機械製造

MANUFACTURING PROCESSES
講義參考資料 -- 僅供清大學生本課程中參考用
Course slides for NTHU students’ reference only

Introduction
Revision 10

Ed. by Che-Chih Tsao, PME, NTHU P1

機械製造 Manufacturing Processes
週二 Tuesday 8:00-8:50, 9:00-9:50 週五 Friday 9:00-9:50 工一館 107 室

New schedule: Tuesday 8:30-9:50 Friday 8:30-9:50

教師: (Instructor)
曹哲之 / Che-Chih Tsao [email protected]
03-5715131 x33741 工一館 527 室

助教: (Teaching Assistants)

林頡宥 <[email protected]> (Chief TA)
馮安萱 <[email protected]>, 王瑜華 <[email protected]>, 王勝瑋 <[email protected]>,
Alvin Winata <[email protected]>, LEO 廖 <[email protected]>,
陳亮宇 <[email protected]>, 邱敬文 <[email protected]>, 羅晟恩 <[email protected]>,
03-5715131 x33714 工一館 506 室 創新工程系統設計開發實驗室 Innovative Engineering Systems Lab.

課程說明 (Course Description)

機械製造(製造程序)課程的目的在了解與機械工程相關的各種主要工業與商業的產品及其零組件的生產方法、可採用
之各種加工法、各種加工法的基本原理、特性與所須之設備、以及生產加工過程中要精進生產力所涉及的工程方法。
The purpose of this course is to introduce methods of production and manufacturing of mechanical-engineering related
industrial and commercial products and their parts, basic principle, characteristics and required equipment of various manufacturing
processes, and engineering methods for improving productivity in these processes and methods.

指定用書 (Text Books)

Manufacturing Engineering and Technology, 6th edition, Kalpakjian and Schmid, Prentice Hall 2010.
(or 8th edition (2023) published by Pearson Education South Asia Pte Ltd.)

Ed. by Che-Chih Tsao, PME, NTHU P2

教學方式 (Teaching Method)
課堂授課、學生作業、小專題及學期專題實驗報告。
Lectures, homeworks, mini-projects and term projects.

教學內容大綱 (Course Outline)

Introduction
Processes overview, History, Process features, Recent Developments and Current Trends
Materials
Engineering materials
Fundamentals: macroscopic: Physical properties, Mechanical properties
Fundamentals: microscopic
Types, Properties and Cost
Casting (Metal casting)
Sand casting, Shell, Plaster, Ceramic, Lost-foam, Investment, Permanent-mold, Die
Processes and Equipment, Fundamentals, Processes Summary
Design, Materials, Economics
Forming and Shaping (Deformation Processes)
Rolling, Forging, Drawing and extrusion, Sheet Metal forming
Cutting (Material Removal Processes)
Turning/Milling/Drilling
Cutting Fundamentals
Tools, Economics
Advanced Machining Processes (non-conventional machining)*
Abrasive Machining and Finishing Operations,
Machine tools: structure and control
Ultra-precision Machining*
Joining
Powder Metallurgy
Polymer (Plastics) (and Composites) Processes
Plastics properties / usages,
Plastic injection molding, Thermal forming,
Composite materials and processes*
Ceramics and Glasses Processes*

Ed. by Che-Chih Tsao, PME, NTHU P3

 Additive Manufacturing (Rapid Prototyping, Production and Tooling)
Electronics Manufacturing Processes
IC, Parts, PCB MEMS processes
Quality Management
Statistic Process Analysis, Statistic Process Control
Process Optimization
Manufacturing Systems
Design for Manufacturing
Process Planning, Factory Layout and Simulation, Scheduling, Material Handling
Automation
Engineering Metrology and Instrumentation*
(*: 視時間允許 if time allows)

Term Project (TP) 學期專題實驗

Design and make molds and a small casting system to produce a small quantity of casts, including tasks of
Product design / mold design / production system design
Process planning: mold fabrication / production system setup
Make molds, production system
Casting products
Result analysis and report

成績考核 (Evaluation)
作業+報告(50%)
期中考(20%) (Closed book)
期末考(30%) (Closed book)
Home works + mini-project reports + term project report (50%)
Mid-term exam (20%)
Final exam (30%)

可連結之網頁位址 (Web link)

(歡迎參閱去年度講義、作業與報告範例、試題) (隨後更新)
Course slides, home works, selected reports and examination test sheets can be found in the following google drive:
https://drive.google.com/drive/folders/1UeCmDlvISK6k_Nxlxex_fbZh0KdBt2lb?usp=drive_link

Ed. by Che-Chih Tsao, PME, NTHU P4

2023F MP classes exhibiting casting project results in PME Specail Project show

Ed. by Che-Chih Tsao, PME, NTHU P5

2023F MP classes casting project result example

Ed. by Che-Chih Tsao, PME, NTHU P6

2023F MP classes casting project result example

Ed. by Che-Chih Tsao, PME, NTHU P7

2023F MP classes casting project result example

Ed. by Che-Chih Tsao, PME, NTHU P8

Course outline and schedule

See separate file:

MP_Outline & Schedule_2024F.pdf

Ed. by Che-Chih Tsao, PME, NTHU P9

How to learn in this course?

--- Take notes in classes.

