8/2/2019 2- General Introductio
1/27
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 0
General Introduction
8/2/2019 2- General Introductio
2/27
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.
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 Ford Motor Company. Illustration by David Kimball.)
8/2/2019 2- General Introductio
3/27
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.
Components inProducts
Single component
(nail, bolt, fork, coathanger, etc.)
Multi-component(ball point pens,
automobiles, washingmachines, etc.)
All components aremanufactured.
Manufacturing means,literally, Made by Hand .
8/2/2019 2- General Introductio
4/27
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.
Components in Products
Some products are a singlecomponents (nail, bolt, fork,coat hanger, etc.)
Some products are assemblies
of many components (ball pointpens, automobiles, washingmachines, etc.)
All components aremanufactured.
Manufacturing means, literally,Made by Hand .
8/2/2019 2- General Introductio
5/27
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.
Historical Development of Material and Manufacturing Process
8/2/2019 2- General Introductio
6/27
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.
History of Manufacturing (1700-1960)
8/2/2019 2- General Introductio
7/27
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.
History of Manufacturing (1960-2000s)
8/2/2019 2- General Introductio
8/27
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.
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 are
required? What manufacturing attributes are
required? Would the material and processing
strategy change if the desiredquantity was 10,000 vs. 1 million perday?
8/2/2019 2- General Introductio
9/27
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.
Manufacture of Light Bulbs
Figure I.3a Components of a commonincandescent light bulb.Source : Courtesy of General Electric Company.
Figure I.3b Manufacturing steps inmaking an incandescent light bulb.Source : Courtesy of General ElectricCompany .
8/2/2019 2- General Introductio
10/27
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.
(b) Product flow in concurrentengineering, from market analysis toselling the product. Source : After S.Pugh, Total Design . Addison-Wesley,1991.
Product Design Process
Depending on thecomplexity of theproduct and the typeof materials used, thetime span betweenthe original conceptand the marketing ofthe product mayrange from a fewmonths to manyyears.
Figure I.4
(a) Various steps involved in design andmanufacturing a product.
8/2/2019 2- General Introductio
11/27
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.
Redesign of Parts
Figure I.5 Redesign of parts to facilitate assembly.Source: Reprinted from G. Boothroyd and P. Dewhurst, Product Design for Assembly, 1989. Courtesy of Marcel Dekker, Inc.
8/2/2019 2- General Introductio
12/27
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.
Manufacturing Characteristics of Alloys
8/2/2019 2- General Introductio
13/27
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.
Baseball Bat Cross-sections
Figure I.6 Cross-sections of baseballbats made of aluminum (top portion)and composite material (bottomportion).
8/2/2019 2- General Introductio
14/27
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.
Manufacturing Processes: Casting
Figure I.7a Schematic illustration of various casting processes
8/2/2019 2- General Introductio
15/27
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.
Manufacturing Processes: Forming and Shaping
Figure I.7b Schematic illustration of various bulk deformation processes
8/2/2019 2- General Introductio
16/27
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.
Manufacturing Processes: Forming and Shaping
Figure I.7c Schematic illustration of various sheet metal forming processes
8/2/2019 2- General Introductio
17/27
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.
Manufacturing Processes: Forming and Shaping
Figure I.7d Schematic illustration ofvarious polymer processing methods
8/2/2019 2- General Introductio
18/27
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.
Manufacturing Processes: Joining
Figure I.7f Schematic illustration of various joining processes
8/2/2019 2- General Introductio
19/27
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.
Manufacturing Processes: Machining
Figure 1.7e Schematic illustrations of variousmachining and finishing processes.
8/2/2019 2- General Introductio
20/27
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.
Laser Cutting
Figure I.8 Cutting sheet metal witha laser beam. Source: Courtesy ofRofin-Sinar, Inc. and Manufacturing Engineering Magazine, Society of
Manufacturing Engineers
8/2/2019 2- General Introductio
21/27
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.
Hip Replacement
Figure 1.9 Components of atotal hip replacement.Source: Courtesy of Zimmer, Inc.
8/2/2019 2- General Introductio
22/27
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.
Manufacturing of Hip Replacement
(b) Manufacturing steps in the production of aforged stem. Hip stems can also be producedby investment casting, metal injection molding,insert injection molding, and assorted otherprocesses. Source: Courtesy of Zimmer, Inc.
(a) Manufacturing steps in the production of aroll-formed and machined total hip replacement
stem;
Figure 1.10
8/2/2019 2- General Introductio
23/27
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.
Microscopic Components
(b) A movable micro-mirror component ofa light sensor.
Source: Courtesy of Richard Mueller,University of California at Berkeley.
(a) Microscopic gears with dust mite.Source: Courtesy Sandia National Laboratory;
Figure I.11
8/2/2019 2- General Introductio
24/27
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.
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.
8/2/2019 2- General Introductio
25/27
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.
Automated welding of automobiles
Figure I.13 Automated spotwelding of automobile bodiesin a mass production line.Source: Courtesy of Ford Motor Company.
8/2/2019 2- General Introductio
26/27
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.
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.
8/2/2019 2- General Introductio
27/27
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.
Hourly Compensation for Production Workers