Veljko SamardzicME-215 Engineering Materials and Processes
ME -215 ENGINEERING
MATERIALS AND PROCESES
Instructor: Veljko Samardzic
Office: MEC 325, Tel.: 973-642-7455
E-mail: [email protected]
Veljko SamardzicME-215 Engineering Materials and Processes
Objectives of the of Course• To combine lectures and laboratory practice as
introduction to: Engineering Materials and Manufacturing Processes
• Key objectives:
– Introduction to engineering materials and alloy design;
– Introduction to microstructure-properties relations;
– Introduction to manufacturing processes;
– Laboratory report writing practice.
• Textbook: E. Paul De Garmo, J.T.Black, R.A. Kohser, Materials and Processes in Manufacturing, 10th edition, NY, 2009
Veljko SamardzicME-215 Engineering Materials and Processes
More specifically
• Establish foundation of engineering thinking;
• Expand engineering communication means;
• Expand foundation of engineering knowledge;
• Practice new problem solving techniques;
• Preparation for advanced ME courses;
Veljko SamardzicME-215 Engineering Materials and Processes
Tests& home assignments
• Three closed book tests will be given ( 5th week,
11th week and final exam);
• Homework is due first 5 minutes of next lecture;
• Laboratory report due one week after completion
of lab practice at the beginning of next lab session;
Veljko SamardzicME-215 Engineering Materials and Processes
Grading and performance
• Homework-5%, Laboratory reports& performance-30%, Test 1-20%, Test 2-20%, Final exam-25%.
• Detailed explanation of lab manual, lab rules and requirements posted at: ME home page-undergraduate-ME 215. Print it and have it ready for next class;
• Be ready for the lecture and lab practice (read assigned material prior to class) and bring with you printed material to the class;
• Submit homework and lab reports on time or you loose;
• HW assignments posted on ME 215 syllabus.
Veljko SamardzicME-215 Engineering Materials and Processes
1.1 Materials, Manufacturing, and
the Standard of Living• Standard of living of a society is determined
by the goods and services that are available
to its people
• Manufactured goods
– Producer goods:
• Intermediate goods used to manufacture either
producer or consumer goods
– Consumer goods:
• Purchased directly by the consumer
Veljko SamardzicME-215 Engineering Materials and Processes
History of Materials
• The development of materials and man’s
ability to process them is linked to the
history of man
– Stone Age
– Copper and Bronze Age
– Iron Age
– Steel Age
• The current age is that of plastics,
composite materials, and exotic alloys
Veljko SamardzicME-215 Engineering Materials and Processes
Important Dates in Technologies
Development• B. Pascal- Mechanical calculator, France,1642
• Industrial revolution, England,1760
• Vertical lathe machine,USA,1840
• H. ford-Conveyer assembly line, USA, 1913
• J. von Newman- Principles of computer programming, USA,1945
• Industrial robot (cylindrical config.), USA,1959
• EXAPT-Programming language, W. Germany,1966
• Microprocessors, CNC, CIM, 1970
• Intelligent automation, automatic production cells, PC,USA,1980
• Engineering revolution, 1997 (ongoing)
Veljko SamardzicME-215 Engineering Materials and Processes
Impact on Societies
• From Stone age until nowadays tools design and development controlled the pace of engineering advancement;
• Bronze age led to rise of empires;
• Printing press (1450) led to expansion of literacy, knowledge;
• Industrial revolution, 1760, led to the fastest advances of all aspects of human existence;
• Engineering revolution, 1997, computer based means for simulation and optimization shortened the time from the concept and sellable product.
Veljko SamardzicME-215 Engineering Materials and Processes
Wheel Evolution
• Dated around 2700 B.C. this ancient wooden wheel is one
of the oldest known wheels in Europe.
