1 Introduction To Material Technology

Dr.
Arman Shah Bin Abdullah,

B.Eng Hon.(Manuf. Eng), M.Eng. Adv. Manuf. Eng, Phd Mechanical engineering
Coordinator
Research Management Unit
Research Management and Innovation Centre
Research Management Innovation Complex
Introduction to Manufacturing Technology

Chapter 1: INTRODUCTION TO
MANUFACTURING TECHNOLOGY
• 1.1 WHAT IS MANUFACTURING?
• 1.2 MANUFACTURING PROCESSES
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
What is Manufacturing?
• The word manufacture is derived from two Latin words manus (hand) and factus
(make); the combination means “made by hand”
 “Made by hand” accurately described the fabrication methods that were used when
the English word “manufacture” was first coined around 1567 A.D.
 Most modern manufacturing operations are accomplished by mechanized and

automated equipment that is supervised by human workers
• Manufacturing Defined
• In Serope Kalpakjian & Steven R. Schmid:
• “Manufacturing is the process of converting raw materials into products. It

includes,
• The design of products.

• The selection of raw materials.
•Manufacturing Defined:
•In Mikell P Groover:
•“Technologically, manufacturing is the application of physical and chemical processes to alter the
geometry, properties, and/or appearance of a starting material to make parts or products
 Manufacturing also includes assembly

 Almost always carried out as a sequence of
operations”
•1.1.1 Manufacturing Defined:

•In Mikell P Groover:
•“Economically, manufacturing is transformation of materials

into items of greater value by means of one or more processing
and/or assembly operations
 Manufacturing adds value to the material by

• changing its shape or properties, or by
• combining it with other materials”
1.1 What is Manufacturing?
1.2 Manufacturing Processes
• Can be divided into two basic types:
• i. Processing Operation
• ii. Assembly Operation
Processing Operation
• transform a work material from one state of completion to a more advanced
state that is closer to the final desired product.
• it adds value by changing the geometry, properties, or appearance of the starting

material.
• performed on discrete workparts and applicable to assembled items.
Assembly Operation
 joins two or more components in order to create a new entity called an assembly,
subassembly, or some other term that refers to the joining process.
Figure 1.2 Classification of manufacturing processes
Shaping Processes – Four Categories
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
Solidification Processes
• Starting material is heated sufficiently to transform it into a liquid or highly plastic
state
 Examples: metal casting, plastic molding
Particulate Processing
• Starting materials are powders of metals or ceramics
 Usually involves pressing and sintering, in which powders are first compressed
and then heated to bond the individual particles
Deformation Processes
• Starting workpart is shaped by application of forces that exceed the yield strength
of the material
 Examples: (a) forging, (b) extrusion
Material Removal Processes
• Excess material removed from the starting piece so

what remains is the desired geometry
 Examples: machining such as turning, drilling, and

milling; also grinding and nontraditional processes
Property‑Enhancing Processes
• Performed to improve mechanical or physical
properties of work material
 Part shape is not altered
 Examples:
• Heat treatment of metals and glasses
• Sintering of powdered metals and ceramics
Surface Processing Operations
 Cleaning - chemical and mechanical processes
to remove dirt, oil, and other contaminants from
the surface
 Surface treatments - mechanical working such

as sand blasting, and physical processes like
diffusion
 Coating and thin film deposition - coating

exterior surface of the workpart
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

 Welding, brazing, soldering, and adhesive bonding
2. Mechanical assembly – fastening by mechanical
methods
 Threaded fasteners (screws, bolts and nuts); press

fitting, expansion fits
1.3 Production Systems
 Production systems consists of people, equipment,

and procedures used for the combination of
materials and processes that constitute a firm's
manufacturing operations
 A manufacturing firm must have systems and

procedures to efficiently accomplish its type of
production
1.3 Production Systems
 Two categories of production systems:

