Range of Materials & Processes in a Tractor

Steel pistons with friction-welded

skirt and crown and chrome/
molybdenum disulfide
Silicon microprocessors with
coated piston ring
gold-plated connectors
Titanium turbocharger
Die-cast aluminum
compressor wheel
valve cover
Lexan windshield
Forged steel connecting
rods with precisionfractured joint

Centrifugal cast-iron
cylinder bores

Aluminum/copper/nickel
journal bearings

Fiberglass hood
Copper tube,
aluminum fin coolers

High-strength steel bolts

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.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7

History of Manufacturing
TABLE 1.1
H i st or i ca l D evel op m en t of M a t er i a l s a n d M a n u f a ct u r i n g Pr ocesses
D a t es

Egypt: ' 3100 B.C . to ' 300 B.C .

Greece: ' 1100 B.C . to ' 146 B.C .
Roman Empire: ' 500 B.C . to 476
Middle Ages: ' 476 to 1492
Renaissance: 14th to 16th centuries

M et a ls a n d
ca st in g

Befo r e 4 0 0 0 B.C .

G o ld , co p p er, m et eo r ic
ir o n

4 0 0 0 3 0 0 0 B.C .

C o p p er ca st in g, st o n e
a n d m et a l m o ld s, lo st w a x p r o cess, silver,
lea d , t in , b r o n ze

3 0 0 0 2 0 0 0 B.C .

Br o n ze ca st in g a n d
d r a w in g, go ld lea f

2 0 0 0 1 0 0 0 B.C .

Wr o u gh t ir o n , b r a ss

1 0 0 0 1 B.C .

Va r io u s
m a t er ia ls a n d
co m p o sit es
Ea r t h en w a r e, gla zin g,
n a t u r a l fib er s

F o r m in g a n d
sh a p in g

Jo in in g

H a m m er i n g

To o ls, m a ch in in g,
a n d m a n u fa ct u r in g
syst em s
To o ls o f st o n e, flin t ,
w o o d , b o n e, ivo r y,
co m p o sit e t o o ls

St a m p in g, jew elr y

So ld er in g (C u -Au ,
C u -Pb , Pb -Sn )

C o r u n d u m (a l u m i n a ,
em er y)

G la ss b ea d s, p o t t er s
w h eel, gla ss vessels

W ir e b y slit t in g sh eet
m et a l

R ivet in g, b r a zin g

H o e m a k in g, h a m m er ed
a x es, t o o ls fo r
ir o n m a k in g a n d
ca r p en t r y

C a st ir o n , ca st st eel

G la ss p r essin g a n d
b lo w in g

St a m p in g o f co in s

Fo r ge w eld in g o f
ir o n a n d st eel,
glu in g

Im p r o ved ch isels, sa w s,
files, w o o d w o r k in g la t h es

1 1 0 0 0 A.D .

Z in c, st eel

Ven et ia n gla ss

Ar m o r, co in in g,
fo r gin g, st eel sw o r d s

Et ch in g o f a r m o r

1 0 0 0 1 5 0 0

Bla st fu r n a ce, t yp e
m et a ls, ca st in g o f b ells,
p ew t er

C r yst a l gla ss

W ir e d r a w in g, go ld a n d silver sm it h w o r k

Sa n d p a p er, w in d m illd r iven sa w

1 5 0 0 1 6 0 0

C a st -ir o n ca n n o n ,
t in p la t e

C a st p la t e gla ss,
flin t gla ss

Wa t er p o w er fo r
m et a lw o r k in g, r o llin g
m ill fo r co in a ge st r ip s

H a n d la t h e fo r w o o d

1 6 0 0 1 7 0 0

Per m a n en t -m o ld
ca st in g, b r a ss fr o m
co p p er a n d m et a llic
zin c

Po r cela in

R o llin g (lea d , go ld ,
silver ), sh a p e r o lling
(lea d )

Bo r in g, t u r n in g, scr ew cu t t in g la t h e, d r ill p r ess

A. D .

Per io d

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7

History of Manufacturing (cont.)