--- Download and Look through class slides and make sure you understand every one
page of them.
--- Get a textbook. Read sections in the textbook covered in the class slides. Try to
understand "what" "how" and "why", instead of memorizing equations or guessing what
the test problems will be.
--- Do the homeworks, reports and mini-projects.
--- Ask questions.
--- Do the term project.
--- Learning Matrices and make your own concise notes.
--- Make use of internet but keep a "core knowledge bank" in your head.
化繁為簡，以簡馭繁 --- 沈君山
“Converting complex into basics, then applying basics to handle complex”

What you will learn from this course are all real stuffs that are useful and
make money for some, and in many cases many, people.

Ed. by Che-Chih Tsao, PME, NTHU P 10

引言 Introduction

What is Manufacturing?

Why do we study Manufacturing?

History

Fundamentals of Manufacturing Processes

Ed. by Che-Chih Tsao, PME, NTHU P 11

機械製造 (製造程序) (What)
與機械工程相關的各種主要工業與商業的產品及其零組件的生產方法、可採用之各種加工
法、各種加工法的基本原理、特性與所須之設備、以及生產加工過程中要精進生產力所涉及
的工程方法。
Methods of production and manufacturing of mechanical-engineering related industrial and
commercial products and their parts, basic principle, characteristics and required equipment of
various manufacturing processes, and engineering methods for improving productivity in these
processes and methods.
原材料 零組件 總成
產品
Materials Components/parts Assembly/Module
Product
- consumer
製造 裝配 裝配 - industrial
Manufacturing Assembly (component,
Assembly
product,
equipment)
加工法 設備
Manufacturing Equipment
processes/methods (manufacturing,
assembly,
inspection …)

Ed. by Che-Chih Tsao, PME, NTHU P 12

 Casting 鑄 造

molten metal -- pattern -- mold

鐵(銅…) 水 -- 模 -- 範
模型 -- 鑄模

永久式模型 消失式鑄模
消失式模型 永久式鑄模

permanent
dispensible

Product/Company examples:

- Car body: Giga Press/Tesla

- Car engine (internal combustion engine)
- Wind turbine hub: Vestas, Goldwind (金風)
- Jet engine blades: Rolls-Royce
- Golf club head: 復盛精密
- Electric motor casing

Ed. by Che-Chih Tsao, PME, NTHU P 13

 Forming 成 形

material, work piece -- die

滾 鍛 擠 、抽
料、工件 -- 模具

沖床
壓床

punch, stamping
press, pressing

Product/Company examples:

- Car body
- Submarine hull: 台船
- Wind turbine tower
- Electronic parts leadframe stamping

Ed. by Che-Chih Tsao, PME, NTHU P 14

 剪 彎、抽

Ed. by Che-Chih Tsao, PME, NTHU P 15

 Machining 切 削

工具機 machine tool

車床 lathe
車刀 lathe tool bit

鑽床 drill press
鑽頭 drill bit
車
磨
銑床 milling machine
銑刀 mill, milling cutter

鑽
Product/Company examples:

- Almost all molds for die casting, metal

forging, sheet stamping
- Phone casing: 鴻準、立訊
- Optical lens grinding, polishing:
銑 拋 保勝
- Silicon wafer slicing, polishing, dicing:
DISCO

拉削

Ed. by Che-Chih Tsao, PME, NTHU P 16

 Joining 結 合

熔接

膠結合

Product/Company examples:

螺栓結合 - Car body

- Submarine hull
- Wind turbine tower base:
電弧焊 電阻焊
中鋼
- Electronics soldering, bonding

Ed. by Che-Chih Tsao, PME, NTHU P 17

 Powder Metallurgy 粉末冶金
Polymer (Plastics) Processes
Plastic injection molding, Thermal forming 塑膠射出成型、熱成型
Composites Processes* 複合材料製程
Ceramics and Glasses Processes* 陶磁、玻璃加工
Additive Manufacturing (Rapid Prototyping) (3D Printing)
積層製造 (快速模型)
Electronics Manfacturing Processes
IC, Parts, PCB, MEMS*
Engineering Metrology and Instrumentation*
Quality Management
Statistical Quality Analysis,
Process Optimization,
Process Control
Manufacturing Systems
Design for Manufacturing, Concurrent Engineering
Process Planning,
Factory Layout and Simulation,
Scheduling,
Material Handling
Automation

Ed. by Che-Chih Tsao, PME, NTHU P 18

瞭解機械製造 (製造程序)的重要性 (Why)

* Manufacturing creates jobs, makes society rich and imroves living

standard

If we think about basic human needs:

食 Food
衣 Clothes
住 Housing
行 Transportation
育 Health, Education
樂 Entertainment, High-level fulfillment

Systems of manufacturing coupled with economic supply-demand drive promote

development to satisfy as well as evelate every aspects of the human needs.

Ed. by Che-Chih Tsao, PME, NTHU P 19

 The best modern example is recent development of Mainland China

Modern Shanghai as seen in a Royal Caribbean cruise advertisement

https://www.royalcaribbean.com/cruise-from/shanghai-china

Ed. by Che-Chih Tsao, PME, NTHU P 20

 Trillion US$

World Bank data

https://data.worldbank.org/indicator/NV.IND.MANF.CD?locations=CN-JP-DE-US-GB-FR

Ed. by Che-Chih Tsao, PME, NTHU P 21

 China moved its people from subsistence agriculture to urban employment. 600 million
people—the equivalent of two Americas—moved from country to city in the last 35 years.
And over that period per capita GDP in China has risen by 45 times – that’s 4,500%.

