Range of Materials & Processes in a Tractor

Steel pistons with friction-welded skirt and crown and chrome/ molybdenum disulfide Silicon microprocessors with coated piston ring gold-plated connectors Titanium turbocharger Die-cast aluminum compressor wheel valve cover Lexan windshield Centrifugal cast-iron cylinder bores Forged steel connecting rods with precisionfractured joint

Aluminum/copper/nickel journal bearings

Fiberglass hood Copper tube, aluminum fin coolers

High-strength steel bolts

FIGURE 1.1 Model 8430 tractor, with detailed illustration of its diesel engine, showing the variety of materials and processes incorporated. Source: Courtesy of John Deere Company.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

History of Manufacturing
TABLE 1.1 H i st or i ca l D evel op m en t of M a t er i a l s a n d M a n u f a ct u r i n g Pr ocesses
Per io d D a t es M et a ls a n d ca st in g G o ld , co p p er, m et eo r ic ir o n C o p p er ca st in g, st o n e a n d m et a l m o ld s, lo st w a x p r o cess, silver, lea d , t in , b r o n ze Br o n ze ca st in g a n d d r a w in g, go ld lea f G la ss b ea d s, p o t t er s w h eel, gla ss vessels Va r io u s m a t er ia ls a n d co m p o sit es Ea r t h en w a r e, gla zin g, n a t u r a l fib er s F o r m in g a n d sh a p in g H a m m er i n g Jo in in g To o ls, m a ch in in g, a n d m a n u fa ct u r in g syst em s To o ls o f st o n e, flin t , w o o d , b o n e, ivo r y, co m p o sit e t o o ls So ld er in g (C u -Au , C u -Pb , Pb -Sn ) C o r u n d u m (a l u m i n a , em er y) Befo r e 4 0 0 0 B.C .

4 0 0 0 3 0 0 0 B.C .

St a m p in g, jew elr y

3 0 0 0 2 0 0 0 B.C . Egypt: ' 3100 B.C . to ' 300 B.C . Greece: ' 1100 B.C . to ' 146 B.C . Roman Empire: ' 500 B.C . to 476 Middle Ages: ' 476 to 1492 Renaissance: 14th to 16th centuries
A. D .

W ir e b y slit t in g sh eet m et a l

R ivet in g, b r a zin g

H o e m a k in g, h a m m er ed a x es, t o o ls fo r ir o n m a k in g a n d ca r p en t r y

2 0 0 0 1 0 0 0 B.C . 1 0 0 0 1 B.C .

Wr o u gh t ir o n , b r a ss C a st ir o n , ca st st eel G la ss p r essin g a n d b lo w in g Ven et ia n gla ss C r yst a l gla ss St a m p in g o f co in s Fo r ge w eld in g o f ir o n a n d st eel, glu in g Im p r o ved ch isels, sa w s, files, w o o d w o r k in g la t h es Et ch in g o f a r m o r Sa n d p a p er, w in d m illd r iven sa w H a n d la t h e fo r w o o d

1 1 0 0 0 A.D . 1 0 0 0 1 5 0 0

Z in c, st eel Bla st fu r n a ce, t yp e m et a ls, ca st in g o f b ells, p ew t er C a st -ir o n ca n n o n , t in p la t e Per m a n en t -m o ld ca st in g, b r a ss fr o m co p p er a n d m et a llic zin c

Ar m o r, co in in g, fo r gin g, st eel sw o r d s W ir e d r a w in g, go ld a n d silver sm it h w o r k Wa t er p o w er fo r m et a lw o r k in g, r o llin g m ill fo r co in a ge st r ip s R o llin g (lea d , go ld , silver ), sh a p e r o lling (lea d )

1 5 0 0 1 6 0 0

C a st p la t e gla ss, flin t gla ss Po r cela in

1 6 0 0 1 7 0 0

Bo r in g, t u r n in g, scr ew cu t t in g la t h e, d r ill p r ess

Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

History of Manufacturing (cont.)