• Production facilities
• Manufacturing support systems
 Both categories include people (people make the systems work)
 In general, direct labor people are responsible for operating the manufacturing equipment, and
professional staff people are responsible for manufacturing support.
1.3.1 Production Facilities
 The factory, production equipment, and material handling
systems
 Refers to the physical equipment and the arrangement of

equipment in the factory.
 Equipment usually organized into logical groupings, called

manufacturing systems
• Examples:
 Automated production line
 Machine cell consisting of an industrial robot and two
machine tools
Manufacturing Support Systems
• A company must organize itself to design the processes and
equipment, plan and control production, and satisfy product
quality requirements
 Accomplished by manufacturing support systems ‑ people

and procedures by which a company manages its production
operations
 Typical departments:
1. Manufacturing engineering
2. Production planning and control
3. Quality control
1.3.2 Manufacturing Support Systems
 To design the processes and equipment, plan and control the production orders,
and satisfy product quality requirements.
 Most of these support systems do not directly contact the product, but they plan
and control its progress through the factory.
 Manufacturing support functions are often carried out in the firm by people
organized into departments such as :
• 1.3.2.1 Manufacturing Engineering
 responsible for planning the manufacturing processes – deciding which processes should be used to make
the parts and assemble the products.
 this department is also involved in designing and ordering the machine tools and other equipment used by
the operating departments to accomplish processing and assembly.
• 1.3.2.2 Production Planning and Control
 responsible for solving the logistics problems in manufacturing - ordering

materials and purchased parts, scheduling production, and making sure that the
operating departments have the necessary capacity to meet the production
schedules.
• 1.3.2.3. Quality Control
 producing high-quality products should be a top priority of any manufacturing firm in today’s competitive
environment.
 it means designing and building products that conform to specifications and satisfy customer expectations.
 much of this effort is the responsibility of the QC department.
Manufacturing and Production System
A spectacular scene in steelmaking is charging of a basic oxygen furnace, in
which molten pig iron produced in a blast furnace is poured into the BOF.
Temperatures are around 1650°C (3000 ° F).
A machining cell consisting of two horizontal machining centers supplied by an in-line pallet shuttle
(photo courtesy of Cincinnati Milacron).
A robotic arm performs
unloading and loading
operation in a turning
center using a dual
gripper (photo courtesy
of Cincinnati Milacron).
Metal chips fly in a high
speed turning operation
performed on a
computer numerical
control turning center
(photo courtesy of
Cincinnati Milacron).
Photomicrograph of the cross section of multiple coatings of titanium nitride
and aluminum oxide on a cemented carbide substrate (photo courtesy of
Kennametal Inc.).
A batch of silicon wafers enters a furnace heated to 1000°C (1800°F) during fabrication of integrated
circuits under clean room conditions (photo courtesy of Intel Corporation).
Two welders perform
arc welding on a large
steel pipe section
(photo courtesy of
Lincoln Electric
Company).
Automated dispensing of
adhesive onto
component parts prior to
assembly (photo
courtesy of EFD, Inc.).
Assembly workers on
an engine assembly
line (photo courtesy of
Ford Motor Company).
Assembly operations
on the Boeing 777
(photo courtesy of
Boeing Commercial
Airplane Co.).
History of Manufacturing (until 1700)
History of Manufacturing (1700-1960)
History of Manufacturing (1960-2000s)
Manufacture of Light Bulbs
Figure I.3a Components Figure I.3b

of a common Manufacturing steps
incandescent light bulb. in making an
Source: Courtesy of incandescent light
bulb. Source:
Product Design Process
Figure I.4 (a)
Chart showing the
various steps
involved in design
and manufacturing
a product.
Depending on the
complexity of the
product and the
type of materials
used, the time span
Redesign of Parts
Figure I.5 Redesign of parts to facilitate

assembly. Source: Reprinted from G.
Boothroyd and P. Dewhurst, Product
Manufacturing Characteristics of Alloys
Baseball Bat Cross-sections
Figure I.6 Cross-

sections of baseball
bats made of
aluminum (top
portion) and
composite material
(bottom portion).
Manufacturing Processes: Casting
Figure I.7a Schematic illustration of

various casting processes
Manufacturing Processes: Forming and Shaping
Figure I.7d Schematic

illustration of various
Manufacturing Processes: Machining
Figure 1.7e Schematic

illustrations of various
Manufacturing Processes: Joining
Figure I.7f Schematic illustration of various joining processes