From David P. Goldman, “Open letter to Kudlaw: You need a different China strategy”, Asia Times, July 19, 2018
http://www.atimes.com/article/open-letter-to-larry-kudlow-you-need-a-different-china-strategy/

Ed. by Che-Chih Tsao, PME, NTHU P 22

… in some ways the Asian century has already arrived. China is on the brink of surpassing
the American share of global manufacturing, having overtaken Germany and Japan in the
past 10 years.
... China recently overtook the U.S. as the world's biggest automobile market (14 million
sales a year, compared to 11 million), and its demand is projected to rise tenfold in the
years ahead.
By 2035, according to the International Energy Agency, China will be using a fifth of all
global energy…
It accounted for about 46% of global coal consumption in 2009, the World Coal Institute
estimates, and consumes a similar share of the world's aluminum, copper, nickel and zinc
production. Last year China used twice as much crude steel as the European Union, United
States and Japan combined.
the world's leading manufacturer of wind turbines and photovoltaic panels.
In 2007 China overtook Germany in terms of new patent applications. This is part of a wider
story of Eastern ascendancy. In 2008, for the first time, the number of patent applications
from China, India, Japan and South Korea exceeded those from the West.
What we are living through now is the end of 500 years of Western predominance. This
time the Eastern challenger is for real, both economically and geopolitically.

From Niall Ferguson, “In China’s Orbit”, Wall Street Journal, Nov. 18, 2010
http://www.wsj.com/articles/SB10001424052748704104104575622531909154228

Ed. by Che-Chih Tsao, PME, NTHU P 23

Moving into the future … China Manufacturing 2025 ---- actually continues
中國製造 2025 產業供應鏈 New Rail
Transportation Space equip. 「中國製造 2025」於 2015
年 5 月 19 日由中國國務院正
式公布，為大陸邁向製造強國
Machine tools
的第一個十年階段目標，也是
New Energy
New IT & robots 大陸版的工業 4.0規劃。該計
Smart cars
畫以創新驅動、品質為先、綠
色發展、結構優化、人才為本
等為基本方針，並以市場主
導、政府引導，立足當前、著
眼長遠，整體推進、重點突
Agriculture
破，自主發展、開放合作為基
machines 本原則；主要以透過信息化與
Ocean
Engineering 工業化的深度融合發展，實現
Electric power
中國大陸從製造業大國轉型為
製造業強國目標，已規劃以三
Bio-medical
New materials 個十年的時程分階段完成設定
目標，預計 2025 年即可進入
製造強國行列；2035 年大陸
製造業可達到世界製造強國中
等水準；2049 年則將進入世
界製造強國前列。

Ed. by Che-Chih Tsao, PME, NTHU P 24

 The economic development of Taiwan after WWII is similar

Ed. by Che-Chih Tsao, PME, NTHU P 25

Ed. by Che-Chih Tsao, PME, NTHU P 26
 Taiwan’s “Trillion NTD industrial sectors” 兆元產業

Sector Production Output Note

in Trillion NT$ (Billion US$)
IC manufacturing 3.2 (107) 2024 projected
IC design 1.2 (40)
IC packaging 0.43 (14.3)
IC testing 0.22 (7.3)
Server 2.5 (83) 2024 projected

Opto-Electronics 2.0 (67) 2023

Communication 1.3 (43) 2024 projected

PCB 1.2 (40) 2024 projected

Mechanical Equipment 1.45 (48.3) 2022

14000 companies
500,000 workers

Mechanical equipment is required in every sector!

Ed. by Che-Chih Tsao, PME, NTHU P 27

From the Viewpoint of Products, Engineering, Business and Society

https://www.bloomberg.com/news/newsletters/2023-09-08/huawei-s-breakthrough-chip-fuels-tensions-
with-us-next-china
Huawei's Breakthrough Chip Fuels Tensions With US: Next China - Bloomberg
2023

https://www.bloomberg.com/news/articles/2022-07-05/us-pushing-for-asml-to-stop-selling-key-
chipmaking-gear-to-china#xj4y7vzkg
Semiconductor Market: US Bans ASML From Selling Chipmaking Gear to China - Bloomberg

https://www.scmp.com/tech/big-tech/article/3229767/tech-war-chinese-media-boast-imminent-chip-
making-tech-breakthrough-us-threatens-more-equipment
Tech war: Chinese media boast imminent chip-making tech breakthrough, as US threatens more equipment export
restrictions | South China Morning Post (scmp.com)

https://www.reuters.com/article/us-usa-huawei-tech-tsmc-idUSKBN22U0EW
TSMC stops new Huawei orders after U.S. restrictions: Nikkei | Reuters
2020