T ABLE 1 1 . H i st or i ca l D evel op m en t of M a t er i a l s a n d M a n u f a ct u r i n g Pr ocesses ( con t . )
Per io d D a t es M et a ls a n d ca st in g M a llea b le ca st ir o n , cr u cib le st eel (ir o n b a r s a n d r o d s) C en t r igu fa l ca st in g, Bessem er p r o cess, elect r o lyt ic a lu m in u m , n ick el st eels, b a b b it t , ga lva n ized st eel, p o w d er m et a llu r gy, o p en -h ea r t h st eel W in d o w gla ss fr o m slit cylin d er, ligh t b u lb , vu lca n iza t io n , r u b b er p r o cessin g, p o lyest er, st yr en e, cellu lo id , r u b b er ex t r u sio n , m o ld i n g Au t o m a t ic b o t t le m a k in g, b a k elit e, b o r o silica t e gla ss Va r io u s m a t er i a l s a n d co m p o sit es F o r m in g a n d sh a p in g Ex t r u sio n (lea d p ip e), d eep d r a w in g, r o llin g St ea m h a m m er, st eel r o llin g, sea m less t u b e, st eel-r a il r o llin g, co n t in u o u s r o llin g, elect r o p la t in g Sh a p in g, m illin g, co p yin g la t h e fo r gu n st o ck s, t u r r et la t h e, u n iver sa l m illin g m a ch in e, vit r ified gr in d in g w h eel Jo in in g To o ls, m a ch in in g, a n d m a n u fa ct u r in g syst em s 1 7 0 0 1 8 0 0 ' 1750 1850 to

1 8 0 0 1 9 0 0

Industrial Revolution:

1 9 0 0 1 9 2 0

Tu b e r o llin g, h o t ex t r u sio n

O x ya cet ylen e; a r c, elect r ica lr esist a n ce, a n d t h er m it w eld in g C o a t ed elect r o d es

G ea r ed la t h e, a u t o m a t ic scr ew m a ch in e, h o b b in g, h igh -sp eed -st eel t o o ls, a lu m in u m o x id e a n d silico n ca r b id e (syn t h et ic) Tu n gst en ca r b id e, m a ss p r o d u ct io n , t r a n sfer m a ch in es

1 9 2 0 1 9 4 0

D ie ca st in g

WWI

D evelo p m en t o f p la st ics, ca st in g, m o ld in g, p o lyvin yl ch lo r id e, cellu lo se a cet a t e, p o lyet h ylen e, gla ss fib er s Acr ylics, syn t h et ic r u b b er, ep o x ies, p h o t o sen sit ive gla ss Acr ylo n it r ileb u t a d ien e-st yr en e, silicon es, flu o r o ca r b o n s, p o lyu r et h a n e, flo a t gla ss, t em p er ed gla ss, gla ss cer a m ics

Tu n gst en w ir e fr o m m et a l p o w d er

1 9 4 0 1 9 5 0

Lo st -w a x p r o cess fo r en gin eer in g p a r t s

WWII

Ex t r u sio n (st eel), Su b m er ged a r c sw a gin g, p o w d er w eld in g m et a ls fo r en gin eer in g parts C o ld ex t r u sio n (st eel), ex p lo sive fo r m in g, t h er m o m ech a n ica l p r o cessin g G a s m et a l a r c, ga s t u n gst en a r c, a n d elect r o sla g w eld in g; ex p lo sio n w eld in g

Ph o sp h a t e co n ver sio n co a t in gs, t o t a l q u a lit y co n t r o l Elect r ica l a n d ch em ica l m a ch in in g, a u t o m a t ic co n t r o l

1 9 5 0 1 9 6 0

C er a m i c m o l d , n o d u la r i r o n , sem ico n d u ct o r s, co n t in u o u s ca st in g

Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

History of Manufacturing (conc.)

