ie 337: materials & manufacturing processes lecture 1: introduction chapter 1 & 5
TRANSCRIPT
IE 337: Materials & Manufacturing Processes
Lecture 1: Introduction
Chapter 1 & 5
Course Instructor
Brian K. Paul PhD 1995, Penn State
Office: 322 Rogers Hall E-mail: [email protected] Phone: 737-7320
Office Hours: T: 11:30 – noon R: 11:30 – 13:00
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Items to Address
Course Introductions Course Logistics Course Expectations Feedback
Introduction to Materials & Processes Material-Geometry-Process Relationships Manufacturing Materials Manufacturing Processes How do we characterize processes?
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Introductions
Lectures: Section 001: T, R 10:00 – 11:20 AM 218 Covell
Hall
Labs: 126 Rogers Section 1: W 14:00 – 15:50 Section 2: F 16:00 – 17:50
Course Website: TEACH website – http://classes.engr.oregonstate.edu/
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Lab Instruction
Mr. Barath Palanisamy (Instructor) E-mail: [email protected]
Ms. Negar Abolhassani (co-Instructor) E-mail: [email protected]
Steve Etringer (Technician) E-mail: [email protected]
Lab 126 Rogers Hall
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Books & Materials
Required Text: Groover, M.P. (2006). Fundamentals of Modern
Manufacturing (3rd ed.). New York NY: John Wiley & Sons. 1040 pp. ISBN 0-471-74485-9.
Required Materials: Engineering Problems Paper – 8-1/2" x 11", three hole drilled,
ruled five squares/division, 50 pp. (approx.). Scientific Calculator Safety Glasses (Z-87 NIOSH) for lab
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Grading
Homework (6): 15%
Midterm: 25%
Final: 35%
Laboratory (9): 25%
Learning Outcomes
1. State basic properties of materials and apply these properties to manufacturing process and product design.
2. Compare and contrast the design and production advantages of traditional mechanical manufacturing processes (casting, forming, machining, and joining).
3. Evaluate material-process-geometry relationships in manufacturing processes.
4. Differentiate advanced mechanical manufacturing processes e.g. micro-scale and nano-scale technologies.
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Expectations
Due Dates & Late Assignments Everything is due at the start of class – on scheduled date Partial Credit for late work – turn in to 204 Rogers
Lose 10% of earned credit per day
Make-up Work & Absences – use memorandum format Unforseeable – as soon as practicable Foreseeable – as far in advance as possible
Grade Appeals – use memorandum format Laboratory Participation and Safety Special Needs Accommodation Academic Integrity
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Introduction to Materials & Processes
Material-Geometry-Process Relationships Manufacturing Materials Manufacturing Processes How do we characterize processes?
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What is Manufacturing?
Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and appearance of a starting material to make parts or products for a given application
Material-Process-Geometry Relationships
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Function
Process
Material Geometry
Role of Prod Engr
Role of Mfg Engr
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Complexity in Manufacturing
Materials: 106
metals, ceramics, polymers, composites
Processes: 105 process conditions are ~ ∞
Properties: 102
applications are ~ ∞
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Purpose of Manufacturing
Manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations
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Manufacturing: Everchanging
Wilbur & Orville Wright, 1903fabric, wood, steel120 ft, 12 s, 400 kg
Boeing, 2003titanium, aluminum
14,000 km, 400,000 kg, 14+ hours
Manufacturing & Globalization
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Tracking Manufacturing Problems
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Exploding tires, 2004 Melamine in milk, 2008
Toxic toys, 2007 Medicines, 2006
Transformations
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China over 2000 years
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Materials in Manufacturing
Most engineering materials can be classified into one of four basic categories: 1. Metals
2. Ceramics
3. Polymers
4. Composites
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Processing Operations
Three categories of processing operations:
1. Shaping operations - alter the geometry of the starting work material
2. Property‑enhancing operations - improve physical properties of the material without changing its shape
3. Surface processing operations - clean, treat, coat, or deposit material onto the exterior surface of the work
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Shaping – Four Main Categories
Solidification Processes - starting material is a heated liquid that solidifies to form part geometry
Deformation Processes - starting material is a ductile solid that is deformed
Material Removal Processes - starting material is a ductile/brittle solid, from which material is removed
Assembly Processes - two or more separate parts are joined to form a new entity
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Solidification Processes
Starting material is heated sufficiently to transform it into a liquid or highly plastic state
Examples: casting for metals, molding for plastics
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Deformation Processes
Starting workpart is shaped by application of forces that exceed the yield strength of the material
Examples: (a) forging, (b) extrusion
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Material Removal Processes
Excess material removed from the starting workpiece so what remains is the desired geometry
Examples: machining such as turning, drilling, and milling; also grinding and nontraditional processes
Turning Drilling Milling
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Assembly Operations
Two or more separate parts are joined to form a new entity
Types of assembly operations:1. Joining processes – create a permanent joint.
• Examples: welding, brazing, soldering, and adhesive bonding
2. Mechanical assembly – fastening by mechanical methods
• Examples: use of screws, bolts, nuts, other threaded fasteners; press fitting, expansion fits
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Property‑Enhancing Processes
Performed to improve mechanical or physical properties of the work material
Part shape is not altered, except unintentionally
Examples: Heat treatment of metals and glasses Sintering of powdered metals and ceramics
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Surface Processing
1. Cleaning - chemical and mechanical processes to remove dirt, oil, and other contaminants from the surface
2. Surface treatments - mechanical working such as sand blasting, and physical processes like diffusion
3. Coating and thin film deposition - coating exterior surface of the workpart
Several surface processing operations used to fabricate integrated circuits
Developing a Manufacturing Process
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1. Understand Function/Geometry
2. Properties Identify candidate Material(s)
3. Material Identify required Processing
• Processing: changes structure and overall shape• Material and Geometry compatibility• Other considerations
Properties: mechanical, electrical, thermal,magnetic, optical, deteriorative.
Material: structure, composition.
How do we characterize processes?
Quality Dimensional – bulk and surface Properties – bulk and surface
Economics Cycle time Materials utilization
Flexibility Tooling development Setup time Cycle time
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Dimensional Quality
Bulk Tolerances
Bilateral, unilateral or limits Size and location
Geometric tolerances – flatness, roundness, cylindricity, straightness, parallelism, perpendicularity, angularity, true position, etc.
Surface Surface texture – roughness, waviness, lay
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Quality – properties
Defects Inclusions, voids, porosity …
Microstructure Grain size, residual stress, precipitate size, etc.
Surface integrity Absorption, alloy depletion, cracks, craters,
hardness changes, heat affected zones, inclusions, intergranular attacks, seems, pits, plastic deformation, recrystallization, residual stresses, selective etch …
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Waste in Shaping Processes
It is desirable to minimize waste and scrap in part shaping i.e. have high material utilization Material removal processes tend to be wasteful in the unit
operation, simply by the way they work Casting and molding waste less material
Terminology: Net shape processes - when most of the starting
material is used and no subsequent machining is required to achieve final part geometry
Near net shape processes - when minimum amount of machining is required
Comparing Processes
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You should have learned today:
The key design responsibility of a manufacturing engineer
Key categories of manufacturing materials Key categories of manufacturing processes
How to compare them materials-processes-geometry
IE 337: Got to work hard tons of information, regular study habits
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Next Class
Metals
From Chapters 2 and 3