Veljko SamardzicME-215 Engineering Materials and Processes
Product Development
• Sustaining technology:
– Innovations bring more
value to the consumer
– Improvements in
materials, processes,
and design
• Product growth
normally follows the
“S” curve Figure 1-1a) A product development curve
Veljko SamardzicME-215 Engineering Materials and Processes
Technology
ORGWARE
TECHNOLOGY
HARDWARE
SOFTWARE
Veljko SamardzicME-215 Engineering Materials and Processes
Structural Development of
Technologies
CONVENTIONAL
NEW ADVANCED
HIGH-END
TECHNOLOGIES
Veljko SamardzicME-215 Engineering Materials and Processes
General Technology Classification
TECHNOLOGY
NON-MATERIALMATERIAL
ENERGIES
INFORMATION
TRANSPORTATION
OTHER
MECHANICAL BASIC
Processing of raw
materials
Structure
modification
Casting
Sintering
Forming and
shearing
Material removal
Non-conventional
Joining
Welding
Protection
Veljko SamardzicME-215 Engineering Materials and Processes
Basic Manufacturing Processes
Process Operation
ShapingProperty enhancing Surface enhancing
Material RemovalCasting & molding
Coating Surfacetreatment
HeatTreating
ComposeMaterials
Liquid Semi fluid
Veljko SamardzicME-215 Engineering Materials and Processes
1.2 Manufacturing and Production
Systems• Manufacturing is the ability to make goods and services to
satisfy societal needs
– Manufacturing processes are strung together to create a
manufacturing system (MS)
• Production system is the total company and includes
manufacturing systems
Figure 1-3
The manufacturing
system converts
inputs to outputs using
processes to add
value to the goods for
the external customer.
Veljko SamardzicME-215 Engineering Materials and Processes
Manufacturing
• Making goods to satisfy human needs.
• MS-manufacturing system formed by integration
of manufacturing processes;
• PS- production system unifies manufacturing
system and other areas of the plant for information
, design, analysis and control;
• SPS-Service production system( transportation,
banking, finance, savings & loan, insurance,
health care, utilities, education, communication,
entertainment, sporting events, etc).
Veljko SamardzicME-215 Engineering Materials and Processes
Production System- The
Enterprise• Production systems include
– People
– Money
– Equipment
– Materials
– Supplies
– Markets
– Management
– Manufacturing System
– All aspects of commerce
Veljko SamardzicME-215 Engineering Materials and Processes
Common Aspects of
Manufacturing• Job and station
– Job is a group of related operations generally done at one station
– Station is the location or area where production is done
• Operations
– Distinct action to produce a desired result or effect
– Categories of operations
• Materials handling and transport
• Processing
• Packaging
• Inspecting and testing
• Storing
Veljko SamardzicME-215 Engineering Materials and Processes
Common Aspects of
Manufacturing• Treatments operate continuously on a workpiece
– Heat treating, curing, galvanizing, plating, finishing,
chemical cleaning, painting
• Tools, tooling and workholders
– Lowest mechanism in the production is a tool
• Used to hold, shape or form the unfinished product
• Tooling for measurement and inspection
– Rulers, calipers, micrometers, and gages
– Precision devices are laser optics or vision systems that
utilize electronics to interpret results
Veljko SamardzicME-215 Engineering Materials and Processes
Manufacturing Systems
• The job shop: machines situated by function and
parts circulated in containers between them;
• The linked cell shop: fluently connected
manufacturing cells by special information control;
• The project shop: product built on the spot of use
(bridge, etc);
• The flow shop: mass production designated shop
with specific manufacturing orientation;
• The continuous process: liquid and gasses
production systems (oil refineries);
Veljko SamardzicME-215 Engineering Materials and Processes
Job Shop
Figure 1-8 This rack bar machining area is functionally designed so it operates like a job shop, with
lathes, broaches, and grinders lined up.
Veljko SamardzicME-215 Engineering Materials and Processes
Manufacturing and Society
• Contributes by 20 % to GNP;
• Employs about 18 % of workforce;
• Accounts for 40 % of the exports of the US;
• Producer goods and Consumer goods;
• Converting materials adds value to them (high
manufacturing efficiency, high quality, better
living standard of employees);
Veljko SamardzicME-215 Engineering Materials and Processes
The Manufacturing Process
• Raw material/components are subjected to
Manufacturing process (involving
machinery, tooling, power, labor and cost)
providing con.
