IE 337: Materials & Manufacturing

Processes

Lecture 1:
Introduction

Chapter 1 & 5
 Course Instructor

 Brian K. Paul
 PhD 1995, Penn State

 Office:
 322 Rogers Hall
 E-mail: brian.paul@oregonstate.edu
 Phone: 737-7320

 Office Hours:
 T: 11:30 – noon
 R: 11:30 – 13:00

2
 Items to Address

 Course Introductions
 Course Logistics
 Course Expectations
 Feedback
 Introduction to Materials & Processes
 Material-Geometry-Process Relationships
 Manufacturing Materials
 Manufacturing Processes
 How do we characterize processes?

3
 Introductions

 Lectures:
 Section 001: T, R 10:00 – 11:20 AM 218 Covell Hall

 Labs: 126 Rogers

 Section 1: W 14:00 – 15:50
 Section 2: F 16:00 – 17:50

 Course Website:
 TEACH website – http://classes.engr.oregonstate.edu/

4
 Lab Instruction

 Mr. Barath Palanisamy (Instructor)

 E-mail: palanisb@onid.orst.edu
 Ms. Negar Abolhassani (co-Instructor)
 E-mail: abolhasn@onid.orst.edu

 Steve Etringer (Technician)

 E-mail: etringer@engr.orst.edu

 Lab
 126 Rogers Hall

5
 Books & Materials

 Required Text:
 Groover, M.P. (2006). Fundamentals of Modern
Manufacturing (3rd ed.). New York NY: John Wiley & Sons.
1040 pp. ISBN 0-471-74485-9.

 Required Materials:
 Engineering Problems Paper – 8-1/2" x 11", three hole drilled,
ruled five squares/division, 50 pp. (approx.).
 Scientific Calculator
 Safety Glasses (Z-87 NIOSH) for lab

6
 Grading

 Homework (6): 15%

 Midterm: 25%

 Final: 35%

 Laboratory (9): 25%

7
 Learning Outcomes

1. State basic properties of materials and apply these

properties to manufacturing process and product
design.
2. Compare and contrast the design and production
advantages of traditional mechanical manufacturing
processes (casting, forming, machining, and joining).
3. Evaluate material-process-geometry relationships
in manufacturing processes.
4. Differentiate advanced mechanical manufacturing
processes e.g. micro-scale and nano-scale
technologies.
8 IE 337: Materials & Manufacturing Processes
 Expectations
 Due Dates & Late Assignments
 Everything is due at the start of class – on scheduled date
 Partial Credit for late work – turn in to 204 Rogers
 Lose 10% of earned credit per day

 Make-up Work & Absences – use memorandum format

 Unforseeable – as soon as practicable
 Foreseeable – as far in advance as possible
 Grade Appeals – use memorandum format
 Laboratory Participation and Safety
 Special Needs Accommodation
 Academic Integrity
9
 Introduction to Materials & Processes

 Material-Geometry-Process Relationships
 Manufacturing Materials
 Manufacturing Processes
 How do we characterize processes?

10
 What is Manufacturing?
 Manufacturing is the application of physical and
chemical processes to alter the geometry,
properties, and appearance of a starting material
to make parts or products for a given application

11
 Material-Process-Geometry Relationships

Function Role of
Prod Engr

Material Geometry

Role of
Process Mfg Engr

12 IE 337: Materials & Manufacturing Processes

 Complexity in Manufacturing

Materials: 106
metals, ceramics, polymers, composites

Processes: 105
process conditions are ~ ∞

Properties: 102
applications are ~ ∞

13
 Purpose of Manufacturing

 Manufacturing is the transformation of materials into

items of greater value by means of one or more
processing and/or assembly operations

14
 Manufacturing: Everchanging

Wilbur & Orville Wright, 1903

fabric, wood, steel
120 ft, 12 s, 400 kg

Boeing, 2003
titanium, aluminum
14,000 km,
400,000 kg, 14+ hours
15
 Manufacturing & Globalization

16
 Tracking Manufacturing Problems

Exploding tires, 2004 Melamine in milk, 2008

Toxic toys, 2007 Medicines, 2006

17
 Transformations

China over 2000 years

18
 Materials in Manufacturing

 Most engineering materials can be classified

into one of four basic categories:
1. Metals
2. Ceramics
3. Polymers
4. Composites

