module

With Obstacles :

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Manufacturing Process Term Project

Final Presentation 5

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Team

Extrusion

Rolling Drilling Welding

Injection Molding

How it Made

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..

Patents

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10조

35

2003-11748 정영배 2004-11655

서종민 2004-11734

정태부 2004-11737

조성제 2004-11745

조한수

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37

-200 0 200 400 600 800 1000 1200

0 1 2 3

For ce (N )

시간(sec)

두 발로 70cm 높이에서 뛰었을 때 가해지는 하중

X축 Y축 Z축 F

953 N

Reaction Force Test : Experiment Result

I 2 3 4 5

1764 N

-500 0 500 1000 1500 2000

0 0.5 1 1.5 2 2.5 3

For ce (N )

시간(sec)

한 발로 70cm 높이에서 뛰었을때 가해지는 하중

X축 Y축 Z축 F

Maximum Possible

Force!

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ANSYS Analysis : Solution Information

I 2 3 4 5

• 94g

Weight

• 42.5Mpa

Maximum Principal Stress

• 23.8Mpa

Maximum Shear Stress

• 1.19x 10-

⁴

Maximum Principal Strain

• 2.189 x10-

⁵

m

Total Deformation

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I 2 3 4 5 6

Practical Issues : Weight

I 2 3 4 5

310/92=3.37

CFRP

Steel

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Manufacturing Process Term Project

Final Presentation 5

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Team

LED, Light Emitting Diode embedded GFRP , Glass Fiber Reinforced Plastic

Hong Seung-il

Cho Yu-bin

Han Sang-jun

Han Won-young

Heo Chang-min

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• Summary of Mid Presentation

: What are we going to make? “Marvelous Illuminating Plate !”

• Process of Making “M.I.P”

: Determine LED type, design circuit, lay up GFRP.

• Applications

: It’s Strong light source, but also Water-proof !

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Manufacturing Process Term Project

Final Presentation 5

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Team

Summary of last Presentation

At last presentation, we introduced LED, GFRP.

Our concept of this Project is, : Combination of each other.

+

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Manufacturing Process Term Project

Final Presentation 5

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Team

Making Process

 Choose a LED : A LED with an intergrated Circuit

 Design the Circuit Diagram : A parallel circuit with Dimming system

 Lay up GFRP : Fill up a vacancy – Handmade(!) GFRP slice

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Applications

2 Key words of M.I.P

 Hard strength

 Water-proof

☞ It can be applied to the any parts!!

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Manufacturing Process Term Project

Final Presentation

5

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