IE 337: Materials & Manufacturing Processes

1. IE 337: Materials & Manufacturing Processes Lecture 1: Introduction Chapter 1 & 5

2. Course Instructor • Brian K. Paul • 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

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: • 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/

5. 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

6. Books & Materials • Required Text: • 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

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

8. 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. 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 What is Manufacturing?

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

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

24. 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 Material Removal Processes

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 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

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 • Cycle time IE 337: Materials & Manufacturing Processes

30. 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 IE 337: Materials & Manufacturing Processes

31. 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. 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