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IE 2521

Manufacturing Processes I
Ch. 2
(Principles of Materials and processes Selection)
by
Ali Abd El-Aty, ​PhD, MASME, FISME
Assistant Professor,
Mechanical Engineering Department
Faculty of Engineering-Kharj
Prince Sattam Bin Abdulaziz University
2023-2024
 Ch. 2 : Principles of Materials and processes Selection 2

The Concept of DFM

▪ Steps in the Engineering design process: ▪ The scope of the DFMA process.

Design of products requires:

 Ch. 2 : Principles of Materials and processes Selection 3

Materials in Manufacturing

• Function: What does the component do?

• Constraints: What non-negotiable conditions must be met?, and What negotiable but desirable conditions must be
met?
Ch. 2 : Principles of Materials and processes Selection 4

Materials in Manufacturing
Ch. 2 : Principles of Materials and processes Selection 5

Materials in Manufacturing
 Ch. 2 : Principles of Materials and processes Selection 6

Materials in Manufacturing

Metals
▪ Usually alloys, which are composed of
two or more elements, at least one of
which is metallic. Two basic groups:
➢ Ferrous metals - based on iron,
comprises about 75% of metal
tonnage in the world such as: Steel
and cast iron
➢ Nonferrous metals - all other metallic
elements and their alloys such as:
Aluminum, copper, nickel, silver, tin,
etc.
Ceramics
▪ Compounds containing metallic (or semi-
metallic) and nonmetallic elements.
▪ Typical nonmetallic elements are oxygen,
nitrogen, and carbon
▪ For processing, ceramics divide into:
➢ Crystalline ceramics – includes
traditional ceramics, such as clay, and
modern ceramics, such as alumina
(Al2O3)
➢ Glasses – mostly based on silica (SiO2)
 Ch. 2 : Principles of Materials and processes Selection 7

Materials in Manufacturing

Polymers
▪ Compound formed of repeating structural
units called mers, whose atoms share electrons
to form very large molecules. Three
categories:
➢ Thermoplastic polymers - can be
subjected to multiple heating and cooling
cycles without altering molecular structure
➢ Thermosetting polymers - molecules
chemically transform into a rigid structure
– cannot reheat
➢ Elastomers - shows significant elastic
behavior
Composites
▪ Material consisting of two or more phases that
are processed separately and then bonded
together to achieve properties superior to its
constituents
➢ Phase - homogeneous material, such as
grains of identical unit cell structure in a
solid metal
➢ Usual structure consists of particles or fibers
of one phase mixed in a second phase
➢ Properties depend on components, physical
shapes of components, and the way they are
combined to form the final material
Ch. 2 : Principles of Materials and processes Selection 8

Materials in Manufacturing
Ch. 2 : Principles of Materials and processes Selection 9

Selection of Manufacturing Processes

Ch. 2 : Principles of Materials and processes Selection 10

Processing Operations

▪ Alters a material’s shape, physical

properties, or appearance in order to add
value.
▪ Three categories of processing operations:
➢ Shaping operations - alter the
geometry of the starting work material.
➢ Property-enhancing operations -
improve physical properties without
changing shape.
➢ Surface processing operations - clean,
treat, coat, or deposit material on
surface of work
Ch. 2 : Principles of Materials and processes Selection 11

Processing Operations (Shaping operations)

1. Solidification processes - starting

material is a heated liquid or
semifluid
2. Particulate processing - starting
material consists of powders
3. Deformation processes - starting
material is a ductile solid (commonly
metal)
4. Material removal processes - starting
material is a ductile or brittle solid
 Ch. 2 : Principles of Materials and processes Selection 12

Processing Operations (Shaping operations)

Solidification Processes Particulate Processing

▪ Starting material is heated sufficiently
to transform it into a liquid or highly
plastic state
▪ (1) Casting process and (2) casting
product
▪ (1) Starting materials are metal or
ceramic powders, which are (2) pressed
and (3) sintered.
 Ch. 2 : Principles of Materials and processes Selection 13

Processing Operations (Shaping operations)

Deformation Processes Material Removal Processes

▪ Starting material is shaped by
application of forces that exceed the
yield strength of the material
➢ Examples: (a) forging and (b)
extrusion
▪ Excess material removed from the
starting piece so what remains is the
desired geometry.
➢ Examples: (a) Turning and (b)
Milling
Ch. 2 : Principles of Materials and processes Selection 14
 Ch. 2 : Principles of Materials and processes Selection 15

Manufacturing Processes and Process Selection

The steps of Process selection

▪ Step 1:-Translation: express design requirements ▪ Step 3:- Ranking: find the processes that do th
as constraints & objectives. job most cheaply
▪ Step 2:-Screening: eliminate processes that cannot ▪ Step 4:- Documentation: explore pedigrees of
do the job. top-ranked candidates
Ch. 2 : Principles of Materials and processes Selection 16

The PROCESS TREE

 Ch. 2 : Principles of Materials and processes Selection 17

Processing Operations (Waste in Shaping operations)

▪ It is desirable to minimize waste in part shaping

▪ Material removal processes are wasteful in the unit operations, but molding and
particulate processing operations waste little material

▪ Terminology for minimum waste processes:

➢ Net shape processes - little or no waste of the starting material and no machining is
required

➢ Near net shape processes - when minimum machining is required

Ch. 2 : Principles of Materials and processes Selection 18

Processing Operations (Shaping operations)

▪ Cleaning - chemical and mechanical
processes to remove dirt, oil, and other
surface contaminants
▪ Surface treatments - mechanical
working such as sand blasting, and
physical processes like diffusion
▪ Coating and thin film deposition -
coating exterior surface of the workpart
▪ Examples:
➢ Electroplating
➢ Painting
Ch. 2 : Principles of Materials and processes Selection 19

Processing Operations (Assembly Operations )

▪ Two or more separate parts are joined
to form a new entity
▪ Types of assembly operations:
➢ Joining processes – create a
permanent joint such as : welding,
brazing, soldering, adhesive
bonding
➢ Mechanical assembly – fastening
by mechanical methods such as:
Threaded fasteners (screws, bolts
and nuts); press fitting, expansion
fits
Ch. 2 : Principles of Materials and processes Selection 20

Questions…