Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

MEIE-4262

Manufacturing Processes

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Chapter-1

Introduction

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Manufacturing Processes - Definition

• A method of converting raw material into a finished products by

using machines, tools and labour

• Finished products may be used as such or for manufacturing

other, more complex products, such as aircraft, household

appliances or automobiles

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Evolution of Manufacturing

• Began about 5000 to 4000 B.C with the production of various

articles of wood, ceramic, stone and metal

• Derived from Latin word manu factus – meaning “made by hand”

• The word manufacture first appeared in 1567

• The word manufacturing appeared in 1683

• Production is also used interchangeably .

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

What is Manufacturing?Range of Materials & Processes in a Tractor

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

FIGURE 1.1 Model 8430 tractor, with detailed illustration of

its diesel engine, showing the variety of materials and

processes incorporated. Source: Courtesy of John Deere

Company.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

History of Manufacturing

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

History of Manufacturing (cont.)

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

History of Manufacturing (conc.)

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Manufacturing Importance

FIGURE 1.2 Importance of manufacturing to national economies. The trends

shown are from 1982 until 2006. Source: After J.A. Schey with data from the

World Development Report, World Bank, various years.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Classification of Manufacturing

Processes

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Manufacturing Process

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Classification of Manufacturing Processes

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Manufacturing Processes

• Two basic types:

1. Processing operations - transform a work material from one state of

completion to a more advanced state

• Operations that change the geometry, properties, or

appearance of the starting material

2. Assembly operations - join two or more components to create a new

entity

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Processing Operations

• Shaping operations

• Solidification processes

• Particulate processing

• Deformation processes

• Material removal processes

• Property-enhancing operations (heat treatments)

• Surface processing operations

• Cleaning and surface treatments

• Coating and thin-film deposition

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Shaping Processes – Four Categories

• Solidification processes - starting material is a heated liquid or

semifluid

• Particulate processing - starting material consists of powders

• Deformation processes - starting material is a ductile solid

(commonly metal)

• Material removal processes - starting material is a ductile or

brittle solid

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Solidification Processes

• Starting material is heated sufficiently to transform it into a liquid or

highly plastic state

• Examples: metal casting, plastic molding

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Particulate Processing

• Starting materials are powders of metals or ceramics

• Usually involves pressing and sintering, in which powders are first

compressed and then heated to bond the individual particles

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Deformation Processes

• Starting workpart is shaped by application of forces that exceed

the yield strength of the material

• Examples: (a) forging, (b) extrusion

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Material Removal Processes

• Excess material removed from the starting piece so what remains is

the desired geometry

• Examples: machining such as turning, drilling, and milling; also

grinding and nontraditional processes

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Property-Enhancing Processes

• Performed to improve mechanical or physical properties of work

material

• Part shape is not altered, except unintentionally

• Examples:

• Heat treatment of metals and glasses

• Sintering of powdered metals and ceramics

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Surface Processing Operations

• Cleaning - chemical and mechanical processes to remove dirt, oil,

and other contaminants from the surface

• Surface treatments - mechanical working such as sand blasting,

and physical processes like diffusion

• Coating and thin film deposition - coating exterior surface of the

workpart

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Assembly Operations

• Joining processes

• Welding

• Brazing and soldering

• Adhesive bonding

• Mechanical assembly

• Threaded fasteners (e.g., bolts and nuts, screws)

• Rivets

• Interference fits (e.g., press fitting, shrink fits)

• Other

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Development Process

FIGURE 1.3 (a) Chart showing various steps

involved in designing and manufacturing a

product. Depending on the complexity of the

product and the type of materials used, the

time span between the original concept and

the marketing of a product may range from a

few months to many years. (b) Chart showing

general product flow, from market analysis to

selling the product, and depicting concurrent

engineering. Source: After S. Pugh.

Product Design and Concurrent

Engineering

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Shapes &

Manufacturing

Process

TABLE 1.2 Shapes and some common

methods of production.

Design for

Manufacture,

Assembly,

Service, …

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Design for Assembly

FIGURE 1.4 Redesign of parts to facilitate automated assembly. Source: Reprinted from G. Boothroyd and P.

Dewhurst, Product Design for Assembly, 1989, by courtesy of Marcel Dekker, Inc.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

All-Aluminum

Automobile

FIGURE 1.5 (a) The Audi A8 automobile, an example of advanced materials construction; (b) The aluminum

body structure, showing various components made by extrusion, sheet forming, and casting processes.

Source: Courtesy of ALCOA, Inc.

Design for Environment; Sustainable

Manufacturing; Product Life Cycle

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Material Selection

• Types of materials

• Material substitution

• Material properties

• Cost and availability

• Service life and recycling

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Methods of Manufacture

FIGURE 1.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or

upsetting, (c) extrusion, (d) machining, (e) joining two pieces.

Selection of Manufacturing Process

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Scales in

Manufacturing

FIGURE 1.7 Illustration of the range of

common sizes of parts and the

capabilities of manufacturing processes in

producing these parts.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Machining a Mold Cavity

FIGURE 1.8 Machining a mold cavity for making sunglasses. (a) Computer model of the sunglasses as

designed and viewed on the monitor. (b) Machining the die cavity using a computer numerical control milling

machine. (c) Final product produced from the mold. Source: Courtesy Mastercam / CNC Software, Inc.

Computer Integrated Manufacturing

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Flexible Manufacturing

FIGURE 1.9 General view of a flexible manufacturing system, showing several machines (machining centers)

and an automated guided vehicle (AGV) moving along the aisle. Source: Courtesy of Cincinnati Milacron, Inc.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Lean Production and Agile Manufacturing;

Quality Assurance and TQM

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid

© 2008, Pearson Education

ISBN No. 0-13-227271-7

Global Labor Rates

Manufacturing Cost