Ed. by Che-Chih Tsao, PME, NTHU P 28

https://www.cnbc.com/2023/08/15/china-can-become-worlds-number-1-car-exporter-by-2023-
moodys.html
China can become world's number 1 car exporter by 2023: Moody's (cnbc.com)

https://www.digitimes.com/news/a20230809VL201/china-vehicle-
exports.html#:~:text=Cui%20Dongshu%2C%20secretary%2Dgeneral%20for,be%20the%20largest%20d
riving%20force.
China automobile exports expected to surpass 5 million in 2023 (digitimes.com)
China automobile exports expected to surpass 5 million in 2023
Peng Chen, DIGITIMES Asia, Taipei Wednesday 9 August 2023

https://www.visualcapitalist.com/global-ev-production-byd-surpasses-tesla/
Global EV Production: BYD Surpasses Tesla (visualcapitalist.com)

Ed. by Che-Chih Tsao, PME, NTHU P 29

https://baijiahao.baidu.com/s?id=1762510944172113443&wfr=spider&for=pc
2022 年全球汽车产量 8502 万，排名第 1 的国家不意外，第 10 名很意外 (baidu.com)

https://new.qq.com/rain/a/20230730A04JDF00
校招 3.18 万应届生 硕博比例超 61% 汽车行业再成就业新热门_腾讯新闻 (qq.com)
相关消息显示：今年毕业的大学生择业，新能源车企很受欢迎，很多新能源车企也抓紧开拓校招市场，比
如新能源汽车领导者-比亚迪，2023 年校招总量将近 3.2 万人，硕士生和博士生占比约 61.3%，而且其中
超过 80%岗位是研发相关。…
目前，比亚迪拥有将近 7 万名研发工程师，11 个研究院，全球申请专利数量超过 4 万项，授权专利将近
3 万项，

Ed. by Che-Chih Tsao, PME, NTHU P 30

https://zhuanlan.zhihu.com/p/631006073
汽车行业现在还是一个好的行业吗？ - 知乎 (zhihu.com)
汽车行业现在还是一个好的行业吗？
wuzhijieqy
国际汽车营销商务

2021 年汽车行业直接及周边产业从业总人数 3500 万人，占全国就业人数的 11.2％。2022 年，汽车制造业完

成营业收入 92899.9 亿元，同比增长 6.8%，占规模以上工业企业营业收入总额的比重为 6.7%。

https://www.youtube.com/watch?v=Df3tajBAxdw
ASML EUV in action
2020 年 4 月 23 日

https://www.youtube.com/watch?v=XzA7HJuDCps
[English Annotation] Three Giant Die Casting Machines (Giga Press) in Tesla Shanghai factory
2021 年 2 月 20 日

Ed. by Che-Chih Tsao, PME, NTHU P 31

https://www.youtube.com/watch?v=FaIBdVdu0wo
#17 Tesla's Gigacastings, Micron Precision, and Unique Alloy
2021 年 5 月 27 日

Self study
https://www.youtube.com/watch?v=CQfKZ5lo9dc
Elon Musk explains how Giga casting works for the Model Y
2020 年 9 月 24 日

Ed. by Che-Chih Tsao, PME, NTHU P 32

Self study

Jet engine / blade

Southwest Airlines Engine Explodes in Flight, Killing a
Passenger
[New York Times]

A Southwest Airlines plane at Philadelphia International Airport after it made an emergency landing there on
Tuesday. One person was killed after an engine exploded in midair.
CreditCreditDavid Maialetti/The Philadelphia Inquirer, via Associated Press
By Liam Stack and Matt Stevens April 17, 2018

Ed. by Che-Chih Tsao, PME, NTHU P 33

[Washington Post]

After fatal accident, Southwest Airlines inspects 35,000 engine fan

blades and finds no flaws
By Ashley Halsey III
May 16, 2018
Southwest Airlines has completed the federally mandated inspection of 35,000 engine fan blades like the one that
disintegrated in a fatal accident last month without finding additional flaws, but Southwest CEO Gary Kelly said
Wednesday that “a handful” of blades had been sent to the manufacturer for further examination.
Southwest said the blades were sent to engine maker General Electric out of “an abundance of caution” because of
“coating anomalies” on the blades, and not because they showed any sign of metal fatigue.

Ed. by Che-Chih Tsao, PME, NTHU P 34

Fig. 6.1 PW2037 jet engine for Boeing 757 has 38%Ti, 37%Ni, 12% Cr, 6% Co, 5% Al, 1%
Nb, and 0.02% Ta.

Ed. by Che-Chih Tsao, PME, NTHU P 35

Skip

Ball screw 滾珠螺桿

https://www.youtube.com/watch?v=wCtawTEXGss

Ed. by Che-Chih Tsao, PME, NTHU P 36

經國號戰機近距離伴飛中共轟六 K。圖／國防部提供
經國號攔截伴飛中共轟六 國軍首度發布照片 2017-07-21 12:08 聯合報 記者程嘉文╱即時報導
F124 Jet engine
https://home.gamer.com.tw/creationDetail.php?sn=2650614

Ed. by Che-Chih Tsao, PME, NTHU P 37

Skip

▲New HTC One 機身以全鋁合金材質打造，並採一體成形切削設計。

Ed. by Che-Chih Tsao, PME, NTHU P 38

Ed. by Che-Chih Tsao, PME, NTHU P 39
Ed. by Che-Chih Tsao, PME, NTHU P 40
Ed. by Che-Chih Tsao, PME, NTHU P 41
Ed. by Che-Chih Tsao, PME, NTHU P 42
Ed. by Che-Chih Tsao, PME, NTHU P 43
Ed. by Che-Chih Tsao, PME, NTHU P 44
Ed. by Che-Chih Tsao, PME, NTHU P 45
Ed. by Che-Chih Tsao, PME, NTHU P 46
Fig. II.2 (Kalpakjian & Schmid) Cast Parts in a typical automobile