19
 Processing Operations

 Three categories of processing operations:

1. Shaping operations - alter the geometry of the

starting work material

2. Property-enhancing operations - improve physical

properties of the material without changing its shape

3. Surface processing operations - clean, treat, coat, or

deposit material onto the exterior surface of the work
20
 Shaping – Four Main Categories

 Solidification Processes - starting material is a

heated liquid that solidifies to form part geometry

 Deformation Processes - starting material is a

ductile solid that is deformed

 Material Removal Processes - starting material is a

ductile/brittle solid, from which material is removed

 Assembly Processes - two or more separate parts

are joined to form a new entity
21
 Solidification Processes

 Starting material is heated sufficiently to transform it

into a liquid or highly plastic state
 Examples: casting for metals, molding for plastics

22
 Deformation Processes

 Starting workpart is shaped by application of forces

that exceed the yield strength of the material
 Examples: (a) forging, (b) extrusion

23
 Material Removal Processes

 Excess material removed from the starting workpiece

so what remains is the desired geometry
 Examples: machining such as turning, drilling, and
milling; also grinding and nontraditional processes

Turning Drilling Milling

24
 Assembly Operations

 Two or more separate parts are joined to

form a new entity

 Types of assembly operations:

1. Joining processes – create a permanent joint.
• Examples: welding, brazing, soldering, and adhesive
bonding
2. Mechanical assembly – fastening by mechanical
methods
• Examples: use of screws, bolts, nuts, other threaded
fasteners; press fitting, expansion fits
25
 Property-Enhancing Processes

 Performed to improve mechanical or physical

properties of the work material
 Part shape is not altered, except
unintentionally
 Examples:
 Heat treatment of metals and glasses
 Sintering of powdered metals and ceramics

26
 Surface Processing

1. Cleaning - chemical and mechanical processes to

remove dirt, oil, and other contaminants from the
surface
2. Surface treatments - mechanical working such as
sand blasting, and physical processes like diffusion
3. Coating and thin film deposition - coating exterior
surface of the workpart

 Several surface processing operations used to

fabricate integrated circuits

27
 Developing a Manufacturing Process

1. Understand Function/Geometry
Properties: mechanical, electrical, thermal,
magnetic, optical, deteriorative.

2. Properties Identify candidate Material(s)

Material: structure, composition.

3. Material Identify required Processing

• Processing: changes structure and overall shape
• Material and Geometry compatibility
• Other considerations
28
 How do we characterize processes?

 Quality
 Dimensional – bulk and surface
 Properties – bulk and surface
 Economics
 Cycle time
 Materials utilization
 Flexibility
 Tooling development
 Setup time
 Cycle time

29 IE 337: Materials & Manufacturing Processes

 Dimensional Quality

 Bulk
 Tolerances
 Bilateral, unilateral or limits
 Size and location
 Geometric tolerances – flatness, roundness,
cylindricity, straightness, parallelism,
perpendicularity, angularity, true position, etc.
 Surface
 Surface texture – roughness, waviness, lay

30 IE 337: Materials & Manufacturing Processes

 Quality – properties

 Defects
 Inclusions, voids, porosity …
 Microstructure
 Grain size, residual stress, precipitate size, etc.
 Surface integrity
 Absorption, alloy depletion, cracks, craters,
hardness changes, heat affected zones, inclusions,
intergranular attacks, seems, pits, plastic
deformation, recrystallization, residual stresses,
selective etch …
31 IE 337: Materials & Manufacturing Processes
 Waste in Shaping Processes

 It is desirable to minimize waste and scrap in part

shaping i.e. have high material utilization
 Material removal processes tend to be wasteful in the unit
operation, simply by the way they work
 Casting and molding waste less material

 Terminology:
 Net shape processes - when most of the starting
material is used and no subsequent machining is
required to achieve final part geometry
 Near net shape processes - when minimum
amount of machining is required
32
 Comparing Processes

33 IE 337: Materials & Manufacturing Processes

 You should have learned today:

 The key design responsibility of a

manufacturing engineer
 Key categories of manufacturing materials
 Key categories of manufacturing processes
 How to compare them
 materials-processes-geometry
 IE 337: Got to work hard
 tons of information, regular study habits

44
 Next Class

 Metals

From Chapters 2 and 3

45