manufacturing
DESCRIPTION
itroductinTRANSCRIPT
![Page 1: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/1.jpg)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
MEIE-4262
Manufacturing Processes
![Page 2: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/2.jpg)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
Chapter-1
Introduction
![Page 3: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/3.jpg)
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
![Page 4: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/4.jpg)
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 .
![Page 5: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/5.jpg)
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.
![Page 6: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/6.jpg)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
History of Manufacturing
![Page 7: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/7.jpg)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
History of Manufacturing (cont.)
![Page 8: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/8.jpg)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
History of Manufacturing (conc.)
![Page 9: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/9.jpg)
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.
![Page 10: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/10.jpg)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
Classification of Manufacturing
Processes
![Page 11: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/11.jpg)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
Manufacturing Process
![Page 12: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/12.jpg)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
Classification of Manufacturing Processes
![Page 13: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/13.jpg)
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
![Page 14: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/14.jpg)
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
![Page 15: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/15.jpg)
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
![Page 16: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/16.jpg)
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
![Page 17: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/17.jpg)
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
![Page 18: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/18.jpg)
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
![Page 19: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/19.jpg)
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
![Page 20: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/20.jpg)
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
![Page 21: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/21.jpg)
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
![Page 22: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/22.jpg)
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
![Page 23: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/23.jpg)
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
![Page 24: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/24.jpg)
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, …
![Page 25: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/25.jpg)
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.
![Page 26: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/26.jpg)
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
![Page 27: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/27.jpg)
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
![Page 28: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/28.jpg)
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
![Page 29: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/29.jpg)
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.
![Page 30: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/30.jpg)
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
![Page 31: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/31.jpg)
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.
![Page 32: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/32.jpg)
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
![Page 33: manufacturing](https://reader030.vdocument.in/reader030/viewer/2022020306/5451488eb1af9f3d3a8b45d1/html5/thumbnails/33.jpg)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
Global Labor Rates
Manufacturing Cost