1. BASIC WORKSHOP MENG130

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

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

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

5. 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

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

7. 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

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

9. 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

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

11. 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

12. 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

13. 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

14. 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

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

16. 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

17. 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

18. Part I Fundamentals of Materials: Behavior and Manufacturing Properties
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19. MANUFACTURING PROCESSES (will be explained in later lectures) CASTING FORMING MACHINING (Turning, Milling, Grinding, etc.) JOINING FINISHING

20. 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)

21. METHODS OF ASSEMBLY OF COMPONENTS adhesives welding soldering use of fasteners

22. 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

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

24. MATERIALS Name some of the materials you know

25. Steel glass wood aluminum plastic lead cast iron ceramic glass

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

27. 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

28. 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

29. FIGURE I.1 An outline of the topics described in Part I.
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30. Approximate Number of Parts in Products
FIGURE I.2 An outline of the engineering materials described in Part I.
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31. Approximate Number of Parts in Products
FIGURE I.3 An outline of the behavior and the manufacturing properties of materials described in Part I.
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32. Chapter 1 Structure of Metals
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33. Approximate Number of Parts in Products
FIGURE 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.
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34. FIGURE 1.2 An outline of the topics described in this chapter.
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35. 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

36. 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

37. BODY CENTERED CUBIC CHROMIUM TUNGSTEN ALPHA IRON

38. Approximate Number of Parts in Products
FIGURE The body-centered cubic (bcc) crystal structure: (a) hard-ball model, (b) unit cell, and (c) single crystal with many unit cells.
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39. FACE CENTERED CUBIC ALLUMINUM COPPER NICKEL LEAD BETA IRON

40. Approximate Number of Parts in Products
FIGURE The face-centered cubic (fcc) crystal structure: (a) hard-ball model, (b) unit cell, and (c) single crystal with many unit cells.
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41. HEXAGONAL CLOSE PACKED ZINC COBALT MAGNESIUM

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FIGURE The hexagonal close-packed (hcp) crystal structure: (a) unit cell and (b) single crystal with many unit cells.
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43. DEFECTS IN SINGLE CRYSTAL LATTICE SELF INTERSTITIAL ATOM INTERSTITIAL ATOM SUBSTITUTIONAL ATOM VACANCY

44. Approximate Number of Parts in Products
FIGURE Schematic illustration of types of defects in a single-crystal lattice: selfinterstitial, vacancy, interstitial, and substitutional.
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45. Approximate Number of Parts in Products
FIGURE Types of dislocations in a single crystal: (a) edge dislocation and (b) screw dislocation.
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46. Approximate Number of Parts in Products
FIGURE 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.
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47. SOLIDIFICATION OF MOLTEN METALS

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FIGURE 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.
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49. TABLE Grain sizes

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FIGURE 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.
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51. Approximate Number of Parts in Products
FIGURE (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.
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52. Approximate Number of Parts in Products
FIGURE 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.
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53. TABLE 1.2 Homologous Temperature Ranges for Various Processes