JABATAN KEJURUTERAAN MEKANIKAL DAN

PEMBUATAN
UNIVERSITI PUTRA MALAYSIA

ADVANCED MANUFACTURING TECHNOLOGY AND

PROCESS
EMM570

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SYLLABUS

1. Product Specification and overall manufacturing requirement.

2. Selection of Materials.
3. Factors in manufacturing process selection
4. Metal-based manufacturing methods.
5. Polymer-based manufacturing methods
6. Other manufacturing processes
7. Case study.

Final Examination : 40%

Tests/Assignment : 60%

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Manufacturing

 Manu factus = made by hand

- appeared in 1567 (manufacture)
1683 (manufacturing)
- manufacturing involves making products from raw materials by
various processes, machinery and operations following a well
organised plan for each activity required.
- manufacturing engineering describes area of industrial activity
(United States)
- Production engineering (Europe and Japan)
- Manufacturing - complex activity
- involves people with broad range of disciplines and
skills, wide variety of machinery equipment and
tooling with various levels of automation.
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Product specification/requirements

1. Must fully meet design requirements.

2. Must be manufactured by the most economical methods in order to minimize the
costs.
3. Quality must be built into the product at each stage
(i.e from design to assembly)
4. Production methods must be sufficiently flexible so as to respond to changing
market demands, types of products, production rates, production quantities and
on-time delivery.
5. New developments in materials, production methods and computer integration of
both technological and managerial activities must constantly be evaluated with a
view to their timely and economic implementation.
6. Manufacturing activities must be viewed as a large system - each part interrelated
to others.
7. Organisation must constantly strive for higher productivity - optimum use of all
its resources such as materials, machine, etc.

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Material Properties

1. Physical materials melting point, density, moisture content, porosity

and surface texture.
2. Chemical relate to resistance to corrosion and dissolution.
3. Thermal measures of the effects of temperature on materials.
4. Electrical determine material conductivity and resistance to electrical
charges.
5. Acoustical indicate reactions to sound.
6. Optical indicate reactions to light.
7. Mechanical important indicators of strength, productivity and
durability
tension, compression, torsion, shear.

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 Physical + Mechanical properties - design and manufacture of any
product.
 Stress, strain, tensile strength, compression strength, safety factor,
torsion, shear, ductility, impact, creep, fatigue, modulus of elasticity
and hardness.
 Strength-to-weight and stiffness-to-weight ratio of material are
important aerospace and automotive application.
 Example: Aluminium, titanium and reinforced plastics - higher ratios
that steels and cast iron.

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Materials Selection

 To design and manufacture a good, usable and dependable product

1. Understand the various properties of materials
2. Able to select the right materials for the right application
 general types of materials used in manufacturing today :
1. Irons + steels (carbon, alloy, stainless)
2. Nonferrous metals and alloys (Aluminium, magnesium, copper,
nickel, titanium, superalloys, refractory metals)
3. Plastics (thermoplastics, thermosets and elastomers)
4. Ceramics, glass ceramics, glasses, graphite and diamond
5. Composite materials (FRP, MMC and CMC)

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 Other major concern

1. Availability of raw and processed materials

- quantities, shapes and dimensions
- not available substitutes and/or additional processing will be
required which can contribute significantly to product cost.
2. Cost-economic aspects raw and processed materials
- reliability of supply
- methods of processing - expensive machinery, extensive labour.
3. Appearance - finished products such as colour, feel, surface texture.
4. Service life - time-and service-dependent phenomena such as wear,
fatigue, creep and dimensional stability.
- product performance

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5. Compatibility of materials - friction and wear, corrosion
- e.g galvanic action- dissimilar metals
increase corrosion rate
6. Recycling/proper disposal of materials
- eg biodegradable packaging, recyclable glass bottles and aluminium
cans.

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Process Selection

 Processes - Material removal - e.g machining

Material addition - e.g electroplating
Change of form - e.g forging
Change of condition e.g heat treatment
Materials joining - e.g welding
Finishing -e.g laping
 Basic considerations 1. Types of materials
2. Material properties
 Others 3. Dimensional and surface finish requirements (size,
thickness, shape complexity, tolerances)
4. Operational and cost considerations (design and cost of tooling, time,
tool and die life, availability of machines, operating experience)

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Improper selecting materials and processes

 Product failure.
 Product is generally failed when :
1. It stop functioning (e.g broken shaft, bolt, gear, etc)
2. Does not function properly (e.g worn bearings, dies, etc)
3. Unreliable and/or unsafe for further use (e.g poor connection in
PCB, delamination of a reinforced plastic component)

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