디자이너를 위한
기초생산공정
2006년도 가을학기
MANUFACTURING
재료적, 기하학적 특성에 의해 정의된 제품을 일련의 순차적 조작작업을 통해 산출
Manufacturing Process
1. Primary Shaping
2. Forming
3. Cutting
4. Joining
5. Coating
6. Changing of Material Properties
(Assembling)
Shape-Changing
1.
Primary
Shaping
2. Metal
Forming
4. Joining
5.
Coating
6. Changing of Material Properties
Rearrangement
of material
particles
기초생산공정 생 산 공 정 개 론
3. Cutting
Elimination
of material
particles
Addition of
material
particles
2006년 가을학기
PRIMARY SHAPING
원자재(원료)로부터 일정 결합력을 발생 시킴으로써 solid body 산출
Primary Shaping의 2대 분류
1. forming, cutting 등의 가공을 위한 solid body 산출
2. 최종 부품 또는 제품의 형태와 크기를 갖는 solid body 제조
Primary Shaping Process
•
원자재 공급 및 생산
•
Primary Shaping에 적합한 상태로 준비
•
Primary Shaping Tool에 재료 주입
•
Primary Shaping Tool에서 재료의 응고
•
Primary Shaping Tool에서 응고된 제품 이탈
기초생산공정 1. Primary Shaping
2006년 가을학기
MANUFACTURING of CAST PARTS
Hand Moulding:
1. bottom half of
box (drag), 2. top
half of box (cope),
3. core, 4. casting,
5. plate with
wooden pattern
half, 6. risers,
7. pouring gate
기초생산공정 1. Primary Shaping
Mechanical Moulding:
1. plate with metal
pattern, 2.
compaction of the
moulding sand in a
frame, 3. boxless
mould ready for
casting, 4. casting
2006년 가을학기
VACUUM MOULDING
Vacuum moulding:
1 heating, 2 plastic sheeting,
3 pattern, 4 vacuum box;
a The plastic sheeting is softened by means of sheet-type
heating element and drawn tightly against the pattern by
vacuum through holes.
b The mould box is placed on top, filled with sand, precompacted, and the top of the box is covered with plastic
sheeting.
c A vacuum is applied to the mould box, compacting the
sand. By switching off the vacuum, the mould box can be
easily lifted off the pattern.
d The top and bottom halves of the box are joined. The
vacuum is maintained during casting.
기초생산공정 1. Primary Shaping
2006년 가을학기
INJECTION MOULDING
Injection moulding: The plasticised material (injection
moulding compound) is injected into either a cooled primary
shaping tool (injection moulding tool) in the case of
thermoplastics where the material solidifies due to cooling or
into a heated tool in the case of thermosets at high pressure
and solidifies there under the action of pressure
a Injection moulding tool is closed;
b Nozzle is placed in position,
c Moulding compound is injected and compressed,
d Injec-tion-moulded part solidifies, Moulding compound is
metered in and plasticised.
e Nozzle is with drawn,
f Injection moulding tool is opened and injection-moulded
part is ejected
기초생산공정 1. Primary Shaping
2006년 가을학기
FORMING
Forming의 분류
1.
작용하중에 따른 분류
- Forming under compressive conditions(DIN 8583)
- Forming under a combination of tensile and compressive conditions(DIN 8584)
- Forming under tensile conditions(DIN 8585)
- Forming under bending conditions(DIN 8586)
- Forming under shearing conditions(DIN 8587)
2. 형태에 따른 분류
- sheet/plate forming
- massive forming
3. 작업온도에 따른 분류
- cold forming
- hot forming
기초생산공정 2. Forming
2006년 가을학기
STRETCH FORMING
Produce large sheet parts (VDI 3140)
Stretch forming:
a simple stretch forming,
b tangential stretch forming;
1 workpiece,
2 clamping jaw,
3 former,
4 tool
Cyril-Bath process: 1
to 3 sequence of
operation
기초생산공정 2. Forming
2006년 가을학기
DEEP DRAWING
First-operation
drawing
Secondoperation
drawing
기초생산공정 2. Forming
Schematic diagram of deep
drawing with punch applied:
1 punch,
2 blank holder,
3 drawing die;
Do outside diameter of blank,
do punch diameter,
so thickness of blank,
Fst force of punch,
FN force of blank holder,
rst punch edge radius,
rN die radius
2006년 가을학기
BENDING
1. Punch, 2 blank holder,
3 support ring, 4 drawing die,
5 cup after first drawing,
6 cup being redrawn
기초생산공정 2. Forming
2006년 가을학기
SUPERPLASTIC FORMING
Metal mould process
a Sheet metal blank; 1 in place, b Workpiece;
4 moulded; 2 moulding tool, 3 pressure space
Female mould process
a Blank; 1 in place, b Forming the blank into a
bubble by gas pressure 3. c Drawing over the
mould 2. Showing 5 intermediate stages of
forming. d Final shape of workpiece 4.
