Professional Documents
Culture Documents
Aluminum/copper/nickel
journal bearings
Fiberglass hood
Copper tube,
aluminum fin coolers
ca r p en t r y
Egypt: ' 3100 B.C . to ' 300 B.C .
2 0 0 0 1 0 0 0 B.C . Wr o u gh t ir o n , b r a ss
Middle Ages: ' 476 to 1492
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, W in d o w gla ss fr o m St ea m h a m m er, st eel Sh a p in g, m illin g, co p yin g
Bessem er p r o cess, slit cylin d er, ligh t r o llin g, sea m less t u b e, la t h e fo r gu n st o ck s, t u r r et
elect r o lyt ic a lu m in u m , b u lb , vu lca n iza t io n , st eel-r a il r o llin g, la t h e, u n iver sa l m illin g
n ick el st eels, b a b b it t , r u b b er p r o cessin g, co n t in u o u s r o llin g, m a ch in e, vit r ified
Industrial Revolution:
gla ss fib er s
1 9 4 0 1 9 5 0 Lo st -w a x p r o cess fo r Acr ylics, syn t h et ic Ex t r u sio n (st eel), Su b m er ged a r c Ph o sp h a t e co n ver sio n
en gin eer in g p a r t s r u b b er, ep o x ies, sw a gin g, p o w d er w eld in g co a t in gs, t o t a l q u a lit y
p h o t o sen sit ive gla ss m et a ls fo r en gin eer in g co n t r o l
parts
WWII
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 .
30 Australia
Japan
Kuwait France
20
Germany
Canada
10 Mexico Thailand
Bangladesh
Ethiopia China
0
0 5 10 15 20 25 30 35 40 45
Contribution of manufacturing to GDP, %
Development Process
Conceptual design and evaluation;
feasibility study
Computer-aided
Prototype production; testing design (CAD)
and evaluation
Computer-aided
Material specification; process and manufacturing and
Specification
equipment selection; safety review process planning
(CAM and CAPP)
Iterations
Pilot production
Concept design
design
Main
Flow
Production
Computer-integrated
manufacturing (CIM) FIGURE 1.3 (a) Chart showing various steps
Detail design
involved in designing and manufacturing a product.
Inspection and quality assurance
Depending on the complexity of the product and the
type of materials used, the time span between the
Packaging; marketing and Manufacture original concept and the marketing of a product may
sales literature
range from a few months to many years. (b) Chart
showing general product flow, from market analysis
Product Sell to selling the product, and depicting concurrent
(a) (b)
engineering. Source: After S. Pugh.
Shapes &
Flat surfaces Rolling, planing, broaching, milling, shaping, grinding
Parts with cavities End milling, electrical-discharge machining, electrochemical
machining, ultrasonic machining, blanking, casting, forging,
Manufacturing
extrusion, injection molding, metal injection molding
Parts with sharp features Permanent-mold casting, machining, grinding, fabricating b ,
powder metallurgy, coining
Thin hollow shapes Slush casting, electroforming, fabricating, lament winding,
Tubular shapes
blow molding, sheet forming, spinning
Extrusion, drawing, lament winding, roll forming, spinning,
centrifugal casting
Process
Tubular parts Rubber forming, tube hydroforming, explosive forming, spin-
ning, blow molding, sand casting, lament winding
Curvature on thin sheets Stretch forming, peen forming, fabricating, thermoforming
Openings in thin sheets Blanking, chemical blanking, photochemical blanking, laser
machining
Cross-sections Drawing, extrusion, shaving, turning, centerless grinding,
swaging, roll forming
Square edges Fine blanking, machining, shaving, belt grinding
Small holes Laser or electron-beam machining, electrical-discharge ma-
chining, electrochemical machining, chemical blanking
Surface textures Knurling, wire brushing, grinding, belt grinding, shot blast-
ing, etching, laser texturing, injection molding, compression
molding
Detailed surface features Coining, investment casting, permanent-mold casting, ma-
chining, injection molding, compression molding
Threaded parts Thread cutting, thread rolling, thread grinding, injection
molding
Very large parts Casting, forging, fabricating, assembly
Very small parts Investment casting, etching, powder metallurgy, nanofabrica- TABLE 1.2 Shapes and some common methods
tion, LIGA, micromachining of production.
Notes:
a Rapid prototyping operations can produce all of these features to some degree.
b `Fabricating' refers to assembly from separately manufactured components.
Parts can Chamfer allows part Part must be released Part is located Can easily Will tangle only
hang up to fall into place before it is located before release tangle under pressure
(a) (b) (c)
Poor Good
Poor Good
Difficult to feedparts overlap Easy to feed Insertion Air-relief hole Air-relief Air-relief
difficult in workpiece hole in pin flat on pin
(d) (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.
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.
Before After
Joined
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.
Aircraft
Scales in
10 m
1m
Human
height
Casting
Automobile Manufacturing
Macromanufacturing
Forging
Machinery
0.1 m gears
Mouse
Machining
0.01 m
Integrated
5 1 cm Ant circuit
package
Grain
manufacturing
1 mm of sand
Chemical
blanking
Meso-
0.1 mm Human
5 100 mm cell
Gear for
MEMS
Size
Micromanufacturing
LIGA
10 mm Virus
Features in
integrated
Lithography circuit
1 mm
Dust
particle
0.1 m
5 100 nm
Nanomanufacturing
10 nm
Atoms FIGURE 1.7 Illustration of the range of
1 nm common sizes of parts and the capabilities of
5 10
manufacturing processes in producing these
parts.
1
(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.
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.
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.