IM 112 Manufacturing Processes

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Industrial & Management Engineering Department

Dr.-Ing. Islam El-Galyhttp://elgalyAAST.4shared.com/

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Donation for 57357

Sharing Integration Respect

DiscussionTopics

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Marking Scheme

1st Exam. (7th week) 30 marks 2nd Exam. (12th week) 20 marks Final Exam. (16th week) 40 marks Cont. Assessment 10 marks

total 100 marksAttendance is mandatory.Workshop is attended with white coat.Workbook should be at hand at workshop.

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Course Content

Engineering Materials and Mechanical Properties

Steel and Heat Treatment

Casting Processes

Forming Processes

Machining Processes

Welding Processes

Dimensional Measurement

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Reading Resources1. Lecture Notes2. E.P. De Garmo, Materials and processes in

manufacturing, 8th Ed. , Prentice Hall, 1997, ISBN 0-02-328621-0

3. S. Kalpakjian, Manufacturing Processes for Engineering Materials, 4th Ed., Prentice Hall, 2003, ISBN 0-13-045373-0.

4. W.A.J. Chapman, Workshop Technology, part1, 5th Ed. E. Arnold limited, 1981, ISBN 0 7131 3287 6.

5. W.A.J. Chapman, Workshop Technology, part2, 5th Ed. E. Arnold limited, 1979, ISBN 0 7131 3291 4.

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Introduction to

Manufacturing Technology

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1. Definition of manufacturing2. Engineering Materials3. Nature of materials

Atomic Structure and the Elements Bonding between Atoms and Molecules Crystalline Structures

4. Steel alloys and cast iron

Lecture Content

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Manufacturing Cycle

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Objectives1. To understand the meaning of manufacturing process.

2. To identify the types of manufacturing processes.

3. To be aware of the principles of each production process.

4. To associate the products to the manufacturing processesaccording to their principles and features.

5. To recognize and discriminate the types of engineering materials.

6. To select suitable engineering materials according to certain prerequisites and criteria .

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To know about the iron and steel production processes as well as their applications.

To be aware of the different metal joining methods and techniques as well as the principles and characteristics of each method.

To understand the principles of dimensional measurement, tools used in industrial measurements.

To apply simple measurement techniques to determine the dimensions of a product.

To identify the elements of industrial cost and to know how to determine the production cost, volume and profit.

Objectives (cont.)

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TOP 1

Engineering Materials

and

Mechanical Properties

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How to select materials for a specific product?

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Classification of Materials Properties

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Density Mechanical Strength

Ductility High Temp. Stability

Metals High Medium to High

High Good to Very Good

Plastics Low Low to Medium

Very High(thermoplastic)

Low (thermoset)

Relatively Poor

Ceramics Medium High to Excellent

Low Excellent

Composites Low Medium to High

Medium Poor to Excellent

Ranges of Important Properties

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Crystal Structure of Metals

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Crystals Atoms arrange themselves into various ordered configuration, called crystals.

Crystalline structure.The arrangement of the atoms in the crystal is called crystalline structure.

Unit cellThe smallest group of atoms showing the characteristic lattice structure of a particular metal is known as a unit cell.

Crystal Structure of materials

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Metallic Materials Ferrous

Steel Alloy steel Cast iron

Non- Ferrous Aluminum Copper Gold Silver Lead,etc.

Wrought Iron Pure iron is called wrought iron Melting temperature = 1539 oC Ductile

Crystalline unit BCC ( iron) FCC ( iron) BCC ( iron)

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Steel (Plain Carbon steel)

It is an iron-carbon alloy Has less than 2 % carbon of its weight Called Plain Carbon Steel if it has low content alloying elements. Possesses high ability for plastic deformation.

0.9 2.00.60.25% C

cutting tools (drills, milling tools, etc.)Non-industrial-purpose knives & axles

0.9% < C < 1.2% 1.2% < C < 2.0%

Tool SteelUltra-high carbon steel

For wires, springs, forming and cutting dies due high strength and wear resistance

0.6% < C < 0.9%High Carbon Steel

Machine parts and Forgings due to its good mechanical properties

0.25% < C < 0.6%Medium Carbon Steel

Structural steel (rel. low strength)Acceptable performance at low cost

C < 0.15%0.16% < C < 0.29%

Low Carbon Steel Mild Steel

Applications / Properties% CarbonClass

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Alloy steel Undesired impurities in carbon steel: Sulphur phosphorous

oxygen nitrogen. Some elements are added to carbon steel to improve its

mechanical properties such as chrome Cr, tungsten W, nickel Ni, manganese Mn.

Types:1. High strength structure steel: 0.1% (titanium,

vanadium and boron )2. Chrome steel : high wear resistance and refractory steel 3. Nickel-chrome steel: Stainless steel4. Manganese steel: High wear resistance.5. Tungsten steel: Tool steel (High speed steel HSS).

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Cast Iron Iron-carbon alloy with >2% carbon. Has low relatively melting temperature. Preferred in casting operations.

Types:White cast iron:

carbon is united with iron in form of ferrous carbide Fe3C - high brittleness limited non-industrial applications.

Grey cast iron: carbon is found in form of flakes - hardness lower than white cast iron used in manufacturing of machine structures.

Malleable cast iron:high impact resistance made of white cast iron that is heat treated.

Spheroidal cast iron (ductile cast iron): ductile, strong heat treated white cast iron with magnesium

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Ductile iron

Grey cast iron White cast iron Malleable iron

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Non ferrous materials Aluminum:

Aluminum melting temperature = 658 oC. Crystalline cell: FCC Has good rust resistance light in weight. Used in manufacturing of electric cables.

Aluminum alloys: Wrought alloys Casting alloys. Used in manufacturing of ships, air crafts

Copper Copper :

melting Temp.= 1083 oC - FCC used in making electric cables. Copper alloys:

1. Brass: copper + tin2. Bronze : copper + zinc3. Aluminum bronze : copper + aluminum

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