Laser Cutting
Figure I.8 Cutting sheet metal with a
laser beam. Source: Courtesy of
Rofin-Sinar, Inc. and Manufacturing
Engineering Magazine, Society of
Manufacturing Engineers
Hip Replacement
Figure 1.9 Components of a

total hip replacement.
Manufacturing of Hip Replacement
Figure 1.10 (a) Manufacturing steps in the production of a roll-formed and m

achined total hip replacement stem; (b) Manufacturing steps in the production of a forged stem. Hip
stems can also be produced by investment casting, metal injection molding, insert injection molding, and
assorted other processes. Source: Courtesy of Zimmer, Inc.
Microscopic Components
Figure I.11 (a) Microscopic gears with dust

mite. Source: Courtesy Sandia National
Laboratory; (b) A movable micromirror
component of a light sensor. Source: Courtesy
Automated welding of automobiles
Figure I.13
Automated spot
welding of
automobile bodies
in a mass
production line.
Source: Courtesy
of Ford Motor
Company.
Application of CAD/CAM to make sunglasses mold
Figure I.14 Machining a mold

cavity for making sunglasses.
(a) Computer model

of the sunglass as
designed and viewed
(b) Machine the die
on the monitor.
cavity using a
(c) Final product.
computer numerical-
control milling
Source: Courtesy of
machine
Mastercam/CNC
Software, Inc.
Hourly Compensation for Production Workers

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Dr.

Arman Shah Bin Abdullah,

Introduction to Manufacturing Technology

• 1.1 WHAT IS MANUFACTURING?

• 1.2 MANUFACTURING PROCESSES

 Most modern manufacturing operations are accomplished by mechanized and

• In Serope Kalpakjian & Steven R. Schmid:

• “Manufacturing is the process of converting raw materials into products. It

• The design of products.

•In Mikell P Groover:

 Manufacturing also includes assembly

•1.1.1 Manufacturing Defined:

•“Economically, manufacturing is transformation of materials

 Manufacturing adds value to the material by

• Can be divided into two basic types:

• ii. Assembly Operation

• it adds value by changing the geometry, properties, or appearance of the starting

• performed on discrete workparts and applicable to assembled items.

2. Particulate processing - starting material

3. Deformation processes - starting material is a

4. Material removal processes - starting material is

 Examples: metal casting, plastic molding

• Starting materials are powders of metals or ceramics

 Examples: (a) forging, (b) extrusion

• Excess material removed from the starting piece so

 Examples: machining such as turning, drilling, and

 Part shape is not altered

• Heat treatment of metals and glasses

• Sintering of powdered metals and ceramics

 Surface treatments - mechanical working such

 Coating and thin film deposition - coating

 Types of assembly operations:

1. Joining processes – create a permanent joint

 Threaded fasteners (screws, bolts and nuts); press

 Production systems consists of people, equipment,

 A manufacturing firm must have systems and

 Two categories of production systems:

 Both categories include people (people make the systems work)

 Refers to the physical equipment and the arrangement of

 Equipment usually organized into logical groupings, called

 Accomplished by manufacturing support systems ‑ people

 responsible for solving the logistics problems in manufacturing - ordering

• 1.3.2.3. Quality Control

Figure I.3a Components Figure I.3b

Figure I.5 Redesign of parts to facilitate

Figure I.6 Cross-

Figure I.7a Schematic illustration of

Figure I.7d Schematic

Figure 1.7e Schematic

Figure I.7f Schematic illustration of various joining processes

Figure 1.9 Components of a

Figure 1.10 (a) Manufacturing steps in the production of a roll-formed and m

Figure I.11 (a) Microscopic gears with dust

Figure I.14 Machining a mold

(a) Computer model

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