Exercises

Manufacturing Processes - Classification and Properties

(To accompany Lecture Unit 10)

Professor Mike Ashby

Department of Engineering
University of Cambridge

© M. F. Ashby, 2013
For reproduction guidance see back page

This exercise unit is part of a set based on Mike Ashby’s books to help introduce students to materials, processes and rational selection.

The Teaching Resources website aims to support teaching of materials-related courses in Design, Engineering and Science. Resources come in various formats and are aimed

primarily at undergraduate education.

www.grantadesign.com/education/resources
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 Exercises – Unit 10

Exercises with Worked Solutions

This collection of exercises and solutions has been put together to help you as an instructor choose or
develop your own exercises for your students. You may simply want to browse through them for inspiration,
or you may use them with your class. We are providing these in Word format so that you may pick and
choose the questions you find suitable for your course this year. We have also included variations on a
theme so that you can set different questions for different classes.

Most of the questions come from or are inspired by the exercises in the following books by Professor Mike
Ashby of the University of Cambridge Engineering Department, co-founder of Granta Design.

• Materials Selection for Mechanical Design by Michael F. Ashby (ISBN-13: 978-1-85617-663-7)

• Materials: Engineering, Science, Processing and Design by Michael F. Ashby, Hugh Shercliff,
and David Cebon (ISBN-13: 978-1856178952)
• Materials and the Environment by Michael F. Ashby (ISBN-13: 978-0-12385971-6)

(Reproduction and copyright information can be found on the last page. Please make sure to credit
Professor Mike Ashby and Granta Design if you use these questions.)

Most of the questions require the use of CES EduPack. CES EduPack is a materials teaching resource
used at 800+ Universities and Colleges worldwide. You can find out all about it at: www.grantadesign.com/education
.

Topics on which there are Exercises with Worked Solutions are 1:

Title Associated Lecture Unit

Materials – classification and properties Lecture Units 1 & 2
Elements Lecture Unit 3
Design – translating requirements into constraints and objectives Lecture Unit 6

Selecting Materials Lecture Unit 7

Manufacturing Processes – classification and properties Lecture Unit 10

Eco Properties and the Eco Audit Tool Lecture Unit 12 and “ Ecoinformed
material selection ”
Low Carbon Power Systems Lecture Unit: “ Materials for low
carbon power”
Sustainable Development Lecture Unit: “ What is a
Sustainable development ”
Bioengineering Lecture Unit: “Teaching
resources for Bioengineering”

You can find the other units here: www.teachingresources.grantadesign.com

If there are suggestions, or if you have questions please contact Teaching Resources Team at teachingresources@grantadesign.c
.

1 Exercise units follow the same numbering of the PowerPoint lectures for the same topic

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M.F. Ashby 2013
 Exercises – Unit 10

Contents

Types of Processes and the Process Tree .................................................................... 3

Finding Process Records in CES EduPack by Browsing .............................................. 3
Finding Process Records in CES EduPack by Seaching .............................................. 3
Key Constraints in Selecting Processes ........................................................................ 4
Process Information in CES EduPack ............................................................................ 5
Longer Project-based Exercises .................................................................................... 5

Types of Processes and the Process Tree

1. What is a shaping process? Look around you and ask yourself how the things you see were shaped.

2. Almost all products involve several parts that are joined. Examine products immediately around you and list the
joining methods used to assemble them.

3. How many ways can you think of for joining two sheets of a plastic like polyethylene? List each with an example of
an application that might use it.

4. How many different surface treatment processes can you think of, based on your own experience? List them and
annotate the list with the materials to which they are typically applied.

Finding Process Records in CES EduPack by Browsing

Finding Process records in CES EduPack follows the same format as finding Material records, except that to
find Process Records in CES EduPack, one has to change from ‘MaterialUniverse’ (the default) to
‘ProcessUniverse’ at the top of the respective Browse/Search windows.

File Edit View Select Tools Window

Browse Search Select

Table: ProcessUniverse
ProcessUniverse

Subset: Edu
EduLevel
Level22

ProcessUniverse

+ Joining

+ Shaping

+ Surface treatment

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 Exercises – Unit 10

5. Use the Browse facility to find records for the polymer-shaping process Rotational
molding . What, typically, is it used to make?

6. Find the composite-shaping process Filament winding , a way of making high quality
composite structures. What, typically, is it used to make?

Finding Process Records in CES EduPack by Searching

7. Use the Search facility to find out about the process Pultrusion . Do the same for TIG
welding .

8. Find what the process RTM is all about by Searching.

9. Find what the process SLS is about by Searching.

Key Constraints in Selecting Processes

10. Use the Browse facility to find the Shaping Process Injection Molding, thermoplastics.

Here is the process schematic for injection molding:

Constraints are criteria that must be met by a process, in order to satisfy the design requirements. If a
process cannot meet a certain constraint it is eliminated, narrowing down the list of possible processes.

Can you think what the key constraints for a shaping process (e.g. Injection Molding) are?

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M.F. Ashby 2013
 Exercises – Unit 10

11. Use the Browse facility to find the Joining Process Gas Tungsten Arc (TIG). What do you
think are the key constraints for a joining process?

