IE 337: Materials & Manufacturing Processes IE 337 Lecture 1: Introduction to Manufacturing Systems IE 337: Materials & Manufacturing Processes Lecture 1: Introduction Chapter 1 & 5 S.V. Atre

Course Instructor Brian K. Paul Office: Office Hours: PhD 1995, Penn State Office: 322 Rogers Hall E-mail: brian.paul@oregonstate.edu Phone: 737-7320 Office Hours: T: 11:30 – noon R: 11:30 – 13:00

Items to Address Course Introductions Course Logistics Course Expectations Feedback Introduction to Materials & Processes Material-Geometry-Process Relationships Manufacturing Materials Manufacturing Processes How do we characterize processes?

Introductions Lectures: Labs: 126 Rogers Course Website: Section 001: T, R 10:00 – 11:20 AM 218 Covell Hall Labs: 126 Rogers Section 1: W 14:00 – 15:50 Section 2: F 16:00 – 17:50 Course Website: TEACH website – http://classes.engr.oregonstate.edu/

Lab Instruction Mr. Barath Palanisamy (Instructor) E-mail: palanisb@onid.orst.edu Ms. Negar Abolhassani (co-Instructor) E-mail: abolhasn@onid.orst.edu Steve Etringer (Technician) E-mail: etringer@engr.orst.edu Lab 126 Rogers Hall

Books & Materials Required Text: Required Materials: Groover, M.P. (2006). Fundamentals of Modern Manufacturing (3rd ed.). New York NY: John Wiley & Sons. 1040 pp. ISBN 0-471-74485-9. Required Materials: Engineering Problems Paper – 8-1/2" x 11", three hole drilled, ruled five squares/division, 50 pp. (approx.). Scientific Calculator Safety Glasses (Z-87 NIOSH) for lab

Grading Homework (6): 15% Midterm: 25% Final: 35% Laboratory (9): 25%

IE 337: Materials & Manufacturing Processes Learning Outcomes State basic properties of materials and apply these properties to manufacturing process and product design. Compare and contrast the design and production advantages of traditional mechanical manufacturing processes (casting, forming, machining, and joining). Evaluate material-process-geometry relationships in manufacturing processes. Differentiate advanced mechanical manufacturing processes e.g. micro-scale and nano-scale technologies. IE 337: Materials & Manufacturing Processes

Expectations Due Dates & Late Assignments Everything is due at the start of class – on scheduled date Partial Credit for late work – turn in to 204 Rogers Lose 10% of earned credit per day Make-up Work & Absences – use memorandum format Unforseeable – as soon as practicable Foreseeable – as far in advance as possible Grade Appeals – use memorandum format Laboratory Participation and Safety Special Needs Accommodation Academic Integrity

Introduction to Materials & Processes Material-Geometry-Process Relationships Manufacturing Materials Manufacturing Processes How do we characterize processes?

What is Manufacturing? Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and appearance of a starting material to make parts or products for a given application

Material-Process-Geometry Relationships Function Role of Prod Engr Material Geometry Role of Mfg Engr Process IE 337: Materials & Manufacturing Processes

Complexity in Manufacturing Materials: 106 metals, ceramics, polymers, composites Processes: 105 process conditions are ~ ∞ Properties: 102 applications are ~ ∞

Purpose of Manufacturing Manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations

Manufacturing: Everchanging Wilbur & Orville Wright, 1903 fabric, wood, steel 120 ft, 12 s, 400 kg Boeing, 2003 titanium, aluminum 14,000 km, 400,000 kg, 14+ hours

Manufacturing & Globalization

Tracking Manufacturing Problems Exploding tires, 2004 Melamine in milk, 2008 Medicines, 2006 Toxic toys, 2007

Transformations China over 2000 years

Materials in Manufacturing Most engineering materials can be classified into one of four basic categories: Metals Ceramics Polymers Composites