Ed. by Che-Chih Tsao, PME, NTHU P 47

 ENERCON E-70
機艙高度：64 公尺
輪轂直徑：71 公尺

新竹海山漁港風機 (Photo by 呂學宗)

Ed. by Che-Chih Tsao, PME, NTHU P 48

From: [AWEA: American Wind Energy Association]
http://www.awea.org/Resources/Content.aspx?ItemNumber=5083&RDtoken=29819&userID=4379

Ed. by Che-Chih Tsao, PME, NTHU P 49

(Left)
Rotor Hub Enercon E82 at Hannover Energy International Fair, Photo by WWEA
http://www.wwindea.org/technology/ch01/en/1_2_1_2.html

(Right)
Hub, SG Iron
http://www.indiamart.com/premier-limited-delhi/wind-turbine-s-g-iron-casting-parts.html

Ed. by Che-Chih Tsao, PME, NTHU P 50

From: Sandia National Labs: http://www.designnews.com/document.asp?doc_id=230008

Ed. by Che-Chih Tsao, PME, NTHU P 51

From the Viewpoint of Industry and Business
Approximate Number of Parts in Products

Common pencil 4
Bicycle 30-100
Rotary lawnmower 300
Motorcycle 500-1000
Grand piano 12,000
Automobile 15,000
Boeing 747-400 6,000,000
(Ref. Kalpakjian & Schmid Tab. I.1 (p. 2), 2014F PME student Homework 1 results)

Typical Cost Break Down in Manufacturing

Design 5%
Materials 50%
Manufacturing
Direct labor 15%
Indirect labor 30%
(Ref. Kalpakjian & Schmid Tab. I.6 (p. 33))

 But ~80% of the cost of a product is determined in the design phase!!

Ed. by Che-Chih Tsao, PME, NTHU P 52

(Ref. Manufacturing Engineering book draft and MIT class notes by N.P. Suh, E.M. Sachs et al.)

Ed. by Che-Chih Tsao, PME, NTHU P 53

History
Wood tool

Stone tool

Ed. by Che-Chih Tsao, PME, NTHU P 54

江西萬年仙人洞

研究称世界最早陶器出自仙人洞遗址 距今 2 万年
2012 年 07 月 27 日 11:26 来源：大江网

万年仙人洞发掘的陶器。
昨日，记者从省考古研究所获悉，北京大学考古文博学院吴小红教授和同事张弛教授等日前在美国 Science 杂志上发表
关于文章《中国仙人洞遗址两万年陶器》，证实万年仙人洞陶器出现的时间为 2 万年，这是目前世界已发现陶器的最早年
代。“该研究是由北京大学考古文博学院联合省文物考古研究所、万年县文物部门，与美国哈佛大学、波士顿大学考古学家
合作进行的。”省考古研究所所长樊昌生说，研究成果为探讨现代人行为、特定文明要素的出现和传播机制等提供了重要资
料。

(Ref. http://www.chinanews.com/cul/2012/07-27/4063161.shtml)

Ed. by Che-Chih Tsao, PME, NTHU P 55

湖南道县玉蟾岩遗址 (10000 BC)

-- Ceramics, molding, firing

Ed. by Che-Chih Tsao, PME, NTHU P 56

江蘇 金壇三星村刻紋骨板器 (<10000 BC)

-- Cutting, drilling

Ed. by Che-Chih Tsao, PME, NTHU P 57

湖北隨縣曾侯乙墓，出土的青銅尊、盤
我國目前所知最早的失蠟鑄件 (西元前五世紀 5 century BC)(失蠟法也稱 "熔模法") (Lost Wax Casting)

-- Lost wax casting

Ed. by Che-Chih Tsao, PME, NTHU P 58

http://baike.baidu.com/view/369650.htm
http://yjhvf900.blog.163.com/blog/static/204238027201268245923/

Ed. by Che-Chih Tsao, PME, NTHU P 59

Chinese Crossbow Trigger (弩機): An Example of mass-produced product of
ancient industry
(Materials are from A Crossbow Mechanism with Some Unique Features from Shandong, China by Stephen
Selby, 2001, retrieved from http://www.atarn.org/chinese/bjng_xbow/bjng_xbow.htm)

Type A mechanism (axles missing). Qin. (200 BCE)

Type A: a bronze mechanism with three working parts
(tumbler, sear and trigger) and two passive axles,
supported completely by the wooden stock of the
crossbow.

Ed. by Che-Chih Tsao, PME, NTHU P 60

 Type B Mechanism from Shandong, China
Early Warring States Period (500-600 BCE)
bronze
(L) Cocked and locked
(Lower L) Cocked and unlocked
(Lower R) Released

Ed. by Che-Chih Tsao, PME, NTHU P 61

 Type B Mechanism from
Shandong, China
The crossbow mechanism under
discussion was found in Zibo,
Shandong province.

Inner parts of the mechanism.

A: tumbler,
B: sear,
C: trigger,
D1,2: axles,
E: bronze catch.

