1. 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

2. Course Instructor Brian K. Paul Office: Office Hours:
PhD 1995, Penn State
Office:
322 Rogers Hall
Phone:
Office Hours:
T: 11:30 – noon
R: 11:30 – 13:00

3. 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?

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

5. Lab Instruction Mr. Barath Palanisamy (Instructor)
Ms. Negar Abolhassani (co-Instructor)
Steve Etringer (Technician)
Lab
126 Rogers Hall

6. Books & Materials Required Text: Required Materials:
Groover, M.P. (2006). Fundamentals of Modern Manufacturing (3rd ed.). New York NY: John Wiley & Sons pp. ISBN
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

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

8. 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

9. 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

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

11. 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

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

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

14. 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

15. 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

16. Manufacturing & Globalization

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

18. Transformations
China over 2000 years

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

20. 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

21. 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

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

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

24. 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

25. 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

26. 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

27. 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

28. Developing a Manufacturing Process1.
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

29. 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

30. 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

31. 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

32. 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

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

44. 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

45. Next Class
Metals
From Chapters 2 and 3