T ABLE 1.1
H i st or i ca l D evel op m en t of M a t er i a l s a n d M a n u f a ct u r i n g Pr ocesses ( con t . )

WWII

WWI

Industrial Revolution:

' 1750to 1850

Per io d

D a t es

M et a ls a n d
ca st in g

1 7 0 0 1 8 0 0

M a llea b le ca st ir o n ,
cr u cib le st eel (ir o n b a r s
a n d r o d s)

1 8 0 0 1 9 0 0

C en t r igu fa l ca st in g,
Bessem er p r o cess,
elect r o lyt ic a lu m in u m ,
n ick el st eels, b a b b it t ,
ga lva n ized st eel,
p o w d er m et a llu r gy,
o p en -h ea r t h st eel

1 9 0 0 1 9 2 0

Va r io u s
m a t er i a l s a n d
co m p o sit es

F o r m in g a n d
sh a p in g

Jo in in g

To o ls, m a ch in in g,
a n d m a n u fa ct u r in g
syst em s

Ex t r u sio n (lea d p ip e),

d eep d r a w in g, r o llin g
W in d o w gla ss fr o m
slit cylin d er, ligh t
b u lb , vu lca n iza t io n ,
r u b b er p r o cessin g,
p o lyest er, st yr en e,
cellu lo id , r u b b er
ex t r u sio n , m o ld i n g

St ea m h a m m er, st eel
r o llin g, sea m less t u b e,
st eel-r a il r o llin g,
co n t in u o u s r o llin g,
elect r o p la t in g

Sh a p in g, m illin g, co p yin g
la t h e fo r gu n st o ck s, t u r r et
la t h e, u n iver sa l m illin g
m a ch in e, vit r ified
gr in d in g w h eel

Au t o m a t ic b o t t le
m a k in g, b a k elit e,
b o r o silica t e gla ss

Tu b e r o llin g, h o t
ex t r u sio n

O x ya cet ylen e;
a r c, elect r ica lr esist a n ce, a n d
t h er m it w eld in g

G ea r ed la t h e, a u t o m a t ic
scr ew m a ch in e, h o b b in g,
h igh -sp eed -st eel t o o ls,
a lu m in u m o x id e a n d
silico n ca r b id e (syn t h et ic)

C o a t ed elect r o d es

Tu n gst en ca r b id e, m a ss
p r o d u ct io n , t r a n sfer
m a ch in es

1 9 2 0 1 9 4 0

D ie ca st in g

D evelo p m en t o f
p la st ics, ca st in g,
m o ld in g, p o lyvin yl
ch lo r id e, cellu lo se
a cet a t e, p o lyet h ylen e,
gla ss fib er s

Tu n gst en w ir e fr o m
m et a l p o w d er

1 9 4 0 1 9 5 0

Lo st -w a x p r o cess fo r
en gin eer in g p a r t s

Acr ylics, syn t h et ic

r u b b er, ep o x ies,
p h o t o sen sit ive gla ss

Ex t r u sio n (st eel),

Su b m er ged a r c
sw a gin g, p o w d er
w eld in g
m et a ls fo r en gin eer in g
parts

Ph o sp h a t e co n ver sio n
co a t in gs, t o t a l q u a lit y
co n t r o l

1 9 5 0 1 9 6 0

C er a m i c m o l d ,
n o d u la r i r o n ,
sem ico n d u ct o r s,
co n t in u o u s ca st in g

Acr ylo n it r ileb u t a d ien e-st yr en e,

silicon es,
flu o r o ca r b o n s,
p o lyu r et h a n e, flo a t
gla ss, t em p er ed gla ss,
gla ss cer a m ics

C o ld ex t r u sio n (st eel),

ex p lo sive fo r m in g,
t h er m o m ech a n ica l
p r o cessin g

Elect r ica l a n d ch em ica l

m a ch in in g, a u t o m a t ic
co n t r o l

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7

G a s m et a l a r c, ga s
t u n gst en a r c, a n d
elect r o sla g w eld in g;
ex p lo sio n w eld in g

History of Manufacturing (conc.)

TABLE 1.1
His t o r ic a l De v e lo p m e n t o f M a t e r ia ls a n d M a n u f a c t u r in g P r o c e s s e s ( c o n t . )
D a t es

Information Age

M et a ls a n d
ca st in g

Va r io u s
m a t er ia ls a n d
co m p o sit es

F o r m in g a n d
sh a p i n g

Jo in in g

To o ls, m a ch in in g,
a n d m a n u fa ct u r in g
syst em s

1 9 6 0 1 9 7 0

Sq u eeze ca st in g,
sin gle-cr yst a l
t u r b in e b la d es

Acet a ls,
p o lyca r b o n a t e, co ld
fo r m in g o f p la st ics,
r ein fo r ced p la st ics,
fila m en t w in d in g