Ed. by Che-Chih Tsao, PME, NTHU P 62

http://en.wikipedia.org/wiki/Mass_production

Mass production
History
Before the Machine Age
Crossbows made of bronze were mass-produced in China during the Warring States period. The Qin
Emperor unified China at least in part by equipping large armies with these weapons, which were
equipped with a sophisticated trigger mechanism made of interchangeable parts. [2]

2 ^ Mass-Produced Pre-Han Chinese Bronze Crossbow Triggers: Unparalleled Manufacturing Technology in the
Ancient World. by David Williams. Arms & Armour, Volume 5, Number 2, October 2008 , pp. 142-153(12)
http://www.ingentaconnect.com/content/maney/aaa/2008/00000005/00000002/art00003

Ed. by Che-Chih Tsao, PME, NTHU P 63

A Brief History of Modern Manufacturing Systems
"System" Machines Example Products, Example Process Control
Workers industries Manufacturing Strategy
Flexibility machines, systems
1600-1700 Boring, turning,
screw-cutting lathe,
drill press
"English" Few, gen. purpose Highly skilled
(Late 1700's-early Skilled workers,
1800's) High Absolute standard
* Henry Maudslay Bramah lock Modern lathe [1] measurement
Hydraulic press [2]
* Joseph Whitworth Whitworth rifle[6] Lathe production [4]
"thou" (mil) [5]
Railways BSW [7]
"American" Many, Specialized Go/no-go gages
(Early-late 1800's) Moderate skill Rifles Interchangeability
* Eli Whitney Medium Cotton gin Milling machine,
* Thomas Blanchard Tacks/Brads making Copying lathe [3]
[1] Combining tool holder, coupled lead screw and changeable gears.
[2] Invented by Joseph Bramah. Piston seal improved, from hemp packing to leather cup washer, by Maudslay.
[3] For gun barrels (octagonal portion) initially.
[4] Box casting scheme for making machine tool frames. General and screw making lathe production.
[5] Introducing "thou" (mil), and "end measurements" system with precision to "micrometer".
[6] Twisted hexagonal barrel. {1860 Q. V. at British rifle association
[7] Screw thread standard, British Standard Whitworth (BSW), initially for rail road screws.

Ed. by Che-Chih Tsao, PME, NTHU P 64

Henry Maudslay -- First modern lathe
http://www.sciencemuseum.org.uk/images/I061/10326590.aspx

Coupling between tool holder

position and workpiece rotation

Tool holder

Tool holder riding on slides and driven by a lead screw

This lathe is said to be the first workshop machine on which English engineer, Henry Maudslay (1771-1831) combined a lead-screw and change wheels for
reproducing screw threads. The bed consists of two triangular bars which carry the headstock, tailstock and slide-rest. The lead-screw is situated between the bars
and was geared to the lathe spindle by change wheels (now missing). Before Maudslay's invention, screws were crudely made by hand. Maudslay went on to
produce tools for the production of both ordinary and specialist screws for all types of machines.

Ed. by Che-Chih Tsao, PME, NTHU P 65

A Very Brief History of Turning

From: John Edwards, "A Short history of Turing", http://www.turnersco.com/a-short-history-of-turning/

Ed. by Che-Chih Tsao, PME, NTHU P 66

Whitworth rifle

Breech-loading artillery

12-pounder Whitworth breechloading rifle

Whitworth also designed a large rifled breech loading gun with a 2.75 inch (70 mm) bore, a 12 pound 11 ounce (5.75 kg) projectile and a range of about six miles
(10 km). The spirally-grooved projectile was patented in 1855.

Ed. by Che-Chih Tsao, PME, NTHU P 67

 "The First Cotton Gin", an engraving from Harper's Magazine
, 1869. This carving depicts a roller gin, which preceded
Eli Whitney's invention.

A cotton gin on display at the Eli Whitney Museum. Cotton Gin patent (1794)

Ed. by Che-Chih Tsao, PME, NTHU P 68

(L) Ref. Manufacturing Engineering book draft and MIT class notes by N.P. Suh, E.M. Sachs et al.
(R) Around 1850, the only available technology for the transmission of fast, circular motion was the so-called
"millwork", e.g. a factory interior in Schaffhausen, Germany. (Ref. Kris De Decker, "The Mechanical
Transmission of Power (3): Endless Rope Drives", Low Tech Magazine, from
http://www.lowtechmagazine.com/2013/03/the-mechanical-transmission-of-power-3-wire-ropes.html

Ed. by Che-Chih Tsao, PME, NTHU P 69

"System" Machines Example Example Process Control Strategy
Workers Products, Manufacturing
Flexibility industries machines, systems
"Taylor" Many, highly Specialized Break down tasks into
(Late 1800's-early Low skill basic elements,
1900's) Low Time motion study,
* Frederick W. Tool life study Static view of process.
Taylor
* Henry Ford cars [14]
"Statistical Applies to any type of Dynamic view of process
Process Control" machine, Results feedback
(1930's-now) Workers involved in Continuous improvement
[10] process improvement,
Low
"NC, CNC" [11] Few, gen. purpose High accuracy
(1950's - now) Mixed skilled, SPC [12]
* MIT High Closed loop
"CIM" [13] Few, gen. purpose Achieve high accuracy on
(Late 1970's-now) Skilled, first part
High
[10] Started at Watertown Arsenal of Massachusetts, USA.
[11] Numerical Control and Computer Numerical Control.
[12] Statistical Process Control.
[13] Computer Integrated Manufacturing.
[14] Model-T $950 in 1909 to $260 in 1926.

