BASIC WORKSHOP MENG130

Industrial Engineering Department COURSE INSTRUCTOR Dr. Nabila Elnahas Associate Professor Industrial Engineering Department Specialty : Mechanical Engineering (Automotive) Office: 211 A2, Email: nalnahas@kau.edu.sa Office Hours: 1:00 PM to 2:00 PM

COURSE SCHEDULE SUNDAY AND TUESDAY 12:00-1:00 LECTURES FIELD VISITS

COURSE GRADES QUIZZES : 10 Major 1:10 Major 2: 10 Final Exam: 40 Presentations: 20 Reports: 10

MAIN TOPICS MATERIALS BEHAVIOR MANUFACTURING PROCESSES MECHANICAL PROPERTIES PHYSICAL PROPERTIES MANUFACTURING PROCESSES METAL CASTING, METAL ROLLING, METAL FORGING METAL EXTRUSION, SHEET METAL FORMING TURNING, MILLING, GRINDING, WELDING

TEXTBOOK MANUFACTURING ENGINEERING AND TECHNOLOGY BY Serope Kalpakjian and Steven Schmid 7th edition Pearson Prentice Hall

IMPORTANCE OF TAKING THE COURSE FOR INDUSTRIAL ENGINEERS INDUSTRIAL ENGINEERING OR MANUFACTURING ENGINEERING BACKGROUND OF ENGINEERS (in general) SPECIALIZATION FIELD OF WORK 1.FACTORIES (ENGINEERS) 2.BANK (MANAGEMENT) 3.HOSPITALS (MANAGEMENT) SUMMER TRAINING

PRODUCTS INTRODUCTION SCREW, CAR, EYE GLASSES DISCRETE: NAILS CONTINUOUS: STEEL ROLL USED TO MANUFACTURE OTHER PRODUCTS: MACHINES PRODUCT IN ITSELF: SCREW

MODIFICATION OF A PRODUCT CHANGE OF MATERIAL CONDITION TO A SOFTER ONE CHANGE OF MANUFACTURING METHOD USE OF A DIFFERENT MATERIAL MODIFY THE DESIGN OF A COMPONENT TO MAKE IT EASIER, FASTER, AND LESS COSTLY TO MANUFACTURE

FAILURE OF A PRODUCT STOPS FUNCTIONING DOES NOT FUNCTION PROPERLY BECOMES UNSAFE EXCESSIVE VIBRATION OR NOISE

FACTORS AFFECTING SERVICE LIFE OF A PRODUCT IMPROPER SELECTION OF MATERIAL IMPROPER SELECTION OF PRODUCTION METHOD INSUFFICIENT CONTROL OF PROCESSING VARIABLES DEFECTIVE RAW MATERIALS OR PARTS POOR MAINTENANCE OF EQUIPMENT IMPROPER USE OF PRODUCT

EVOLUTION OF MANUFACTURING SIMPLE TOOLS FOR CARVING BAKING CLAY UTENSILS AND ORNAMENTS MADE OF GOLD, COPPER, IRON THEN SILVER AND BRASS MADE BY CASTING AND HAMMERING In 1750 GOODS WERE PRODUCED IN BATCHES HAND FITTING: NO TWO ITEMS WERE ALIKE NOWADAYS CANS ARE PRODUCED AT A RATE OF 500/MIN In 1980 COMPUTERS WERE WIDELY USED FOR MASS PRODUCTION DIGITAL MANUFACTURING CAD/CAM

TRENDS IN MANUFACTURING INCREASE IN PRODUCTION VARIETY AND COMPLEXITY SHORT PRODUCTION LIFE CYCLE MULTINATIONAL MARKETS CONSUMERS DEMAND LOW COST AND HIGH QUALITY PRODUCTS WEIGHT SAVINGS

TRENDS IN MANUFACTURING (C0NTINUED) ULTRA PRECISION MANUFACTURING COMPUTER SIMULATION IS APPLIED TO ALL AREAS OF MANUFACTURING QUALITY IS BUILT IN EVERY PROCESS GREEN MANUFACTURING HIGHER LEVEL OF PRODUCTIVITY

