1. Manufacturing Materials and Processes

2. Learning Objectives
Define and describe given manufacturing materials, material terminology, numbering systems, and material treatment
Describe steel and aluminum material selection characteristics
Explain sustainability applications for steel and aluminum processing and manufacturing

3. Learning Objectives
Identify a variety of manufacturing processes used to create plastic products
Explain sustainability applications for plastics processing and manufacturing
Discuss casting processes and terminology
Explain the forging process and terminology

4. Learning Objectives Describe manufacturing processes
Define the representation of various machined features
Explain tool design practices
Discuss the statistical process quality control assurance system

5. Learning Objectives
Evaluate the results of an engineering and manufacturing problem
Explain the use of computer-aided manufacturing (CAM) in industry
Discuss robotics in industry

6. Ferrous Metals Contain iron Cast iron Steel
Alloy containing 1.7% to 4.5% carbon
Varying amounts of silicon, manganese, phosphorus, and sulfur
Steel
Alloy containing 0.8% to 1.5% carbon

7. Gray Cast Iron 1.7% to 4.5% carbon 1% to 3% silicon
Easy to cast and machine
Popular for:
Automotive cylinder blocks
Machine tools
Agricultural implements
Cast iron pipe

8. White Cast Iron Extremely hard and brittle Almost no ductility
Highly resistant to wear

9. Chilled Gray Cast Iron Creates outer surface of white cast iron
Internal characteristics of gray cast iron
Surface advantage of white cast iron

10. Alloy Cast Iron
Nickel, chromium, molybdenum, copper, or manganese alloy
Increased:
Strength
Wear resistance
Corrosion resistance
Heat resistance

11. Malleable Cast Iron Heat-treated white cast iron Strong Ductile
Shock-resistant
Easy to machine

12. Nodular Cast Iron Special casting process Magnesium or cerium alloy
Strong
Ductile
Can be chilled

13. Mild steel (MS) Less than 0.3% carbon Cannot be hardened
Common for forged and machined parts

14. Medium Carbon Steel 0.3% to 0.6% carbon Harder than mild steel
Easy to forge and machine

15. High Carbon Steel 0.6% to 1.50% carbon
Can be hardened by heat treating
Difficult to forge, machine, or weld

16. Hot-Rolled Steel (HRS)
Formed between rollers or forged when red-hot
Consistent grain structure
Strong
Ductile

17. Cold-Rolled Steel (CRS)
Additional forming after initial hot rolling
Smooth, clean surface
Ensures dimensional accuracy
Increases tensile strength

18. Steel Alloys Chromium Manganese Molybdenum Tungsten Carbon Vanadium
Corrosion resistant
Wear resistant
Manganese
Strong
Molybdenum
Heat resistance
Non-brittle
Tungsten
Hard for cutting tools
Carbon
Vanadium
Tough
Strong
Non-brittle

19. Steel Castings Generally stronger and tougher than cast iron
Common for machine parts

20. Stainless Steel Generally at least 10.5% chromium
Excellent corrosion resistance
Oxidation resistant
Heat resistant
Strong

21. Stainless Steel Applications
Restaurant and hospital equipment
Architectural and marine applications
Some aircraft applications
Consumer products

22. Steel Numbering Systems
American Iron and Steel Institute (AISI)
Society of Automotive Engineers (SAE)
Example: SAE 1020
10: type of steel
20: approximate amount of carbon (0.20% carbon)
Added letter between the first and second pair of numbers

23. Heat Treating Steel Heating followed by quenching hardens steel
Case hardening
Hardens the surface layer by carburization, often followed by quenching
Tempering
Annealing

24. Hardness Testing Brinell test Rockwell hardness test
Brinell Hardness Number (BHN)
Rockwell hardness test
Example note: CASE HARDEN 58 PER ROCKWELL “C” SCALE.