TABLE 1.1 His t o r ic a l De v e lo p m e n t o f M a t e r ia ls a n d M a n u f a c t u r in g P r o c e s s e s ( c o n t . )
Per io d D a t es M et a ls a n d ca st in g Sq u eeze ca st in g, sin gle-cr yst a l t u r b in e b la d es Va r io u s m a t er ia ls a n d co m p o sit es Acet a ls, p o lyca r b o n a t e, co ld fo r m in g o f p la st ics, r ein fo r ced p la st ics, fila m en t w in d in g Ad h esives, co m p o sit e m a t er ia ls, sem ico n d u ct o r s, o p t ica l fib er s, st r u ct u r a l cer a m ics, cer a m ic-m a t r ix co m p o sit es, b io d egr a d a b le p la st ics, elect r ica lly co n d u ct in g p o lym er s F o r m in g a n d sh a p i n g H yd r o fo r m in g, h yd r o st a t ic ex t r u sio n , elect r o fo r m in g Jo in in g To o ls, m a ch in in g, a n d m a n u fa ct u r in g syst em s Tit a n iu m ca r b id e, syn t h et ic d ia m o n d , n u m er ica l co n t r o l, in t egr a t ed cir cu it ch ip C u b ic b o r o n n it r id e , co a t ed t o o ls, d ia m o n d t u r n in g, u lt r a p r ecisio n m a ch in in g, co m p u t erin t egr a t ed m a n u fa ct u r in g, in d u st r ia l r o b o t s, m a ch in in g a n d t u r n in g cen t er s, flex ib lem a n u fa ct u r in g syst em s, sen so r t ech n o lo gy, a u t o m a t ed in sp ect io n, ex p er t syst em s, a r t ificia l in t elligen ce, co m p u t er sim u la t io n a n d o p t im iza t io n M icr o - a n d n a n o fa b r ica t io n , LIG A (a G er m a n a cr o n ym fo r a p r o cess in vo lvin g lit h o gr a p h y, elect r o p la t in g, a n d m o ld in g), d r y et ch in g, lin ea r m o t o r d r ives, a r t ificia l n eu r a l n et w o r k s, six sigm a

1 9 6 0 1 9 7 0

Pla sm a -a r c a n d elect r o n -b ea m w eld in g, a d h esive b o n d in g La ser b ea m , d iffu sio n b o n d in g (a lso co m b in ed w it h su p er p la st ic fo r m in g), su r fa cem o u n t so ld er in g

1 9 7 0 1 9 9 0 Space Age

C o m p a ct ed gr a p h it e, va cu u m ca st in g, o r ga n ica lly b o n d ed s a n d , a u t o m a t io n o f m o ld in g a n d p o u r in g, r a p id so lid ifica t io n , m et a l-m a t r ix co m p o sit es, sem iso lid m et a lw o r k in g, a m o r p h o u s m et a ls, sh a p e-m em o r y a llo ys (sm a r t m a t er ia ls), co m p u t er sim u la t io n

Pr ecisio n fo r gin g, iso t h er m a l fo r gin g, su p er p la st ic fo r m in g, d ies m a d e b y co m p u t er-a id ed d esign a n d m a n u fa ct u r in g, n et -sh a p e fo r gin g a n d fo r m in g, co m p u t er sim u la t io n

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 .

Information Age

1 9 9 0 2 0 0 0 s

R h eo ca st in g, co m p u t er-a id ed d esign o f m o ld s a n d d ies, r a p id t o o lin g

N a n o p h a se m a t er ia ls, m et a l fo a m s, a d va n ced co a t in gs, h igh -t em p er a t u r e su p er co n d u ct o r s. m a ch in a b le cer a m ics, d ia m o n d lik e ca r b o n

R a p id p r o t o t yp in g, r a p id t o o lin g, en vir o n m en t a lly fr ien d ly m et a lw o r k in g flu id s

Fr ict io n st ir w eld in g, lea d -fr ee so ld er s, la ser b u t t w eld ed (t a ilo r ed ) sh eet -m et a l b la n k s, elect r ica lly co n d u ct in g a d h esives

Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

Manufacturing Importance
GDP per capita, 1000 US$ 40 USA Australia Kuwait 20 Canada 10 Bangladesh Ethiopia 0 0 5 10 15 20 25 30 35 Contribution of manufacturing to GDP, % Mexico Germany Thailand China 40 45 Japan France

