Dr. HABEEB HATTAB HABEEB Office: BN-Block, Level-3, Room-088 Email: hbuni61@yahoo.com Ext. No.: 7292 University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

College Of Engineering Mechanical Department University TENAGA National College Of Engineering Mechanical Department Lecture Note University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Introduction To Manufacturing University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Japanese sword reworked for hard and soft metal parts University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Space Shuttle University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI The Transistor University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Everyday products University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Manufacturing derived from: “Manufacturing” (derived from Latin) = “manus” (hand) + “factus” (made) = “made by hand” University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Definition of Manufacturing: Manufacturing is an industrial activity that converts raw materials to useful products by the means of machines. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Development of Manufacturing depends on: Materials 1 Machine-Tools 2 Computer-aided Design (CAD)& Computer-aided mfg (CAM). 3 4 Robotics Electronics 5 University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Evolution of the Enterprise 1-1 Evolution Steps: 1 Hand Tool Animals 2 Water Power 3 Steam Engines 4 Electrical Motors 5 University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI The MFG System: INPUT PROCESS OUTPUT University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI INPUT Energy Customer Demand HR Material Education Money R & D University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI PROCESS Design Production Management University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI OUTPUT Consumer Goods Capital Goods Quality Cost Effectiveness University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI INPUT ` Money - Working Capital (Money for employee) Fixed Capital (For machine tools and buildings) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI INPUT Energy - Electricity To run the machines - Compressed air To run the pneumatic systems and clean machines and products - Steam To run the turbines and utilized in produce of polystyrene (Expansion OP.) - Gas To use it in Furness, welding operations and boilers. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI PROCESS Design - Creating plans for new products Lowering the product cost at maintained high quality University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI PROCESS Production - Designated at the design stage - Machine tools types - Machining processes - People are selected at the design stage University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI OUTPUT Products Goods - Consumers goods: People use them (Food, Cars, ….) - Capital goods: Products used to make other consumer goods (Machine tools, Plant, ….) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

The Classification of basic Manufacturing 1-2 Mass production Moderate Job-lot a b c University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Mass Production Features: a - Goods are produced at a high volume for considerable period of time ( >100.000 parts per year). - Machine are not flexible (They are not able to produce other types of products). - Products of this type of mfg are the cheapest. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Moderate production Features: - Variable products (depends on the sale order and the market demand) (2,500-100,000 parts per year). - Multipurpose machine tools and CNC machine tools are usually used in this type of mfg. - Product Ex.: Tools, Moulds, Radio transmitters. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Job-lot production Features: - The plant does not any specific type of products but it is able to produce any type of product that the market is in need of. - Products move in lots between mfg processes (10-500 parts per lot). - Machine are more flexible and universal. - Product Ex: Airplanes, Automobile parts, and Plastic products . University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Organization for Manufacturing -A plant needs an affective organizing method for manufacturing in order to manage its resources / Employees Money Power Materials Machines . *A good mfg strategy is needed. 1 2 3 4 5 University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Concurrent Engineering CE It is a philosophy that promotes interactive design and manufacturing efforts to develop product and processes . CE is not an engineering discipline. - CE Objective: Optimizing the use of company resources and reducing time to market cycle. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI General CE phases for a new project: Ph.-1 Technology and concept development Product and Process Development and Prototype validation -CE Function Ph.-2 Process Validation and Product Design Confirmation Ph.-3 Ph.-4 Production and continuous improvement University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Design, Material and Production 1-3 According to the existing machine tools and the designed product we choose the raw materials. On the other hands, according to the existing materials and required quality we choose the machine tools. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI - Efficiency of production : In order to attain a high production rate with a low labor cost, Automatic features have been built gradually in different machine tools. Nowadays we deal with fully automatic machine tools and computer aided design and manufacturing (CAD/CAM). But the problem is that maintenance of such automatic machines is very expensive. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Cont….. Efficiency of production The quality and accuracy must be maintained for the whole mfg processes so at the output we produce parts that can be quickly assembled (interchangeable). University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI - Economical production is determined by: A functional simple design that has appropriate quality (no more or less). 1 A material choice that represents the best compromise among physical properties, cost, and machinability. 2 The selection of mfg processes that provide the plant with required quality and accuracy (no more accuracy than necessary) at the lowest possible cost. 3 University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Engineering Materials Metallic Non-Metallic Ferrous Organic Non-Ferrous Non- Organic University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Materials Application Chain Processing * SELECTION is the Critical Step for Technologists. Structure Properties Performance Selection Field Application University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Mechanical Properties Stress & Strain Dislocations & Deformation Elasticity & Plasticity University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Tests Mechanical Testing Mechanical Properties Strengthening Mechanisms Failure Analysis University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

The Evolution of Materials University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Classes of Materials Basic Metals Ceramics Polymers Advanced Composites Semiconductors Biomaterials University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Metals Materials that are normally combinations of "metallic elements". Metals usually are good conductors of heat and electricity. Metals are quite strong but malleable and tend to have a lustrous look when polished University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Ceramics Ceramics are generally compounds between Metallic and NONmetallic elements and include such compounds as: -Oxides -Nitrides -Carbides Ceramic materials developed for gas turbine rotors are used in aircraft and diesel engine parts. Typically they are insulating and resistant to high temperatures and harsh environments. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Plastics Plastics (or polymers) are generally compounds based upon carbon and hydrogen (Organic Compounds). They are very large molecular structures. Usually they are low density and are not stable at high temperatures. Using advanced polymer materials, organic light emitting diode (OLEDs) displays produce bright, high-contrast display panels with a wide viewing angle. OLED panels are emissive, eliminating the need for the backlight required in display technologies such as liquid crystal displays (LCDs). University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Semiconductors SEMIconductors have electrical properties intermediate between Metallic conductors and Ceramic insulators. Also, the electrical properties are strongly dependent upon small amounts of Impurities. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Composites Composites consist of more than one material type. Fiberglass, a combination of glass and a polymer, is an example. Concrete and plywood are other familiar composites. Many new combinations include ceramic fibers in a metal or polymer matrix. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Composites University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Composites Hand bag Ghost airplane Graphite Matrix Composite Shaft Liquid Metal FacePlate Golf Clubs University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI BioMaterials Materials compatible with an organism (e.g. Humans) that can be used to make implants, prostheses, and surgical instruments. Designed not to provoke rejection by our bodies (skin, blood, bone, etc.), they can be natural (collagen, cellulose, etc.) or synthetic (metallic, alloy, ceramic, plastic, and others). Dental crowns and contact-lenses use biomaterials. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Data Organization of Materials Kingdom Family Class Attributes Member Ceramics Polymers Metals Natural Foams Composites Steels Cu-alloys Al-alloys Ti-alloys Ni-alloys Zn-alloys 1000 2000 3000 4000 5000 6000 7000 8000 Materials A material record or “properties” Density Mechanical props. Thermal props. Electrical props. Optical props. Corrosion props. Supporting information -- specific -- general Structured information Unstructured information University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI Metallography: to see microstructures metal mount Steel (Fe-C) Nickel Alloy 242 University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Selection and implementation Materials Information for Design The goal of design: “To create products that perform their function effectively, safely, at acceptable cost” What do we need to know about materials to do this? More than just test data. Test data Data capture Stat/Math analysis Selection of material and process Successful applications $ Economic analysis and business case Test Design data Potential applications Characterization Selection and implementation University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI THANK YOU University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Lecturer: Dr. HABEEB ALANI University TENAGA Nasional Lecturer: Dr. HABEEB ALANI