H yd r o fo r m in g,
h yd r o st a t ic ex t r u sio n ,
elect r o fo r m in g

Pla sm a -a r c a n d
elect r o n -b ea m
w eld in g, a d h esive
b o n d in g

Tit a n iu m ca r b id e,
syn t h et ic d ia m o n d ,
n u m er ica l co n t r o l,
in t egr a t ed cir cu it ch ip

1 9 7 0 1 9 9 0

C o m p a ct ed gr a p h it e,
va cu u m ca st in g,
o r ga n ica lly b o n d ed
s a n d , a u t o m a t io n o f
m o ld in g a n d p o u r in g,
r a p id so lid ifica t io n ,
m et a l-m a t r ix
co m p o sit es, sem iso lid
m et a lw o r k in g,
a m o r p h o u s m et a ls,
sh a p e-m em o r y a llo ys
(sm a r t m a t er ia ls),
co m p u t er sim u la t io n

Ad h esives, co m p o sit e
m a t er ia ls,
sem ico n d u ct o r s,
o p t ica l fib er s,
st r u ct u r a l cer a m ics,
cer a m ic-m a t r ix
co m p o sit es,
b io d egr a d a b le
p la st ics, elect r ica lly
co n d u ct in g p o lym er s

Pr ecisio n fo r gin g,
iso t h er m a l fo r gin g,
su p er p la st ic fo r m in g,
d ies m a d e b y
co m p u t er-a id ed d esign
a n d m a n u fa ct u r in g,
n et -sh a p e fo r gin g a n d
fo r m in g, co m p u t er
sim u la t io n

La ser b ea m ,
d iffu sio n b o n d in g
(a lso co m b in ed
w it h su p er p la st ic
fo r m in g), su r fa cem o u n t so ld er in g

C u b ic b o r o n n it r id e ,
co a t ed t o o ls, d ia m o n d
t u r n in g, u lt r a p r ecisio n
m a ch in in g, co m p u t erin t egr a t ed m a n u fa ct u r in g,
in d u st r ia l r o b o t s,
m a ch in in g a n d t u r n in g
cen t er s, flex ib lem a n u fa ct u r in g syst em s,
sen so r t ech n o lo gy,
a u t o m a t ed in sp ect io n,
ex p er t syst em s, a r t ificia l
in t elligen ce, co m p u t er
sim u la t io n a n d
o p t im iza t io n

1 9 9 0 2 0 0 0 s

R h eo ca st in g,
co m p u t er-a id ed d esign
o f m o ld s a n d d ies,
r a p id t o o lin g

N a n o p h a se m a t er ia ls,
m et a l fo a m s,
a d va n ced co a t in gs,
h igh -t em p er a t u r e
su p er co n d u ct o r s.
m a ch in a b le cer a m ics,
d ia m o n d lik e ca r b o n

R a p id p r o t o t yp in g,
r a p id t o o lin g,
en vir o n m en t a lly
fr ien d ly m et a lw o r k in g
flu id s

Fr ict io n st ir
w eld in g, lea d -fr ee
so ld er s, la ser b u t t w eld ed (t a ilo r ed )
sh eet -m et a l b la n k s,
elect r ica lly
co n d u ct in g
a d h esives

M icr o - a n d n a n o fa b r ica t io n , LIG A

(a G er m a n a cr o n ym
fo r a p r o cess in vo lvin g
lit h o gr a p h y, elect r o p la t in g,
a n d m o ld in g), d r y
et ch in g, lin ea r m o t o r
d r ives, a r t ificia l n eu r a l
n et w o r k s, six sigm a

Space Age

Per io d

So u r ce: J.A. Sch ey, C .S. Sm it h , R .F. Tyleco t e, T.K. D er r y, T.I. W illia m s, S.R . Sch m id , a n d S. Ka lp a k jia n .

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7

GDP per capita, 1000 US$

Manufacturing Importance
40

USA
Australia

30

Japan

Kuwait

France

20
Canada
10

Bangladesh

Mexico

Germany
Thailand
China

Ethiopia
0

10
15
20
25
30
35
Contribution of manufacturing to GDP, %

40

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.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7

45

Definition of product need;

marketing information

Development Process

Conceptual design and evaluation;

feasibility study

Design analysis; codes/standards

review; physical and analytical models

Prototype production; testing

and evaluation

Computer-aided
design (CAD)

Production drawings;
instruction manuals

Material specification; process and

equipment selection; safety review

Market

Computer-aided
manufacturing and
process planning
(CAM and CAPP)

Specification
Iterations

Pilot production

Computer-integrated
manufacturing (CIM)

Flow

Production

Main
design

Concept design

Detail design

Inspection and quality assurance

Packaging; marketing and

sales literature

Manufacture

Product

Sell

(a)

(b)

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7

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.