30

FIGURE 1.2 Importance of manufacturing to national economies. The trends shown are from 1982 until 2006. Source: After J.A. Schey with data from the World Development Report, World Bank, various years.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

Definition of product need; marketing information

Conceptual design and evaluation; feasibility study

Development Process
Computer-aided design (CAD)

Design analysis; codes/standards review; physical and analytical models

Prototype production; testing and evaluation

Production drawings; instruction manuals Computer-aided manufacturing and process planning (CAM and CAPP)

Market

Material specification; process and equipment selection; safety review

Specification Iterations

Pilot production Concept design

Main design Flow

Production

Computer-integrated manufacturing (CIM)

Detail design

Inspection and quality assurance

Packaging; marketing and sales literature

Manufacture

Product (a)

Sell (b)

FIGURE 1.3 (a) Chart showing various steps involved in designing and manufacturing a product. Depending on the complexity of the product and the type of materials used, the time span between the original concept and the marketing of a product may range from a few months to many years. (b) Chart showing general product ow, from market analysis to selling the product, and depicting concurrent engineering. Source: After S. Pugh.

Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

Shapes & Manufacturing Process

TABLE 1.2 Shapes and some common methods of production.

Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

Design for Assembly

Poor Good Poor Good Poor Good

Parts can hang up

Chamfer allows part to fall into place (a)

Part must be released before it is located (b)

Part is located before release

Can easily tangle

Will tangle only under pressure (c)

Poor

Good

Poor

Good

Difficult to feedparts overlap (d)

Easy to feed

Insertion difficult

Air-relief hole in workpiece (e)

Air-relief hole in pin

Air-relief flat on pin

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.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

All-Aluminum Automobile
Robotically applied, advanced arc-welding processes provide consistent, high-quality assembly of castings, extrusions, and sheet components Die-cast nodes are thin-walled to maximize weight reduction yet provide high performance

Advanced extrusion bending processes support complex shapes and tight radii (a) (b)

Strong, thin-walled extrusions exhibit high ductility, energy absorption, and toughness

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.

Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

Methods of Manufacture
Before After

Joined

(a)

(b)

(c)

(d)

(e)

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.

Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

Classification

Examples in nature

Manufacturing process examples

Applications Aircraft

10 m Human height Casting Forging Mouse Machining Ant Mesomanufacturing Grain of sand Integrated circuit package Chemical blanking Gear for MEMS LIGA Virus Features in integrated circuit Automobile

Scales in Manufacturing

Macromanufacturing

1m

0.1 m 0.01 m 5 1 cm

Machinery gears

1 mm 0.1 mm 5 100 mm Size Micromanufacturing

Human cell

10 mm

1 mm 0.1 m 5 100 nm

Lithography Dust particle Nanomanufacturing

10 nm 1 nm 5 10

Atoms

FIGURE 1.7 Illustration of the range of common sizes of parts and the capabilities of manufacturing processes in producing these parts.

Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

Machining a Mold Cavity

(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.

Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

Flexible Manufacturing

FIGURE 1.9 General view of a exible manufacturing system, showing several machines (machining centers) and an automated guided vehicle (AGV) moving along the aisle. Source: Courtesy of Cincinnati Milacron, Inc.

Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7

Global Labor Rates

TABLE 1.3 Approximate Relative Hourly Compensation for Production Workers, for 2003. United States = 100. Compensation Costs Vary Depending on Benefits and Allowance.
Denmark Norway Germany Belgium, Switzerland Finland, Netherlands Austria, Sweden United States France United Kingdom Australia, Canada, Japan European countries Asian countries 147 144 136 127 123 116 100 96 93 90 111 33 Ireland, Italy Spain Israel New Zealand, Korea Singapore Portugal, Taiwan Czech Republic Brazil, Mexico China, India 85 67 53 48 33 27 20 11 10

Source: Courtesy of U.S. Department of Labor, November 2004.

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.

Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7