25. Nonferrous metals
No iron content
Copper
Aluminum

26. Aluminum Corrosion resistant Lightweight Easily cast
Conducts heat and electricity
Easily extruded
Very malleable

27. Aluminum Alloy Numbering
Various designations
Example: 1030
1: 99% pure
0: no control of specific impurities
30: 99.30% aluminum

28. Copper Alloys Easily rolled and drawn into wire
Excellent corrosion resistance
Great electrical conductor
Better ductility than any metal except for silver and gold

29. Brass Alloy of copper (about 90%) and zinc (about 10% zinc)
Corrosion resistant
Strong
Ductile

30. Bronze Alloy of copper and tin Phosphor bronze Tin increases: Hardness
Wear resistance
Phosphor bronze

31. Precious and Other Specialty Metals
Gold
Silver
Platinum
Columbium
Titanium
Tungsten

32. Metallurgy Practical use of metals and metalworking
Production of metal components for use in products
Alloy development
Material shaping
Heat treatment
Surface treatment

33. Plastics and Polymers Polymerization Often molded into shape
Machined for tight tolerance situations or when holes or other features are required
Gears
Pinions
Society of the Plastics Industry, Inc. (SPI) identification coding system

34. Thermoplastics Heated and formed by pressure to a desired shape
Reheating changes the shape
Used for most plastic products

35. Thermoplastics
Thousands of different thermoplastic combinations for specific applications
Common examples:
Acrylic
Acrylonitrile-butadiene-styrene (ABS)
Polyamide (nylon)
Polyethylene
Polypropylene
Polyesters

36. Thermosets Heated and formed by pressure to a permanent shape
Cannot be altered by heating after curing
Used when heat exists
More rigid and harder than thermoplastics
About 15% of plastics
Expensive
Brittle
Cannot be reformed

37. Common Thermosets Alkyds Melamine formaldehyde Phenolics
Unsaturated polyesters
Urea formaldehyde

38. Elastomers
Stretch at least equal to their original length and return to their original length
Rubber
Occurs naturally in a number of plants
Produced synthetically
Almost twice as many products as natural rubber

39. Common Elastomers Many different elastomers for specific applications
Butyl rubber
Chloroprene rubber (Neoprene)
Nitrile rubber
Polyurethane
Silicones

40. Inorganic Materials Carbon Graphite Can be molded by pressure
Low tensile strength
High compressive strength

41. Inorganic Materials Ceramics Hard Brittle
Resistant to heat, chemicals, and corrosion

42. Inorganic Materials Clay Glass Refractory Inorganic cements
Used for high-temperature applications
Inorganic cements

43. Composites Reinforced plastics
Polymers combined with reinforcing material
Glass
Graphite
Thermoplastic fibers
Cotton
Paper
Metal

44. Material Selection Typically occurs during initial design or redesign
Requires knowledge of:
Material properties, characteristics, cost, and availability
Manufacturing processes and costs
Part geometry
External and internal forces applied to the parts and the assembly
Product use and appearance
Environmental considerations and sustainability

45. Castings The result of founding
A pattern is constructed that is the same shape as the desired finished product
A mold is made by packing sand or other material around the pattern
The pattern is removed from the mold and molten metal is poured into the hollow cavity

46. Sand Casting Most commonly used method of making castings
Two general types:
Green sand
Dry sand

47. Cores Baked clean sand mixed with binders, or Ceramic products
Reduce casting weight
Save on machining costs

48. Centrifugal Casting No cores needed
Objects with circular or cylindrical shapes
Tubing
Pipes
Wheels

49. Die Casting Nonferrous metal castings Quick and economic
Zinc alloy
Brass
Bronze
Aluminum
Quick and economic
Fine detail and smooth finish

50. Permanent Casting Similar to sand casting and die casting
The mold can be used many times
Good finished qualities

51. Investment Casting

52. Forgings Hot or cold materials
Material retains original grain structure
Strong and ductile

53. Forging Methods Hand forging Machine forging Smithing Blacksmithing
Upset
Swaging
Bending
Punching
Cutting
Welding

54. Metal Stamping Uses a punch press
Holes created by punching through material
Mass production
Example:
Automobile body panels

55. Hydroforming Tube hydroforming Sheet hydroforming
High strength-to-weight ratios
Can be more economical than metal stamping

56. Powder Metallurgy (PM)
Uses metal-alloyed powders
Compacted under pressure in a die
Sintered
Metal Injection Molding (MIM)
Powder Forging (PF)
Quality, precision parts
Mass production

57. Machine Processes Machining Machine tools Machinist
Used to manufacture metal and some plastic products
Machine tools
Machinist