12. Use the Browse facility to find the Surface Treatment Process Induction and Flame
Hardening. What do you think are the key constraints for a surface treatment process?

Process Information in CES EduPack

The datasheets for Processes can be used in the same way as that for materials.

13. Use the Browse facility in CES EduPack to find:

(A) el registro para el moldeo por inyección proceso de conformación, los termoplásticos. ¿Cuál es su
tamaño de lote económico? ¿Qué significa este término?

(B) el proceso de corte por chorro de agua de mecanizado (registros para los procesos de mecanizado están
contenida en la tabla de datos Shaping). ¿Cuáles son sus usos típicos?

(C) el proceso de soldadura por fricción-agitación de unión. ¿Se puede utilizar para unir materiales diferentes?

(D) el tratamiento de superficie de endurecimiento proceso láser. ¿Cuáles son las tres variantes de este
¿proceso?

14. Encuentre materiales que pueden ser Die Cast, utilizando el enlace en la parte inferior de la hoja de datos para Morir
Fundición.

15. Busque el registro de conformación Moldeo por inyección , uno de los más comúnmente utilizados de todos
polímero procesos de conformación. Encontrar materiales que puede ser moldeado por inyección. El polietileno puede ser
moldeado por inyección?

Los ejercicios basados ​en proyectos más largos

16. Un fabricante de muebles de jardín ha escuchado que su competencia está robando parte de su cuota de mercado con
muebles hechos por RTM, un término con el que está familiarizado. Utilizar la función de “Buscar” en el CES EduPack para
averiguar qué RTM es, y si se utiliza para hacer cosas como muebles de jardín.

17. Costo de modelado se utiliza para evaluar el proceso más económico utilizar. Si nos fijamos en la sección de modelos de
costos de la ficha técnica de nivel 2 de un proceso de conformación, verá el

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M.F. Ashby 2013
 Ejercicios - Unidad 10

índice del coste relativo (por unidad) de un proceso y la parámetros usada para evaluarlo (recuerde, usted puede hacer clic en
él para una nota Ciencia proporcionando un análisis en profundidad del índice de costes relativa). En este ejercicio vamos a ver
cómo el parámetro ' tamaño del lote 'Afecta el proceso de ser seleccionado.

definir una subconjunto personalizado ( Under "1. Selection Data" open "Select From:" and choose "Custom:
Define your own subset...".) for thermoplastic molding processes ( for “Selection Table” change to
“ProcessUniverse”, deselect everything and search for the folder “Thermoplastic Molding”). Add rapid prototyping
methods for polymers..

File Edit View Select Tools…

Browse Search Select

1. Selection data

Database: CES Edu Level 2 Change

Select from: Choose …..

Custom
Define your own subset

Edu Level 1
Materials Processes
…..

Edu Level 2
Materials
Materials with Durability props

Materials with Eco properties

Processes …..

Produce a bar chart with Relative cost index (per unit) on the Y-axis. (Polymer Extrusion, being a
continuous process, disappears because it does not have batch figures used to calculate the relative
unit cost).

Open the datasheet of any one of the thermoplastic molding processes and change the parameter ‘batch size’ to
1( click on ‘parameters’ to open a dialog box that allows you to change them). An example of a batch size of 1
would be the production of a prototype. Copy the bar chart out into WORD.

Now change the ‘batch size’ to 1,000,000 ( one million). Copy the resulting bar chart into WORD so that you can
compare the two charts.

What are the differences? What has happened and can you account for the reason?

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MF Ashby 2013
 Autor

Profesor Mike Ashby

Universidad de Cambridge, Granta Design Ltd.
www.grantadesign.com
www.eng.cam.ac.uk

Reproduction
These resources are copyright Professor Mike Ashby. You can reproduce
these resources in order to use them with students, provided you have
purchased access to Granta’s Teaching Resources. Please make sure that
Mike Ashby and Granta Design are credited on any reproductions. You cannot
use these resources for any commercial purpose.

Exactitud
We try hard to make sure these resources are of a high quality. If you have
any suggestions for improvements, please contact us by email at
teachingresources@grantadesign.com.

Open Access Resources include:

• Interactive Case Studies
• Getting Started Guides
• Materials Property Charts
• Engineering Data Booklets

You can register for a user name and password for these resources here:
www.grantadesign.com/education/resources/

Other Resources Available:

• 25 PowerPoint lecture units
• Exercises with worked solutions
• Recorded webinars
• Posters
• White Papers
• Solution Manuals

© M. F. Ashby, 2014

sitio web de Recursos para la Enseñanza de Granta tiene como objetivo apoyar la enseñanza de cursos de materias relacionadas en Ingeniería, Ciencia y Diseño. Los recursos vienen en varios

formatos y están dirigidas a diferentes niveles de estudiantes.

Este recurso es parte de un conjunto de recursos creados por el Profesor Mike Ashby y diseño Granta para ayudar a introducir la selección de materiales y materiales a los estudiantes.

El sitio web también contiene otros recursos donados por la facultad en las más de 700 universidades y colegios de todo el mundo que utilizan el CES de Granta EduPack.

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El sitio web de recursos de enseñanza contiene
M.F. tanto los
Ashby recursos que requieren el uso de CES EduPack y los que no lo hacen.
2013
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