EPP 201EPP 201Manufacturing Technology IManufacturing Technology I

Semester I, 2009/2010Semester I, 2009/2010

JamaluddinJamaluddin AbdullahAbdullahRamdziahRamdziah Bt. Md. Bt. Md. NasirNasirIndraIndra Putra AlPutra Al--ManarManar

Course PlanCourse PlanTEACHING SCHEDULE

EPP 201/3: MANUFACTURING TECHNOLOGY I SEMESTER I, 2009/2010

Class Meetings: Tuesday (11-1, DK7), Friday (11-12, DK7)

Week Day Topics Remark Tue (7/7) Introductory class & overview of manufacturing (Intro Chap) Group Formation 1 (JA) Fri (10/7) Fundamental of metallic materials - structures and properties Chap 1- 2 Tue (14 /7) Mechanical and physical properties of metals Chap 3 2 (JA) Fri (17/7) Alloys and their structures Chap 4, Quiz1 Tue (21/7) Phase Diagram Chap 4 3 (JA) Fri (24 /7) Iron-Carbon system Chap 4 Tue (28/7) Ferrous metals and alloys – Iron and Steel making Chap 5 4 (JA) Fri (31/7) Non-ferrous metals and alloys – Aluminum, Magnesium,

Titanium alloys Chap 6

Tue (4/8) Shape memory alloys, high temperature alloys, nano-materials

Chap 6, Test 1 (2nd hr) 5 (JA) (RN) Fri (7/8) Fundamentals of metal casting Chap 10-11, Assign1

Tue (11/8) Metal-casting processes Chap 11 6 (RN) Fri (14/8) Metal-casting design and casting defects Chap 12

7 15/8 – 23/8 MID SEMESTER BREAK

Tue (25/8) Rolling of metals – flat-rolling process, practice, tools Chap 13 8 (RN) Fri (28/8) Forging of metals – processes Chap 14 Tue (1/9) Forgeability, economics of forging Due Assign1 9 (RN) Fri (4/9) Extrusion and drawing of metals Chap 15, Quiz2 Tue (8/9) Sheet-metal Forming Processes:

Video - Deep Drawing, Shearing, blanking, punching processes, Bending and stretch forming of sheet metals.

Chap 16 10 (RN) (IPA)

Fri (11/9) Mechanics of sheet metal drawing processes Tue (15/9) Fundamental of Machining:

Video - Mechanics of Cutting, Cutting Forces and Power, Merchant equation

Chap 21 11 (IPA)

Fri (18/9) Temperature in Cutting Test 2 12

21/9 – 27/9 SPECIAL BREAK (HARI RAYA)

Tue (29/9) Tool life: Wear and Failure, Taylor's equation for tool life evaluation

13 (IPA)

Fri (2/10) Cutting-Tool Materials and Cutting Fluids Chap 22 Tue (5/10) Abrasive Machining, Finishing Operations

Video – Abrasives and Bonded Abrasives, Grinding Processes

Chap 26 14 (IPA)

Fri (9/10) Ultrasonic Machining, Deburring Operations Quiz3 Tue (12/10) Joining Process and Equipment

Video – Fusion-Welding Processes Solid-State Welding Processes: The Principles, Welding Processes

Chap 30 Chap 31

15 (IPA)

Fri (15/10) Advantages, Limitations, and Applications Tue (19/10) Video - Brazing, Soldering, Adhesive-Bonding, Chap 32 16 (IPA) Fri (22/10) Mechanical-Fastening Processes Test 2

17 STUDY WEEK 18 19 20

EXAM WEEKS

Note: Reading materials (chap 1- 32) all from the main text.

Coursework assessments: Q (10%) + T (20%) + Assignment (10%)

What is manufacturing?What is manufacturing?The process of converting raw materials into useful, The process of converting raw materials into useful, higher value products.higher value products.The science and technology of producing high quality The science and technology of producing high quality goods to fulfill the usergoods to fulfill the user’’s needs/wants in the shortest s needs/wants in the shortest time possible and at acceptable costs. time possible and at acceptable costs. Involves materials, people, machines/tools and Involves materials, people, machines/tools and information/knowledge that are interinformation/knowledge that are inter--related, forming a related, forming a manufacturing system.manufacturing system.A complex activity involving a wide variety of resources A complex activity involving a wide variety of resources and activities such as product design, machinery and and activities such as product design, machinery and tooling, process planning, materials, purchasing, tooling, process planning, materials, purchasing, production control, support services, marketing, sales, production control, support services, marketing, sales, shipping, customer service. shipping, customer service.

