Engineering Materials

FIGURE 1.4 An outline of engineering materials

Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003

Shapes and Production Method

Shape or feature
Flat surfaces
Parts with cavities
Parts with sharp features
Thin hollow shapes
Tubular shapes
Tubular parts
Curvature on thin sheets
Openings in thin sheets
Cross-sections
Square edges
Small holes
Surface textures
Detailed surface features
Threaded parts
Very large parts
Very small parts

Production method
Rolling, planing, broaching, milling, shaping, grinding
End milling, electrical-discharge machining, electrochemical machining,
ultrasonic machining, casting
Permanent-mold casting, machining, grinding, fabricating, powder
metallurgy
Slush casting, electroforming, fabricating
Extrusion, drawing, roll forming, spinning, centrifugal casting
Rubber forming, expanding with hydraulic pressure, explosive forming,
spinning
Stretch forming, peen forming, fabricating, assembly
Blanking, chemical blanking, photochemical blanking
Drawing, extrusion, shaving, turning, centerless grinding
Fine blanking, machining, shaving, belt grinding
Laser, electrical-discharge machining, electrochemical machining
Knurling, wire brushing, grinding, belt grinding, shot blasting, etching,
deposition, laser texturing
Coining, investment casting, permanent-mold casting, machining
Thread cutting, thread rolling, thread grinding, chasing
Casting, forging, fabricating, assembly
Investment casting, machining, etching, powder metallurgy,
nanofabrication, LIGA, micromachining

TABLE 1.2 Shapes and Some Common Methods of Production

Manufacturing Processes for Engineering Materials, 4th ed.

Kalpakjian Schmid
Prentice Hall, 2003

Design Steps
FIGURE 1.2 (a) Chart
showing varous 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, Total Design.
Addison-Wesley, 1991.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003

Materials Engineering Paradigm

PROCESSING

STRUCTURE

PROPERTIES

CHEMICAL
SYNTHESIS

MOLECULAR

MECHANICAL

polymerization
crystallization/precipitation
thermal treatment

molecular weight
conformation
configuration
crystallinity
orientation

ELECTRICAL

SHAPE FORMING

CRYSTALLINE

MAGNETIC

powder processing
deformation processing
deposition processing
solidification processing

stoichiometry
composition
size
morphology
orientation

PHYSICAL

MICROSTRUCTURE

FUNCTIONAL

phase fractions
porosity
texture
gradation

BIOLOGICAL

BIOLOGICAL
biosynthesis
biomineralization
self-assembly
template directed growth
cell mediated assembly

CHEMICAL

THERMAL

AME 50542: Manufacturing Processes for Engineering Materials (R.K. Roeder)

PR

atomic

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SYNTHESIS
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ing
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Modified
Materials
Engineering
Paradigm
(with Parallels
to Biology)

(STIMULUS)

la
m ol e c u
(bi
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ma moleculalar
cromolecu
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(tis tallin
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sys
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tem
(organism, syste
ST
RUCTURE

AME 50542: Manufacturing Processes for Engineering Materials (R.K. Roeder)