MANUFACTURING PRODUCTION CASTING AND HAMMERING MANUAL PRODUCTION INTERCHANGEABLE PARTS MASS PRODUCTION FAST MANUFACTURING (800 holes/min) DIGITAL MANUFACTURING

GREEN DESIGN AND MANUFACTURING DESIGN FOR: 1. MANUFACTURE 2. ASSEMBLY 3. DISASSEMBLY 4. SERVICE GREEN DESIGN AND MANUFACTURING WASTES :chips/slag/additives/toxic materials /lubricants/solvents/smoke/pollutants DESIGN FOR RECYCLING

MODIFICATION OF A PRODUCT CHANGE OF MATERIAL CONDITION TO A SOFTER ONE CHANGE OF MANUFACTURING METHOD USE O FA DIFFERENT MATERIAL MODIFY THE DESIGN OF A COMPONENT TO MAKE IT EASIER, FASTER, AND LESS COSTLY TO MANUFACTURE

Part I Fundamentals of Materials: Behavior and Manufacturing Properties Approximate Number of Parts in Products

MANUFACTURING PROCESSES (will be explained in later lectures) CASTING FORMING MACHINING (Turning, Milling, Grinding, etc.) JOINING FINISHING

TYPES OF PRODUCTION JOB SHOPS LESS THAN 100 BATCH PRODUCTION LESS THAN 500 MASS PRODUCTION MORE THAN 1000 (Dedicated machines and automated equipment for transferring parts and materials)

METHODS OF ASSEMBLY OF COMPONENTS adhesives welding soldering use of fasteners

COSTS MANUFACTURING COST 1 COSTS MANUFACTURING COST 1.MATERIAL 2, TOOLS: FIXTURES, CUTTING TOOLS 3. FIXED: ENERGY, RENT, INSURANCE, TAXES 4. CAPITAL: MACHINES, BUILDING, LAND 5. LABOR: DIRECT AND INDIRECT LABOR COST:10%-15% OF TOTAL COST BUT MAY REACH 60% IN LABOR INTENSIVE PRODUCTS MANUFACTURING COST= 40% SELLING PRICE ASSEMBLY COST = 10%-60% of total cost

TOTAL COSTS MATERIALS TOOLS FIXED COST (ENERGY, RENT, INSURANCE, TAXES) CAPITAL (BUILDING, m/c) LABOR (DIRECT, INDIRECT)

MATERIALS Name some of the materials you know

Steel glass wood aluminum plastic lead cast iron ceramic glass

WHEN DO WE USE ANY OF THEM AND WHY????

STEEL 1. STRONG 2. EASY TO SHAPE 3. INEXPENSIVE PLASTICS 1 STEEL 1.STRONG 2.EASY TO SHAPE 3.INEXPENSIVE PLASTICS 1.LIGHT WEIGHT 2.HIGH RESISTANCE TO CORROSION 3.AVAILABLE IN MANY COLORS 4.LOW COST

GLASS 1. TRANSPARENT (WINDOWS) 2. HARD (SCRATCH RESISTANT) 3 GLASS 1.TRANSPARENT (WINDOWS) 2.HARD (SCRATCH RESISTANT) 3.EASY TO SHAPE 4.EASY TO CLEAN

FIGURE I.1 An outline of the topics described in Part I. Approximate Number of Parts in Products

Approximate Number of Parts in Products FIGURE I.2 An outline of the engineering materials described in Part I. Approximate Number of Parts in Products

Approximate Number of Parts in Products FIGURE I.3 An outline of the behavior and the manufacturing properties of materials described in Part I. Approximate Number of Parts in Products

Chapter 1 Structure of Metals Approximate Number of Parts in Products

Approximate Number of Parts in Products FIGURE 1.1 Turbine blades for jet engines, manufactured by three different methods: (a) conventionally cast, (b) directionally solidified, with columnar grains as can be seen from the vertical streaks, and (c) single crystal. Although more expensive, single-crystal blades have properties at high temperatures that are superior to those of other blades. Source: Courtesy of United Technologies Pratt and Whitney. Approximate Number of Parts in Products

FIGURE 1.2 An outline of the topics described in this chapter. Approximate Number of Parts in Products