(Ref. Manufacturing Engineering book draft and MIT class notes by N.P. Suh, E.M. Sachs et al.; Kalpakjian & Schmid; and
wikipedia.org)

Ed. by Che-Chih Tsao, PME, NTHU P 70

"System" Machines Example Example Process Control Strategy
Workers Products, Manufacturing
Flexibility industries machines, systems
Today toward future:

* Concurrent Engineering
* Digital Modeling
* OEM-ODM
* Rapid Prototype /
Production
* Vendor / Manufacturer
Management
…
* “Industry 4.0”
* “Big data”
* “Internet of Things”

Ed. by Che-Chih Tsao, PME, NTHU P 71

A bit more history for reference

wiki
中國的第一條真正營運的鐵路，是於清朝光緒二年（1876 年）由英國怡和洋行擅自舖設的吳淞鐵路（上海～吳淞），全長 14.5 公
里。… 通車營運一年後（1877 年）就被清政府以 28 萬 5 千兩白銀贖買，即被拆除。
中國的第二條鐵路，也是第一條清廷主張興建的官辦鐵路、中國的標準軌距鐵路，是光緒七年（1881 年）由直隸總督李鴻章下令舖設
的唐胥鐵路（河北省唐山～胥各莊），全長 9.2 公里。為了將唐山附近開灤煤礦的煤運出去，… 聘英國人金達為總工程師，由開平礦
務局集資修築唐胥鐵路。但李鴻章為避免激起反對，起初只以騾馬為動力，至光緒八年（1882 年）才開始使用蒸汽機車牽引。
…
臺灣鐵路興築於清朝光緒年間，由臺灣巡撫劉銘傳籌建，為當時中國第一條以載客為目的的鐵路。1887 年（光緒13 年），劉銘傳奏請
興建台灣鐵路，清廷准許自籌工款後即前往南洋招商，同年 4 月於台北大稻埕開工，臺北車站亦座落於大稻埕。1887 年 5 月 20 日成立
「全台鐵路商務總局」。軌距則為 3 呎 6 吋（1,067mm）並沿續至今。開工初期最先興建的是由基隆港口經台北到新竹（當時稱為竹
塹）。
1891 年 10 月基隆到台北通車…1893 年台北到新竹段通車…
…
一九零一年…慈禧令属下…修筑一条來往高碑店至易縣的新易鐵路，以供慈禧祭祖時乘坐。… 1902 年 10 月 19 日袁世凯正式任命詹天
佑為總工程师，以四個月時間及低廉的成本建成了鐵路。雖然這只有 37 公里長的路線沒有很大的實質作用，但卻是首條由中國人自行
修建的鐵路。[
…
之後清政府準備興建連接北京至張家口的京張鐵路。由於這條鐵路具有重要的戰略價值，英國及俄國都希望得到建造權而相持不下。
然而，在英國、俄國的鐵路高級計劃測量師和工程師在經過多次的探勘後认为难度极大。因為燕山山脈群中有不少的陡峰，其中被選
為｢第二隧道｣的燕山二號峰其大部分的構成材質多為花崗岩以及玄武岩，很難使用一般的｢炸隧開道｣的方法，这使得列强让京张铁路
追加预算资金。結果在袁世凱在 1905 年決定不用外國資金，亦不使用外國人，全部由中國自行修建京張鐵路。詹天佑被任為總工程
師，之後更兼任鐵路總辦。京張鐵路全長約 220 公里，由於要經過長城內外的燕山山脈，需要興建不少隧道及橋樑，工程相當複雜。
當時有部分外國人質疑中國人自行建造這條鐵路的能力；詹天佑亦明白工程艱鉅，並關係到中國工程師的聲譽，但仍然堅持努力嘗
試。詹天佑從三條他親自勘定的路線中，選擇成本及线路走向、客流量均較为适中的一條。… 最終京張鐵路在四年後的 1909 年 8 月
11 日建成，10 月 2 日通車，施工時間比原定縮短了兩年；而建造成本亦比原來預算節省三十五萬兩白銀。鐵路上有四條隧道，其中八
達嶺隧道長 1,092 公尺，採用豎井方法挖掘；另外有二百米長，鋼架結構的懷來大橋；此外還在八達嶺段（盡是懸崖峭壁）則使用了
“z"字軌，道攀斜，解決了地勢險要、坡度过大而资金有限的問題。京張鐵路的成功建造，不單是中國近代工程史上的重要成就，對正
掀起民間自辦鐵路風氣的中國亦起了很大的激勵作用。

Ed. by Che-Chih Tsao, PME, NTHU P 72

清朝劉銘傳所倡建的臺灣鐵路列車經過龜崙嶺古道之景 京張鐵路青龍橋站同時開行的列車，呈現出「之字形」。
（今桃園縣龜山鄉一帶）

劉銘傳 詹天佑

Ed. by Che-Chih Tsao, PME, NTHU P 73

機械製造程序的分類
Categorization of Manufacturing Processes

Process Method of generating shapes More processes

Casting material phase change injection molding
Forming material deformation
Cutting material removal (subtraction)
Joining material joining
material addition electroforming
electroplating
rapid prototyping (3D printing)
change material properties heat treatment

Ed. by Che-Chih Tsao, PME, NTHU P 74

機械製造程序的基本面向(因素) – 選擇製程的依據

Fundamentals of Manufacturing Processes

-- Bases for Process Choice
The fundamentals of Manufacturing Processes
 The engineering details of how things are made, that affect the profitability of
the overall mfg. venture and the products.
 8 engineering aspects:

Fundamental principle
Material/Design
Quality
Flexibility
Rate (cycle time)
Equipment availability/size/nature
Cost
Example products

Ed. by Che-Chih Tsao, PME, NTHU P 75

Fundamental principle
This affects almost all other aspects.

