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Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R.Schmid.

ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Chapter 0General Introduction



Materials in an Automotive Engine

Figure I.1 Section of an automotive engine - the Duratec V-6 - showing variouscomponents and the materials used in making them. Source: Courtesy of FordMotor Company. Illustration by David Kimball.



Components in Products

• Some products are a singlecomponents (nail, bolt, fork, coathanger, etc.)

• Some products are assemblies ofmany components (ball point pens,automobiles, washing machines, etc.)

• All components are manufactured.

• Manufacturing means, literally, “Madeby Hand”.



History of Manufacturing (until 1700)



History of Manufacturing (1700-1960)



History of Manufacturing (1960-2000s)



Materials Selection for Paper Clips

Figure I.2 Examples of the wide variety of materials and geometries for paper clips.

Questions for consideration:

• What material properties arerequired?

• What manufacturing attributes arerequired?

• Would the material and processingstrategy change if the desiredquantity was 10,000 vs. 1 millionper day?



Manufacture of Light Bulbs

Figure I.3a Components of a commonincandescent light bulb. Source: Courtesyof General Electric Company.

Figure I.3b Manufacturing steps inmaking an incandescent light bulb.Source: Courtesy of General ElectricCompany.



Figure I.4 (a) Chart showing thevarious steps involved in designand manufacturing a product.Depending on the complexity ofthe product and the type ofmaterials used, the time spanbetween the original concept andthe marketing of the product mayrange from a few months to manyyears.(b) Chart showing generalproduct flow in concurrentengineering, from market analysisto selling the product. Source:After S. Pugh, Total Design.Addison-Wesley, 1991.

Product Design Process



Redesign of Parts

Figure I.5 Redesign of parts to facilitate assembly. Source: Reprintedfrom G. Boothroyd and P. Dewhurst, Product Design for Assembly, 1989.Courtesy of Marcel Dekker, Inc.



Manufacturing Characteristics of Alloys



Baseball Bat Cross-sections

Figure I.6 Cross-sections of baseballbats made of aluminum (top portion)and composite material (bottomportion).



Manufacturing Processes: Casting

Figure I.7a Schematic illustration of various casting processes



Manufacturing Processes: Forming and Shaping

Figure I.7b Schematic illustration of various bulk deformation processes




Figure I.7c Schematic illustration of various sheet metal forming processes




Figure I.7d Schematic illustration ofvarious polymer processing methods



Manufacturing Processes: Machining

Figure 1.7e Schematic illustrations of variousmachining and finishing processes.



Manufacturing Processes: Joining

Figure I.7f Schematic illustration of various joining processes



Laser Cutting

Figure I.8 Cutting sheet metal witha laser beam. Source: Courtesy ofRofin-Sinar, Inc. and ManufacturingEngineering Magazine, Society of

Manufacturing Engineers



Hip Replacement

Figure 1.9 Components of a total hipreplacement. Source: Courtesy of Zimmer, Inc.



Manufacturing of Hip Replacement

Figure 1.10 (a) Manufacturing steps in the production of a roll-formed and machinedtotal hip replacement stem; (b) Manufacturing steps in the production of a forged stem.Hip stems can also be produced by investment casting, metal injection molding, insertinjection molding, and assorted other processes. Source: Courtesy of Zimmer, Inc.



Microscopic Components

Figure I.11 (a) Microscopic gears with dust mite. Source: Courtesy SandiaNational Laboratory; (b) A movable micromirror component of a light sensor.

Source: Courtesy of Richard Mueller, University of California at Berkeley.



Salt and Pepper Shakers

Figure I.12 A salt and pepper mill set. The twometal pieces (at the bottom) for the pepper millare made by powder-metallurgy techniques.Source: Reproduced with permission fromSuccess Stories on P/M Parts, Metal PowderIndustries Federation, Princeton, NJ, 1998.



Automated welding of automobiles

Figure I.13 Automated spotwelding of automobile bodies ina mass production line. Source:Courtesy of Ford MotorCompany.



Application of CAD/CAM to make sunglasses mold

Figure I.14 Machining a moldcavity for making sunglasses.

(a) Computer model of the sunglassas designed and viewed on themonitor.

(b) Machine the die cavity using acomputer numerical-control millingmachine

(c) Final product. Source: Courtesy ofMastercam/CNC Software, Inc.



Hourly Compensation for Production Workers

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