Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 Chapter 1 Introduction

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 FIGURE 1.1 Section of an automotive engine - the Duratec V-6 - showing various components and the materials used in making them. Source: Courtesy Ford Motor Company. Illustration by David Kimball. Duratec Engine

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 HISTORY OF MANUFACTURING

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 History of Manufacturing (concluded) TABLE 1.1 Historical development of materials and manufacturing processes.

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 FIGURE 1.2 (a) Chart showing varous 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 flow, from market analysis to selling the product, and depicting concurrent engineering. Source: After S. Pugh, Total Design. Addison-Wesley, Design Steps

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 TABLE 1.2 Shapes and Some Common Methods of Production Shapes and Production Method

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 FIGURE 1.3 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. Design for Assembly Design for Manufacture, Assembly, Disassembly, and Service

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 FIGURE 1.4 An outline of engineering materials Engineering Materials

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 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. Aluminum Automobile

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 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. Production Methods for a Simple Part

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 FIGURE 1.7 Gear assembly driven by resonant combdrives. (a) view of entire assembly; (b) Detail of rotor driver portion of the gear assembly. Source: Richard Muller, University of California at Berkeley. Nanofabrication Example

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 Machining of a Mold Cavity 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, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 FIGURE 1.9 General view of a flexible manufacturing system, showing several machines (machining centers) and an automated guided vehicle (AGV) moving along the aisle. Souce: Courtesy of Cincinnati Milacron, Inc. Flexible Manufacturing System

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 Some terms used in Design and Manufacturing Net-Shape Manufacturing, One step to get final shape, not secondary machining, such as: casting, forging, stamping, powder metallurgy, injection molding of metals and plastics, and rapid prototyping. Computer-Integrated Manufacturing CIM, Using computers to integrate and control machines, robots and equipment to manufacture products automatically. Such as CNC machine and automobile production line. Computer-aided Process Planning, CAPP, Flexible Manufacturing Systems, FMS Quality Assurance and Total Quality Management, QA and TQM, Artificial Intelligence, AI Lean Manufacturing Agile Manufacturing Green Manufacturing

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 Materials & Processes For Making Bicycle Components

Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 Chapter 1 Home Work 1. Read Chapter 1 2. Examine your stapler, bicycle, car, wash machine …, any products with more than 10 components, to find out how many components there are, what kind of materials and manufacturing processes used for each component, and explain briefly why these materials and process methods are used. 3. Summarize “What is manufacturing? List 10 top manufacturing activity with high standard living countries and explain how and why.