Process Method of generating More processes Fundamental physics (or chemistry etc.)
shapes
Casting material phase change injection molding Material phase change and microstructure
Heat transfer

Forming material deformation Plastic deformation

Stress induced microstructure change

Cutting material removal Plastic deformation

Joining material joining Phase change

Chemical bonding

material addition electroforming Electrochemical process

electroplating
change material properties heat treatment Heat induced microstructure change

Ed. by Che-Chih Tsao, PME, NTHU P 76

Material/Design

Material limits
e.g. Cutting brittle materials, such as ceramics, is difficult
Die casting Nickel or even silver?
(Ni m.p. 1453C, Ag m.p. 961C, steels m.p. 1371-1352C)

Thermoforming particulate -filled polymers

Stamping aluminum vs. steel (Y / E)

Design (geometry) limits

e.g. Stamping sheet metal: no undercuts, high aspect ratio
Thermoforming: uniform wall thickness difficult
Casting, injection molding: unequal wall thickness may cause problem

Ed. by Che-Chih Tsao, PME, NTHU P 77

Ed. by Che-Chih Tsao, PME, NTHU P 78
Quality:
Geometry: size, tolerance, surface finish
Material properties

Geometry:
 Size
 Surface quality ---- tool,
 Thickness ---- Shrinkage

Material properties due to microstructure

 High temperature, or slow processes allow deformation to relax out
 Many processes can actually improve microstructure, e.g. cold working,
orientation

Ed. by Che-Chih Tsao, PME, NTHU P 79

 (Fig. 35.19)

Ed. by Che-Chih Tsao, PME, NTHU P 80

 (Fig. 35.20)

Ed. by Che-Chih Tsao, PME, NTHU P 81

Ed. by Che-Chih Tsao, PME, NTHU P 82
Flexibility

Design flexibility (product flexibility)

"Can a system produce a variety of products or materials?"
The ability to accommodate changes in design.
 Depending on how new information is imported into part
software
(production management system, CNC, computer driven)
flexibility ~ ___________________________________
hardware (die, tools …)
 Additive and subtractive processes >> Forming processes
 Improve process of set-up: die change, tool change, part routing

Operation flexibility
"Can a product be produced by different machines of systems?"
The ability to deal with machine breakdown.

Volume (capacity) flexibility

Ed. by Che-Chih Tsao, PME, NTHU P 83

Cost

-- Fixed cost, Variable cost

-- Equipment, Material, Labor, Overhead

Mfg. Cost = Fixed + (Mat'l + Labor) x N

Mfg. Cost / N = Fixed / N + (M + L)

Mfg. Cost / N

(M + L)

N (volume)

Ed. by Che-Chih Tsao, PME, NTHU P 84

Typical consumer goods cost structure

Equipment 20-40%
Materials 40-75%
Labor 5-25%
Overhead 10-40%

Mfg. Cost
~ = 0.35
Retail Price

Typical Equipment Cost (machine) [??]

Cutting & bending US $ dollar ~ Force lbs

Presses US $ dollar ~ 1~2 x Force lbs
(Hydraulic press is cheaper)
Extruder US $ dollar ~ (HP) 2
Injection molding machine US $ dollar ~ 1/4 x Force lbs

Ed. by Che-Chih Tsao, PME, NTHU P 85

Rate (cycle time)

-- Preparation, Setup time

Preparation and setup of machine, materials and workpiece
Related to engineering, management, organization
機器、材料、工件的準備與設定 -- 工程的、管理的、組織的

-- Actual process time

Related to physics and chemistry
實際加工時間 -- 物理的、化學的

Equipment availability/size/nature

Example products

Ed. by Che-Chih Tsao, PME, NTHU P 86

A Learning Matrix

Casting Forming Process X

-- Sand casting -- Forging
Fundamental principle
Material limits / features
Design limits / features
Quality
- tolerance
- surface finishing
- material properties
Flexibility

Rate (cycle time)

Equipment
availability/size/nature
Cost

Example products

Ed. by Che-Chih Tsao, PME, NTHU P 87

172 Basic Manufacturing Processes

Ed. by Che-Chih Tsao, PME, NTHU P 88

Skip

Recent Developments and Current Trends

Rheocasting ---- semisolid state metal molding
CAD of molds and dies
Rapid prototyping, tooling
TRIP, TWIP steels ---- TRI-Phase
TWinning-Induced Plasticity
Machinable ceramics?
Diamond like carbon?
LIGA
Six sigma
Blue-arc machining
Soft lithography
…

Ed. by Che-Chih Tsao, PME, NTHU P 89

Ed. by Che-Chih Tsao, PME, NTHU P 90