58. Drilling Machine (Drill Press)
Machine-drill holes
Reaming
Boring
Counterboring
Countersinking
Tapping

59. Grinding Machine
Grinding
Honing
Lapping

60. Lathe
Cut material by turning cylindrically shaped objects

61. Screw Machine Type of lathe Mass-production
Variety of small turned parts
Screws
Threaded parts

62. Milling Machines Horizontal mill Vertical mill
Work fastened to a table
Rotary cutting tool removes material
Large variety of milling cutters
End milling cutters

63. Milling Machines

64. Milling Machines Universal Milling Machine Multiaxis Milling Machines
Table action includes x-, y-, and z-axis movement plus angular rotation
Multiaxis Milling Machines
CNC tools that move in four or more directions

65. Saw Machines Power hacksaw Band saw
Circular abrasive or metal cutting wheels
Cut material to length
Machining operations
Kerf

66. Water-Jet Cutting Cut almost any material
Cut material as thick as 12 in. (305 mm) or more
Hold fine tolerances
Do not produce a heat-affected zone

67. Shaper Horizontal, vertical, or angular flat surfaces
Being replaced by milling machines
Slow
Cuts only in one direction

68. Chemical Machining Uses chemicals to remove material accurately
Electrochemical machining (ECM)
Electrodischarge machining (EDM)
Electron beam (EB) cutting and machining
Ultrasonic machining
Laser machining

69. Drill Features on a Drawing

70. Ream Features on a Drawing

71. Bore Features on a Drawing

72. Counterbore Features on a Drawing

73. Countersink Features on a Drawing

74. Counterdrill Features on a Drawing

75. Spotface Features on a Drawing

76. Chamfer Features on a Drawing

77. Fillet and Round Features on a Drawing

78. Key, Keyseat, Keyway on a Drawing

79. Threads on a Drawing Many different forms of threads
Fasteners to hold parts together
Adjust parts in alignment
Transmit power

80. Knurl on a Drawing

81. Surface Texture (Surface Finish)
Roughness
Waviness
Lay
Flaws

82. Additional Features
Boss
Lug
Pad
Dovetail
Kerf
Neck
Spline
T-slot

83. Injection Molding Process
Most common process for creating thermoplastic products

84. Extrusion Process
Continuous shapes: moldings, tubing, bars, angles

85. Blow Molding Process
Hollow products: bottles, containers

86. Calendering Process
Thermoplastic or thermoset plastics pass through a series of heated rollers
Sheet products
Vinyl flooring
Gaskets

87. Rotational Molding Process
Polymer pellets in a heated, rotating metal mold
Rotation forms a thin coating against the sides of the mold
Large hollow objects
Tanks
Containers
Floats

88. Solid Phase Forming Process
Detailed shapes: containers, electrical housings, automotive parts

89. Thermoforming of Plastic
Similar to solid phase forming, but does not use a die
Thin-walled shapes
Containers
Guards
Fenders

90. Free-Form Fabrication (FFF) of Plastic
Rapid prototyping
Stereolithography
3-D Printing

91. Casting Thermoset Plastics
Similar to permanent casting of metals

92. Compression Molding and Transfer Molding
Common for thermosets
Uses a mold, specific amount of heated material, additional heat, and pressure

93. Foam Molding and Reaction Injection Molding
Similar to casting, but uses an expanding foam material

94. Vulcanization Process
Rubber products such as tires

95. Manufacturing Composites
Layering process
Compression molding of composites
Resin transfer molding
Vacuum bag forming

96. Rapid Prototyping (RP)
Stereolithography (SLA)
Computer controlled ultraviolet laser beam hardens a photo-curable liquid resin
Fused deposition modeling (FDM)
CNC extruder-head squeezes a fine filament of melted thermoplastic through a nozzle
3-D printing
Print head dispenses a thermoplastic material in layers

97. Jig and Fixture Prints
Machining operations require special tools to hold the workpiece or guide the machine tool
Kinematics

98. Computer-Integrated Manufacturing (CIM)
Computer and software controls most, if not all, portions of manufacturing
Brings together:
Computer-Aided Design and Drafting (CADD)
Computer-Aided Engineering (CAE)
Computer Numerical Control (CNC)
Computer-Aided Manufacturing (CAM)
Computer-Aided Quality Control (CAQC)
Robotics

99. CAD/CAM integration
A direct link between the design and manufacture of a product
CAD used to create product geometry
2-D multiview drawings
3-D models
CAM generates instructions for CNC machine tools
Stamping
Cutting
Burning
Bending
Other operations

100. Statistical Process Control (SPC)