Q1: Discuss the development which occurred on the single .

machines to build up automatic center machines

:Answer

Improved manufacturing productivity has occurred in the area of machining through developments in the machining process, in machine tool technology and in manufacturing management. As far as the machine tools were concerned it was found that they were actually productive, removing metal, for only 10 to20% of the time. Different surveys, however, gave different values. For 40 to 60% of the time the machine tools were in use but not productively: i.e. they were being set up for manufacture, or being loaded and unloaded, or during manufacture tools were being moved and positioned for cutting but they were not removing metal. For 20 to 50% of the time they were totally unused. As far as work in progress was concerned, batches of components typically spent from70 to 95% of their time inactive on the shop floor. So overwhelming was the clutter of partly finished work that a component requiring several different operations for its completion, on different machine tools, might find these carried out at the rate of only one a week. From 10 to 20% of their time components were being positioned for machining and for only from 1 to 5% of the time was metal actually being removed. From the late 1960s to the early 1970s both forms of waste the active, non-productive and the idle times began significantly to be attacked, the former mainly by developing machine tool technology and the latter by new forms of manufacturing organization.

Idle and active times in batch manufacturing

Machine tools of new design started to be introduced in significant numbers into manufacturing industry, with the effect of greatly reducing the times for tool positioning and movement between cuts. This new, computer numerical control (CNC), designs stemmed directly from the development of numerically controlled (NC) machine tools. In traditional, mechanically controlled machine tools, for example the lathe, the coordination needed between the main rotary cutting motion of the workpiece and the feed motions of the tool is obtained by driving all motions from a single motor. The feed motions are obtained from the main motion via a gear box and a slender feed rod (or lead screw for thread cutting). In a CNC machine tool, all the motions are mechanically separate, each driven by its own motor and each coordinated electronically (by computer) with the others. Not only are much more complicated feed motions possible, but the requirement of coordination has led to the development of much more precise, backlash-free ball-screw feed drives. For example a combined radial and axial feed to create a radius or to take the shortest path between two points at different axial and radial positions. This precise numerical control of feed motions, with the ability also to drive the tools quickly between cuts, together with other reductions in

set-up times, has approximately halved machine tool non-productive cycle time.

Reductions from the levels shown in the previous Figure of machine tool non-productive time and work in progress idle time, due to better technology and organization

A further halving of non-productive cycle time has been possible, with the spread throughout all manufacturing industry of new types of machine tools that have become called turning centers (related to lathes) and machining centers (developed from milling machines). These new tools, first developed in the 1960s for mass production industry, individually can carry out operations that previously would have required several machine tools. For example, it is possible on a traditional lathe to present a variety of tools to the workpiece by mounting the tools on a turret. In a new turning center, some of the tools may be power driven and the main power drive, usually used to rotate the workpiece in turning operations, may be used as a feed drive to enable milling and drilling as well as turning to be carried out on the one machine. The increased versatility of machine tools (based on turning operations as an example) has been briefly considered the freedom given by CNC to create more complicated feed motions, both by path and speed control; and the evolution of multi-function machine tools (centers).

Q2: Discuss the difference between manufacturing cost .productivity and accuracy
:Answer

Investment in highly productive machine tools is hard to justify. Such a manufacturer may still have some mechanically controlled machines, although the higher quality and accuracy attainable from CNC control will have forced investment in basic CNC machines. If part variety reduces, perhaps to the order of hundreds, and batch size increases, again to the order of hundreds, it begins to pay to organize groups or cells of machine tools to reduce materials handling. Almost certainly the machine tools in a cell will be CNC, and perhaps the programming of the machines will be from a central cell processor. A low level of investment in turning or machining centre type tools maybe justified, but it is unlikely that automatic materials handling outside the machine tools (robotics or automated guided vehicles) will be justifiable. Cell-oriented manufacture is typically found in companies that own products that are components of larger assemblies, for example gear box, brakes or coupling manufacturers.

Reduced materials flow through cell-oriented organizations and group technology

Q3: Define the manufacturing system.

:Answer

A method of organizing production. Machine tools are laid out by type of process; all lathes in one area, all milling machines in .another, all drills in another, and so on For example as might occur in converting sheet metal, steel bar, casting metal, paint and plastics parts into a car. Machine tools were laid out in flow lines or transfer lines. One machine tool followed another in the order in which operations were .performed on the product

In this so-called jobbing shop, or process oriented layout, different components were manufactured by carrying them from area to area as dictated by the ordering of their operations. It resulted in tortuous paths and huge amounts of materials .handling

?Q4: what are the main parameters of manufacturing systems

:Answer

Q1: Make a complete comparison between automatic hot .forging and convectional forging processes
:Answer

Points

Automatic Hot Forging

:Due to the quick process Small parts can be made at a rate of 180 parts per minute (ppm) Larger can be made at a rate of 90 ppm. The parts can be solid or hollow, round or symmetrical, up to 6 kg (13 lb), and up to 18 cm (7.1 in) in diameter Low labor skills is required to operate the machinery Tolerances are usually 0.3 mm Surfaces are clean Draft angles are 0.5 to 1 Air cooling will result in a part .that is still easily machinable Only feasible on smaller symmetric parts Very high cost so Large quantities are required to justify this process suitable only for mass) .(production Automatic Forging considered to be safer as the labor is only monitoring the process but not involved in it Metal should be at molten state .only

Conventional Forging Some types of forging may be

suitable for high productivity due to the speed of the process.

Productivity

Other types may not be suitable

for mass production like press forging which is a very time consuming process.

Labor Skills

Requires high Labor skills and high accuracy Very high surface finishing and .accuracy Also suitable for complex .shapes Suitable for many various dimensions of metals Not very expensive compared to the automatic forging because no high technological machines are required some types may be used with) (small productivity The process mostly depends on the labor which make it not very safe especially that it may involves being near Can be performed at various temperatures

Surface Finishing Product Size (limitations)

Capital Cost

Safety

Casting metal