• Transformed materials have higher value.
• Raw materials are transformed into:
finished goods and/or components.
• Components are transformed into:
components and/or finished goods.
Veljko SamardzicME-215 Engineering Materials and Processes
Basic Manufacturing Processes
• Surface Processes
– Coating (electro plating, plasma, thermal spray);
– Cleaning (chemical agent, water jet, ice jet, etc)
– Surface treatment (carburizing);
Veljko SamardzicME-215 Engineering Materials and Processes
Products and Fabrications
• Products result from manufacture
– Manufacturing can be from either fabricating or processing
• Fabricating is the manufacture of a product from pieces such as parts, components, or assemblies
• Processing is the manufacture of a product by continuous operations
• Workpiece and its configuration
– Primary objective of manufacturing is to produce a component having a desired geometry, size, and finish
Veljko SamardzicME-215 Engineering Materials and Processes
Work piece & it’s Configuration
• By manufacturing goods of prescribed
geometry, size& finish are produced.
• Types of surfaces:
– Plane or flat;
– Cylindrical (Int./Ext.);
– Conical (Int./Ext.);
– Irregular (curved/warped)
Veljko SamardzicME-215 Engineering Materials and Processes
Assembly operations
• Mechanical fastening
• Soldering & brazing
• Welding
• Press, shrink, or snap fittings
• Adhesive bonding
Veljko SamardzicME-215 Engineering Materials and Processes
Basic Manufacturing Processes
• Shaping Processes
– Casting (molten metals) or molding (plastic);
– Materials removal: turning, drilling, milling,
grinding and new techniques;
– Particulate processes: pressing and sintering of
metal powder and ceramics;
– Deformation processes: forging, extrusion,
rolling, bending etc.
Veljko SamardzicME-215 Engineering Materials and Processes
Characteristics of Process
Technology• Mechanics (static or dynamic)
• Economics or costs
• Time Spans
• Constraints
• Uncertainties and process reliability
• Skills
• Flexibility
• Process capability
Veljko SamardzicME-215 Engineering Materials and Processes
Manufacturing and Society
• Good natural resources as foundation for
competitive manufacturing sector which
together support a high standard of living.
Veljko SamardzicME-215 Engineering Materials and Processes
Roles of Engineers in
Manufacturing• Design engineer responsibilities
– What the design is to accomplish
– Assumptions that can be made
– Service environments the product must
withstand
– Final appearance of the product
– Product designed with the knowledge that
certain manufacturing processes will be used
Veljko SamardzicME-215 Engineering Materials and Processes
Roles of Engineers in
Manufacturing• Manufacturing engineer responsibilities
– Select and coordinate specific processes and
equipment
– Supervise and manage their use
• Industrial (Manufacturing) engineer
– Manufacturing systems layout
• Materials engineers
– Specify ideal materials
– Develop new and better materials
Veljko SamardzicME-215 Engineering Materials and Processes
Material Removal
• The best way to create flat surfaces, sharp
corners, external and internal profiles and
process brittle and surface properties altered
materials;
• High accuracy and high quality surface
finish process;
• In most cases economically superior to
concurrent processes.
Veljko SamardzicME-215 Engineering Materials and Processes
Turning on a Lathe
• The workpiece is
mounted in a machine
tool (lathe) with a cutting
tool.
• The workpiece is rotated
while the tool is fed at
some feed rate (inches per
revolution). The desired
cutting speed V
determines the rpm of the
workpiece.