Processing Operations Three categories of processing operations: Shaping operations - alter the geometry of the starting work material Property‑enhancing operations - improve physical properties of the material without changing its shape Surface processing operations - clean, treat, coat, or deposit material onto the exterior surface of the work

Shaping – Four Main Categories Solidification Processes - starting material is a heated liquid that solidifies to form part geometry Deformation Processes - starting material is a ductile solid that is deformed Material Removal Processes - starting material is a ductile/brittle solid, from which material is removed Assembly Processes - two or more separate parts are joined to form a new entity

Solidification Processes Starting material is heated sufficiently to transform it into a liquid or highly plastic state Examples: casting for metals, molding for plastics

Deformation Processes Starting workpart is shaped by application of forces that exceed the yield strength of the material Examples: (a) forging, (b) extrusion

Material Removal Processes Excess material removed from the starting workpiece so what remains is the desired geometry Examples: machining such as turning, drilling, and milling; also grinding and nontraditional processes Turning Drilling Milling

Assembly Operations Two or more separate parts are joined to form a new entity Types of assembly operations: Joining processes – create a permanent joint. Examples: welding, brazing, soldering, and adhesive bonding Mechanical assembly – fastening by mechanical methods Examples: use of screws, bolts, nuts, other threaded fasteners; press fitting, expansion fits

Property‑Enhancing Processes Performed to improve mechanical or physical properties of the work material Part shape is not altered, except unintentionally Examples: Heat treatment of metals and glasses Sintering of powdered metals and ceramics

Surface Processing Cleaning - chemical and mechanical processes to remove dirt, oil, and other contaminants from the surface Surface treatments - mechanical working such as sand blasting, and physical processes like diffusion Coating and thin film deposition - coating exterior surface of the workpart Several surface processing operations used to fabricate integrated circuits

Developing a Manufacturing Process 1. Understand Function/Geometry Properties: mechanical, electrical, thermal, magnetic, optical, deteriorative. 2. Properties Identify candidate Material(s) Material: structure, composition. 3. Material Identify required Processing Processing: changes structure and overall shape Material and Geometry compatibility Other considerations

How do we characterize processes? Quality Dimensional – bulk and surface Properties – bulk and surface Economics Cycle time Materials utilization Flexibility Tooling development Setup time IE 337: Materials & Manufacturing Processes

IE 337 Lecture 1: Introduction to Manufacturing Systems Dimensional Quality Bulk Tolerances Bilateral, unilateral or limits Size and location Geometric tolerances – flatness, roundness, cylindricity, straightness, parallelism, perpendicularity, angularity, true position, etc. Surface Surface texture – roughness, waviness, lay Tolerance – the amount by which a dimension is allowed to vary IE 337: Materials & Manufacturing Processes S.V. Atre

IE 337: Materials & Manufacturing Processes Quality – properties Defects Inclusions, voids, porosity … Microstructure Grain size, residual stress, precipitate size, etc. Surface integrity Absorption, alloy depletion, cracks, craters, hardness changes, heat affected zones, inclusions, intergranular attacks, seems, pits, plastic deformation, recrystallization, residual stresses, selective etch … IE 337: Materials & Manufacturing Processes

Waste in Shaping Processes It is desirable to minimize waste and scrap in part shaping i.e. have high material utilization Material removal processes tend to be wasteful in the unit operation, simply by the way they work Casting and molding waste less material Terminology: Net shape processes - when most of the starting material is used and no subsequent machining is required to achieve final part geometry Near net shape processes - when minimum amount of machining is required

IE 337: Materials & Manufacturing Processes Comparing Processes IE 337: Materials & Manufacturing Processes

You should have learned today: The key design responsibility of a manufacturing engineer Key categories of manufacturing materials Key categories of manufacturing processes How to compare them materials-processes-geometry IE 337: Got to work hard tons of information, regular study habits

Next Class Metals From Chapters 2 and 3