Origin of manufacturing?Origin of manufacturing?Manufacture (Manufacture (latinlatin word word ““manumanu factusfactus”” –– means made by hand. means made by hand. Manufacturing dates back 5000 Manufacturing dates back 5000 -- 4000 B.C. (Older than recorded 4000 B.C. (Older than recorded history!!!) history!!!) –– production of articles made of wood, ceramic, stone production of articles made of wood, ceramic, stone and metal by hand skills into highly customized and specific purand metal by hand skills into highly customized and specific purpose pose products.products.Process used Process used -- Casting, hammering, carving of metals, woods, etc.Casting, hammering, carving of metals, woods, etc.First materials used First materials used –– gold, copper, iron followed by silver, lead, tin, gold, copper, iron followed by silver, lead, tin, bronze and brass. Steel production in year 600bronze and brass. Steel production in year 600--800 was a major 800 was a major milestone, since then many ferrous and nonmilestone, since then many ferrous and non--ferrous metals have ferrous metals have been developedbeen developedToday, engineered materials are being used in advanced Today, engineered materials are being used in advanced applications such supersonic aircraft, computers, spacecraft. applications such supersonic aircraft, computers, spacecraft. Materials with special properties such as advanced ceramics, Materials with special properties such as advanced ceramics, reinforced plastics, composite materials and reinforced plastics, composite materials and nanomaterialsnanomaterials being being used.used.

How manufacturing has evolved?How manufacturing has evolved?

Highly handHighly hand--crafted, specific crafted, specific

skills for skills for customized customized productsproducts

Industrial Industrial Revolution Revolution

(1750 (1750 –– 1850)1850)

DepartmentalizationDepartmentalization1970 1970 --19901990

WWI & IIWWI & II

Machine tool Machine tool intro, war a intro, war a pull factor, pull factor,

quality not a quality not a concernconcern

MassMass--productionproduction1960s1960s

Produce more, Produce more, earn more, earn more,

quality quality secondary, use secondary, use machine toolmachine tool

Big companies, Big companies, many many

departments, departments, specialized specialized skills and skills and process, process,

automationautomation

Information AgeInformation AgeIT, Computer, Global IT, Computer, Global

MfgMfg

AutomationAutomationCAD/CAM/CIMCAD/CAM/CIMBuiltBuilt--in qualityin qualityMultiMulti--functional functional products, short products, short production time, production time,

flexibleflexible

The Stone AgeThe Stone AgeThe Bronze AgeThe Bronze Age

The Iron AgeThe Iron AgeThe The …………………… AgeAge

Materials/Manufacturing Materials/Manufacturing engineering is one of the engineering is one of the earliest engineering earliest engineering practices of mankindpractices of mankind

Materials/Manufacturing Materials/Manufacturing engineering is at the leading engineering is at the leading edge of modern engineeringedge of modern engineering

Titanium alloy rimTitanium alloy rim

FibreFibre reinforced synthetic reinforced synthetic rubber inflated rubber inflated tyretyre

Stainless steel spokesStainless steel spokes

High strength Al alloy High strength Al alloy frame for light weightframe for light weight

Carbon Carbon fibrefibre reinforced reinforced polymeric composite forks polymeric composite forks

High performance steel High performance steel spring absorberspring absorber

Boneshaker, manufactured in 1868, features solid Boneshaker, manufactured in 1868, features solid nature rubber nature rubber tyrestyres, solid iron frame, wooden wheels , solid iron frame, wooden wheels and steel rimes, wooden handles and cow hide and steel rimes, wooden handles and cow hide saddle seatsaddle seat

With rapid development the cutting-edge nanotechnology and micro-electro-mechanical systems (MEMS), which is regarded the hallmark technology for the next few decades with the promise to revolutionize a wide spectrum of modern

technologies and even our life style, production of miniaturised devices and nano-scale components has taken manufacturing to a new challenge

The US government granted US$847 million for research in 2004. The nanotechnology industry swelled 10 times in the past 5 years and is predicted

to reach US$1 trillion in 10 years time.

An electrical motor the size smaller than the diameter of a human hair