Veljko SamardzicME-215 Engineering Materials and Processes
Forming operations
Rolling
Forging
Extrusion
Shear spinning
Tube Spinning
Swaging and
kneading
Deep drawing
Wire and tube
drawing
Stretching
Straight bending
Contoured
flanging
Veljko SamardzicME-215 Engineering Materials and Processes
Joining Processes
• Mechanical fastening
• Soldering and brazing
• Welding
• Press, shrink, or snap fittings
• Adhesive bonding
• Assembly processes
Veljko SamardzicME-215 Engineering Materials and Processes
Surface Treatments
• Finishing operations
• Cleaning
• Removing burrs left by machining
• Providing protective/decorative surfaces
– Painting
– Plating
– Buffing
– Galvanizing
– Anodizing
Veljko SamardzicME-215 Engineering Materials and Processes
Other Manufacturing Operations
• Testing
• Transportation
• Automation
• Removal of material waste
• Packaging
• Storage
Veljko SamardzicME-215 Engineering Materials and Processes
New Manufacturing Systems
• Toyota Production System
– Lean manufacturing system
– 100% good units flow without interruption
– Integrated quality control
– Responsibility for quality is given to
manufacturing
– Constant quality improvement
Veljko SamardzicME-215 Engineering Materials and Processes
Changing World Competition
• Globalization has impacted manufacturing
– Worldwide competition for global products and
their manufacture
– High tech manufacturing for advanced
technology
– New manufacturing systems, designs, and
management
Veljko SamardzicME-215 Engineering Materials and Processes
Schematic of glass fibre manufacturing process.
Aramid Fibre (Kevlar)
Aramids (short for aromatic polyamides) are TP polymers, which
is extruded at 80oC from very small holes to form fibres. Aramid
fibres offer significant improvements in stiffness over glass, but it
is their outstanding toughness and damage tolerance that are most
important. This reinforcement is applied in applications requiring
high impact energy absorption.
Veljko SamardzicME-215 Engineering Materials and Processes
Carbon FibreCarbon fibres have the highest strength and stiffness of any fibrous
composite reinforcement, being applied in applications where these
properties are crucial. The fibres are manufactured from rayon,
polyacrylonitrile (PAN), and petroleum pitch.
Carbon (IM)
A variety of fibre grades are produced;
Carbon (HM)
Carbon (UHM)
Intermediate Modulus
High Modulus
Ultra-high Modulus
Typically, the stiffer the
fibre, the lower the strength
and strain to failure.
2. Pitch
manufacturing
process:
1. PAN
manufacturing
process:
3. Pyrolytic
Deposition
Veljko SamardzicME-215 Engineering Materials and Processes
3D structures are formed using a variety of braiding, weaving, and
knitting techniques:
Examples of complex structures:
Fibre Spools
Veljko SamardzicME-215 Engineering Materials and Processes
Examples of Fabrication
Techniques
3-D Weave
3c Weave
Braid
2-D Weave
Veljko SamardzicME-215 Engineering Materials and Processes
Material Selection
• Optimal combination of properties ( strength,
ductility, hardness, etc.);
• Selected material meets processing requirements;
• Selected material meets operational requirements;
• Lower range price of selected material.
Veljko SamardzicME-215 Engineering Materials and Processes
What is the Composite Material?
• A material system made by mixture or
combination of 2 of micro or macro-
constituents different in chemical
composition and insoluble in each other.