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 methoda
Rolling, planing, broaching, milling, shaping, grinding
End milling, electrical-discharge machining, electrochemical
machining, ultrasonic machining, blanking, casting, forging,
extrusion, injection molding, metal injection molding
Permanent-mold casting, machining, grinding, fabricating b ,
powder metallurgy, coining
Slush casting, electroforming, fabricating, lament winding,
blow molding, sheet forming, spinning
Extrusion, drawing, lament winding, roll forming, spinning,
centrifugal casting
Rubber forming, tube hydroforming, explosive forming, spinning, blow molding, sand casting, lament winding
Stretch forming, peen forming, fabricating, thermoforming
Blanking, chemical blanking, photochemical blanking, laser
machining
Drawing, extrusion, shaving, turning, centerless grinding,
swaging, roll forming
Fine blanking, machining, shaving, belt grinding
Laser or electron-beam machining, electrical-discharge machining, electrochemical machining, chemical blanking
Knurling, wire brushing, grinding, belt grinding, shot blasting, etching, laser texturing, injection molding, compression
molding
Coining, investment casting, permanent-mold casting, machining, injection molding, compression molding
Thread cutting, thread rolling, thread grinding, injection
molding
Casting, forging, fabricating, assembly
Investment casting, etching, powder metallurgy, nanofabrication, LIGA, micromachining

Notes:
a Rapid prototyping operations can produce all of these features to some degree.
b `Fabricating' refers to assembly from separately manufactured components.

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 Assembly

Poor

Parts can
hang up

Good

Chamfer allows part

to fall into place

Poor

Good

Part must be released

before it is located

Part is located
before release

(a)

Poor

Good

Can easily
tangle

Will tangle only

under pressure

(b)

(c)

Poor

Poor

Good

Difficult to feedparts overlap

Easy to feed

(d)

Insertion
difficult

Good

Air-relief hole
in workpiece

Air-relief
hole in pin

Air-relief
flat on pin

(e)

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.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7

All-Aluminum Automobile
Robotically applied, advanced arc-welding processes
provide consistent, high-quality assembly of castings,
extrusions, and sheet components
Die-cast nodes are thin-walled
to maximize weight reduction
yet provide high performance

Strong, thin-walled extrusions

exhibit high ductility, energy
absorption, and toughness

Advanced extrusion bending processes

support complex shapes and tight radii
(a)

(b)

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.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7

Methods of Manufacture
Before

After

Joined

(a)

(b)

(c)

(d)

(e)

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.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7

Classification

Examples
in nature

Manufacturing
process examples

Applications
Aircraft

10 m

0.01 m
5 1 cm

1 mm

1 mm
0.1 m
5 100 nm

10 nm
1 nm
5 10

Automobile

Machinery
gears

Machining
Integrated
circuit
package

Ant
Grain
of sand

Chemical
blanking

Human
cell

Gear for
MEMS
LIGA

Virus

Lithography

Features in
integrated
circuit

Dust
particle
Nanomanufacturing

10 mm

Mouse

Micromanufacturing

Size

0.1 mm
5 100 mm

Casting
Forging

Mesomanufacturing

0.1 m

Macromanufacturing

1m

Human
height

Scales in
Manufacturing

Atoms

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7

FIGURE 1.7
Illustration of the range of
common sizes of parts and the capabilities of
manufacturing processes in producing these
parts.

Machining a Mold Cavity

(a)

(b)

(c)

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.

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.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7

Global Labor Rates

TABLE 1.3
Approximate Relative Hourly Compensation for Production Workers,
for 2003. United States = 100. Compensation Costs Vary Depending
on Benefits and Allowance.
Denmark
Norway
Germany
Belgium, Switzerland
Finland, Netherlands
Austria, Sweden
United States
France
United Kingdom
Australia, Canada, Japan

147
144
136
127
123
116
100
96
93
90

European countries
Asian countries

111
33

Ireland, Italy
Spain
Israel
New Zealand, Korea
Singapore
Portugal, Taiwan
Czech Republic
Brazil, Mexico
China, India

85
67
53
48
33
27
20
11
10

Source: Courtesy of U.S. Department of Labor, November 2004.

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.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7