FACTORS AFFECTING THE BEHAVIOR AND PROPERTIES OF METALS 1 FACTORS AFFECTING THE BEHAVIOR AND PROPERTIES OF METALS 1. ATOMIC STRUCTURE 2. COMPOSITION 3.IMPURITIES 4. VACANCIES 5. GRAIN SIZE 6. GRAIN BOUNDARIES 7.SURFACE CONDITION 8. MANUFACTURING METHOD

STRUCTURE OF METALS ATOM : PROTON +ELECTRON MULTIPLE ATOMS : MOLECULES SOLIDIFICATION OF METALS : CRYSTALS UNIT CELL : SMALLEST GROUP OF ATOMS SHOWING CHARACTERISTIC STRUCTURE OF A METAL

BODY CENTERED CUBIC CHROMIUM TUNGSTEN ALPHA IRON

Approximate Number of Parts in Products FIGURE 1.3 The body-centered cubic (bcc) crystal structure: (a) hard-ball model, (b) unit cell, and (c) single crystal with many unit cells. Approximate Number of Parts in Products

FACE CENTERED CUBIC ALLUMINUM COPPER NICKEL LEAD BETA IRON

Approximate Number of Parts in Products FIGURE 1.4 The face-centered cubic (fcc) crystal structure: (a) hard-ball model, (b) unit cell, and (c) single crystal with many unit cells. Approximate Number of Parts in Products

HEXAGONAL CLOSE PACKED ZINC COBALT MAGNESIUM

Approximate Number of Parts in Products FIGURE 1.5 The hexagonal close-packed (hcp) crystal structure: (a) unit cell and (b) single crystal with many unit cells. Approximate Number of Parts in Products

DEFECTS IN SINGLE CRYSTAL LATTICE SELF INTERSTITIAL ATOM INTERSTITIAL ATOM SUBSTITUTIONAL ATOM VACANCY

Approximate Number of Parts in Products FIGURE 1.8 Schematic illustration of types of defects in a single-crystal lattice: selfinterstitial, vacancy, interstitial, and substitutional. Approximate Number of Parts in Products

Approximate Number of Parts in Products FIGURE 1.9 Types of dislocations in a single crystal: (a) edge dislocation and (b) screw dislocation. Approximate Number of Parts in Products

Approximate Number of Parts in Products FIGURE 1.10 Movement of an edge dislocation across the crystal lattice under a shear stress. Dislocations help explain why the actual strength of metals is much lower than that predicted by theory. Approximate Number of Parts in Products

SOLIDIFICATION OF MOLTEN METALS

Approximate Number of Parts in Products FIGURE 1.11 Schematic illustration of the stages during the solidification of molten metal; each small square represents a unit cell. (a) Nucleation of crystals at random sites in the molten metal; note that the crystallographic orientation of each site is different. (b) and (c) Growth of crystals as solidification continues. (d) Solidified metal, showing individual grains and grain boundaries; note the different angles at which neighboring grains meet each other. Approximate Number of Parts in Products

TABLE 1.1 Grain sizes

Approximate Number of Parts in Products FIGURE 1.12 Plastic deformation of idealized (equiaxed) grains in a specimen subjected to compression (such as occurs in the forging or rolling of metals): (a) before deformation and (b) after deformation. Note the alignment of grain boundaries along a horizontal direction, an effect known as preferred orientation. Approximate Number of Parts in Products

Approximate Number of Parts in Products FIGURE 1.13 (a) Schematic illustration of a crack in sheet metal that has been subjected to bulging (caused, for example, by pushing a steel ball against the sheet). Note the orientation of the crack with respect to the rolling direction of the sheet; this sheet is anisotropic. (b) Aluminum sheet with a crack (vertical dark line at the center) developed in a bulge test; the rolling direction of the sheet was vertical. Source: Courtesy of J.S. Kallend, Illinois Institute of Technology. Approximate Number of Parts in Products

Approximate Number of Parts in Products FIGURE 1.14 Schematic illustration of the effects of recovery, recrystallization, and grain growth on mechanical properties and on the shape and size of grains; note the formation of small new grains during recrystallization. Source: After G. Sachs. Approximate Number of Parts in Products

TABLE 1.2 Homologous Temperature Ranges for Various Processes