Veljko SamardzicME-215 Engineering Materials and Processes
E Glass
S Glass
Kevlar 49
Kevlar 149
Carbon (IM)
Carbon (HM)
Carbon (UHM)
Spectra 900 (PE)
Spectra 1000 (PE)
Density
rkg/m3
Young’s Mod
ElGPa
Tensile
Strength
sl
MPa
Strain to
Failure
el
%
2570 – 2600
2460 – 2490
1440
1470
1700 – 1830
1750 – 2000
1870 – 2000
970
970
69 – 72
86 – 90
131
186
276 – 317
338 – 436
440 – 827
117
172
3.45 – 3.79
4.59 – 4.83
3.6 – 4.1
3.4
2.34 – 7.07
1.9 – 5.52
1.86 – 3.45
2.6
2.9 – 3.3
* At room temperature
4.5 – 4. 9
5.4 – 5.8
2.8
2.0
0.8 – 1.9
0.5 – 1.4
0.4 – 0.5
3.5
0.7
Veljko SamardzicME-215 Engineering Materials and Processes
Thermal Stability of Carbon Fibres
• Good high-temperature properties (far
above 2000 ºC)
• When combined
with polymer
matrixes limit of
use is above 200ºC
Veljko SamardzicME-215 Engineering Materials and Processes
Summary
• Economical and successful manufacturing
requires knowledge of the relationships
between labor, materials, and capital
• Design a manufacturing system that
everyone understands
• Engineers must possess a knowledge of
design, metallurgy, processing, economics,
accounting, and human relations
Veljko SamardzicME-215 Engineering Materials and Processes
Interactive Factors in
Manufacturing• Factors
– Product design
– Materials
– Labor costs
– Equipment
– Manufacturing costs
• Strategies to reduce
cost
– Lean manufacturing
– Systems approach
Figure 1-2
Manufacturing cost is
the largest part of the
selling price, usually
around 40%. The
largest part of the
manufacturing cost is
materials, usually
50%.
Veljko SamardzicME-215 Engineering Materials and Processes
Manufacturing and Production
Systems• Goods
– Material things
• Services
– Nonmaterial things
• Service Production Systems (SPSs)
– Nonmaterial systems that do not provide a
product (i.e. banking, health care, education,
etc.)
Veljko SamardzicME-215 Engineering Materials and Processes
Figure 1-4 The functions and
systems of the production
system, which includes (and
services) the manufacturing
system. The functional
departments are connected by
formal and informal information
systems designed to service
the manufacturing system that
produces the goods.
Veljko SamardzicME-215 Engineering Materials and Processes
Manufacturing Systems
• Manufacturing systems
– Collection of operations and processes to produce a desired product or component
– Design or arrangement of the manufacturing processes
• Manufacturing processes
– Converts unfinished materials to finished products
• Often is a set of steps
– Machine tool is an assembly that produces a desired result
Veljko SamardzicME-215 Engineering Materials and Processes
Manufactured Surfaces
• Products are manufactured by producing the surfaces that bound the shape. Surfaces may be:
– Plane or flat
– Cylindrical (external or internal)
– Conical (external or internal)
– Irregular (external or internal)
Figure 1-6 The component called a pinion shaft is
manufactured by a “sequence of operations” to
produce various geometric surfaces.
Veljko SamardzicME-215 Engineering Materials and Processes
Manufacturing Systems Designs
• Five manufacturing system designs
– Job shop
– Flow shop
– Linked-cell shop
– Project shop
– Continuous process
Veljko SamardzicME-215 Engineering Materials and Processes
Figure 1-7 Schematic layouts of
factory designs:.
Veljko SamardzicME-215 Engineering Materials and Processes
Basic Manufacturing Processes
• Casting, foundry, or molding process
• Forming or metalworking processes
• Machining (material removing) processes
• Joining and assembly
• Surface treatments (finishing)
• Rapid prototyping
• Heat treating
Veljko SamardzicME-215 Engineering Materials and Processes
Lost-Foam Process
Figure 1-11 Schematic of the lost-foam
casting process.
Veljko SamardzicME-215 Engineering Materials and Processes
Forming Process
Figure 1-12 The forming process used to make a fender for a car.
Veljko SamardzicME-215 Engineering Materials and Processes
Single-Point Metalcutting
Figure 1-13 Single-point metalcutting process (turning) produces a chip while creating a new
surface on the workpiece.
Veljko SamardzicME-215 Engineering Materials and Processes
Figure 1-15 Product life-
cycle costs change with the
classic manufacturing
system designs.
Veljko SamardzicME-215 Engineering Materials and Processes
Manufacturing System Design
• Two consumers in a
product design
– External consumer who
buys the product
• Global
• Demands greater variety,
superior quality and
reliability
– Internal consumer who
manufactures the
productFigure 1-16 Different manufacturing
system designs produce goods at different
production rates.
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