기초생산공정 2. Forming
2006년 가을학기
FORGING
Application of basic processes for hammer
forging of steel in sequence
Basic types of operations for
filling die impressions:
a upsetting, b widening, c rising;
1 upsetting, 2 applying pressure,
3 filling
기초생산공정 2. Forming
2006년 가을학기
CUTTING
재료 결합상태의 부분적 파괴로 공작물의 형상을 변형시키는 생산기술
Cutting의 7대 분류
1. Severing(DIN 8588)
2. Machining with geometrically well-defined tool edges(DIN 8589)
3. Machining with geometrically undefined toll edges(DIN 8589)
4. Chipless machining(DIN 8590)
5. Disassembly(DIN 8591)
6. Cleaning and Evacuation(DIN 8592)
기초생산공정 3. Cutting
2006년 가을학기
Machining with geometrically well-defined tool edges
공작물에 대한 공구의 날 끝, 절삭면의 수,
절삭 끝 단의 형상, 절삭 면의 위치를 알고
서술 가능한 가공
기초생산공정 3. Cutting
2006년 가을학기
Machining with geometrically well-defined tool edges
선반가공(DIN 8589E):
연속적인(대개 회전에 의한) 절삭운동과 절
삭방향에 직각을 이루는 면 상에서 요구되는
이송운동을 갖는 가공
Some important turning
processes(DIN 8589 Part 1):
a facing, b parting, c turning,
d thread turning, e profile
turning (workpiece contour is
duplicated in tool), f form
turning
(WP: workpiece, T: tool)
기초생산공정 3. Cutting
2006년 가을학기
Machining with geometrically well-defined tool edges
드릴가공:
회전 절삭운동을 갖는 절삭가공으로 공구,
즉 드릴은 회전축 방향의 이송운동
Drilling processes(DIN 8589):
a Drilling into solid metal; 1 twist drill, b
Hole enlarging; 2 twist-type
counterbore with three cutting
edges, c Counterbore with
multiple diameters; 3 step drill, d
Center drilling; 4 center drill, e
Center drilling and counter sinking;
5 combined enter drill and
countersink, f Tapping; 6 tap, g
Reaming; 7 machine reamer
기초생산공정 3. Cutting
2006년 가을학기
Machining with geometrically well-defined tool edges
밀링가공:
Plain Face Milling with End Milling Cutter
Milling processes(DIN 8589).
Plain milling: a face milling, b peripheral milling,
c combined face and peripheral milling, d thread milling,
e hobbing, f profile milling, g form milling
(WP: workpiece, T: tool)
기초생산공정 3. Cutting
2006년 가을학기
Machining with geometrically well-defined tool edges
밀링가공:
Form Milling
Form milling by a three-axis
milling and b five-axis milling;
1 convex milling cutter, 2 end
milling cutter, 3 tool axis,
4 surface normal
기초생산공정 3. Cutting
2006년 가을학기
Machining with geometrically undefined tool edges
기초생산공정 3. Cutting
2006년 가을학기
Chipless Machining
기초생산공정 3. Cutting
2006년 가을학기
ASSEMBLING
기하학적으로 정의된 제품으로 결합시켜나가는 작업과정
Assembling System
경제적 조건에 따라 조립체계의 유연성과 자동화 수준 결정
Fields of application of different
assembly equipment:
a automatic assembly machine
b flexibly automated assembly line
c flexibly automated assembly station
d mechanised individual workstation
e manual individual workstation
기초생산공정 4. Assembling
2006년 가을학기
Computer Aided Manufacturing
CAD / CAM
CAP
(Computer Aided Planning)
CAD
(Computer Aided Design)
CAQ
(Computer
Aided
Quality
Control)
CAM
(Computer Aided Manufacturing)
기초생산공정 CAM
2006년 가을학기
Computer Aided Manufacturing
Special System
15,000
Production Volume
Parts per Year
(Transfer Lines)
Flexible Manufacturing
System
(Computer Integrated
Manufacturing System)
Manufacturing Cell
(Stand-alone NC
Machines)
15
2
기초생산공정 CAM
800 Part Variety
Number of Different Parts
2006년 가을학기
Computer Aided Manufacturing
(Machining with geometrically well-defined tool edges)
기초생산공정 CAM
2006년 가을학기
Computer Aided Manufacturing
(Chipless Machining
기초생산공정 CAM
- LASER cutting)
2006년 가을학기
Computer Aided Design
& Pototyping
Computer Aided Prototyping ⊆
Computer Aided Manufacturing
기초생산공정 Computer Aided Design & Prototyping
2006년 가을학기
Computer Aided Industrial Design Tools
- 고전적 디자인 도면 작성 도구 : AutoCAD -
기초생산공정 Computer Aided Design & Prototyping
2006년 가을학기
Computer Aided Industrial Design Tools
- 3차원 입체 모델링 도구 -
전문적 도구
Solid modeler
Surface modeler
Pro Engineer
보급형 PC급 도구
Solid Works
CATIA
Rhino
(Alias Design Studio)
3D Max
기초생산공정 Computer Aided Design & Prototyping
2006년 가을학기
Computer Aided Prototyping Tools
- Rapid Prototyping, RP -
재
료
강
도
PULP
RASIN
WAX
정밀도
기초생산공정 Computer Aided Design & Prototyping
2006년 가을학기
Computer Aided Prototyping Tools
- Rapid Prototyping, RP -
Rapid Prototype, RP:
레이저 조형방식을 통한 적층 형식(layer by layer)으로
3차원 형상 시제품의 제작기술
주요 RP Process:
Steleolithography, SLA
Selective Laser Sintering, SLS
Fused Deposition Manufacture, FDM
Laminated Object Manufacture, LOM
기초생산공정 Computer Aided Design & Prototyping
2006년 가을학기
Computer Aided Prototyping Tools
- Rapid Prototyping, RP -
기초생산공정 Computer Aided Design & Prototyping
2006년 가을학기
Computer Aided Prototyping Tools
- Rapid Prototyping, RP -
기초생산공정 Computer Aided Design & Prototyping
2006년 가을학기