Chapter 1 General Introduction

1. Chapter 1General Introduction

2. DEPARTMENT OF INDUSTRIAL ENG. Manufacturing Process I FACULTY: Dr. Mazin Obaidat e-mail: mazin@hu.edu.jo, Room: 3079 Office Hours:  Open door ploicy TEXTBOOKS: • Manufacturing Processes for Engineering Materials, Serope Kalpakjian and Steven R. Schmid, Prentice Hall, 5th Edition, 2008 • Fundamentals of Modern Manufacturing – materials, processes and systems, Mikell P. Groover, Wiley, 2nd Edition, 2002 References: • Materials and Processes in Manufacturing, E. Degarmo, J.T. Black and R.A. Kohser, Wiley, 9th Edition, 2002. • Mechanical Metallurgy, G.E. Dieter, McGraw-Hill, 3rd Edition, 1986 • Material Science and Engineering, W.D. Callister, 6th Edition, Wiley, 2002

3. Manufacturing Process I Handouts: are available at Moodle http://www.mlms.hu.edu.jo/ Assessment1: First Exam 25 % Second Exam 25 % Others 10% Final Exams: 50 % Assessment2: First Exam 30 % Second Exam 30 % Final Exams: 40 % Assessment3: Mid Exam 20% Project 20 % Others 20% Final Exams: 50 %

4. Grading Assessment 2 • 25 30 ( Well done ) • 20 25 ( Hard worker ) • 15 20 ( Slim Chance of passing ) • 10 15 ( Drop the course ) • 5 10 ( Change your major ) • 0 5 ( Stay At home)

5. Manufacturing Processes Course Outline • Introduction to Mechanical Shaping • Review of Mechanical Properties • Annealing – Recrystallization • Forming Process Variables - hot, warm or cold forming • Bulk Deformation: Rolling, Forging, Extrusion, Drawing • Sheet metalworking: • Bending, • Shearing, • Deep drawing • Material Removal: Machining, Cutting Tools • Powder Metallurgy

6. What is Manufacturing? Manufacture is derived from two Latin words manus (hand) and factus (make); the combination means “made by hand” “Made by hand” described the fabrication methods that were used when the English word “ Manufacture” was first coined around 1567 A.D. “. Made by hand???!!! What about the Modern Manufacturing? Modern manufacturing operations are accomplished by Mechanized and automated equipment that is supervised by human workers

7. What is Manufacturing? For our purposes, manufacturing means production of hardware, which ranges from nuts and bolts to digital computers and military weapons, as well as plastic and ceramic products

8. Manufacturing is Important Historically To a significant degree, the history of civilization is the history of humans' ability to make things • Historically, the importance of manufacturing in the development of civilization is usually underestimated • Throughout history, human cultures that were better at making things were more successful • Making better tools meant better crafts & weapons • Better crafts allowed the people to live better • Better weapons allowed them to conquer other cultures in times of conflict

9. Manufacturing Processes Modern Manufacturing Materials Process System Manufacturing adds value to the material by changing its shape or properties, or by combining it with other materials that have been similarly altered So, a manufacturing plant consists of a set of processes and systems (and, of course, people) designed to transform a certain limited range of materials into products of increased value There is a strong interdependency among these three building blocks.

10. Manufacturing • Manufacturing can be defined in two ways: • Technologically • Economically

11. Technologically? • Technologically manufacturing means: is the application of physical and chemical processes to alter the geometry and appearance of the given starting material to make product or part

12. Economically • Economically: manufacturing is the transformation of materials into items of greater value by means of one or more processing or assembly operations. Examples: • When iron core is converted into steel – value is added • When sand is transferred into glass-value added • When petroleum is refined into plastic-value is added

13. What is Manufacturing? It is the process of converting the raw materials into products. Also it involves activities in which the manufactured product itself is used to make other products. • Products are: • Discrete: nails, gears, etc. • Continuous: sheet metal, tubes, hose, wire, etc.

14. Manufacturing capability • Manufacturing capability refers to the technical and physical limitations of any manufacturing firm • We can identify several dimensions of this capability: • Technological processing capability • Physical product limitations • Production capacity.

15. Manufacturing capability • Technological processing capability: it’s the available set of manufacturing process • Examples: • Certain plants or firm performing machining operations, others roll steel sheet, casting, forging…. • Machine job can not produce car.

16. Manufacturing capability • Physical product limitations: one of the most important thing that identify the capability of firm is the weight and size of product. • Examples: • Large and heavy products are difficult to move, to move these products the firm must be equipped with cranes of required load. • Smaller parts and products made in large quantities can be moved by conveyer or other means.

17. Manufacturing capability • Production capacity: is the production quantity that can be produced in a given time (e.g. month, or year). • Plant capacity:maximum rate of production the company can a achieve under assumed operations conditions. • Shift per hours • Direct labors.

18. Type of Production • Mass Production: the manufacturing of large quantities of standardized products utilizing assembly line technology such as mass production of airline and automobile using special purpose machines. The concepts of mass production are applied to various kinds of products to assemblies of such parts such automobile . (over 100,000 piece/year) • Batch Production: refer to a method of manufacturing where several of the same item are put together at the same time. [ is a technique used in manufacturing, in which the object in question is created stage by stage over a series of workstations, and different batches of products are made] Batch production is most common in bakeries and in the manufacture of sports shoes, pharmaceutical ingredients 100-5000 piece/year

19. Type of Production • Job Shop Production: sometimes called jobbing or one-off production, involves producing custom work, such as a one-off product for a specific customer using general purpose machines (making railings for a specific house, building/repairing a computer for a specific customer, making flower arrangements for a specific wedding etc.) (10-100 piece/year)

20. Product Design Process • It is the process where the product is passing through many steps, from the first step (conceptual design) till its manufacturing (product)

21. Product Design Process Figure I.4 (a) Chart showing the various steps involved in design and manufacturing a product. Depending on the complexity of the product and the type of materials used, the time span between the original concept and the marketing of the product may range from a few months to many years.

22. Important ConsiderationsProduct Design Process • Design requirements, Ex: baseball bat • Bat less 1.5 bound • Made out of approved material • Able to hit baseball without breaking • Manufactured by environmentally friendly and economical methods • Quality inspection at each stage.

23. Important ConsiderationsProduct Design Process • Flexible production methods • Computer integration • Productivity

24. Important Considerations-Product Design Process • Manufactured by environmentally friendly and economical methods. • Consider the effects of water and air pollution, acid rain, ozone depletion, hazardous waste, and global warming. • The adverse effects of these activities, their damage to our environment and to earth ecosystem, ultimately, their effect on the quality of human life are now well recognized by the public as well as by the governments. • In response, a wide range of laws and regulations have been promulgated by governments. • These regulations are generally stringent, and their implementation can have a major impact on the economic operation of manufacturing . • These efforts have been most successful when there is value added, such as in reducing energy requirements ( associated cost) that have both cost and environmental design benefits.

25. Important ConsiderationsProduct Design Process • Much progress has also taken place regarding • Design for recycling • Design for environment (DFE) or green design • These comprehensive approaches anticipatethe possible negative environmental impact of materials, products, and process so that they can be considered at the earliest stages of design and production.

26. Important Considerations-Product Design Process • Other developments such as sustainable manufacturing and cardle-to-cardle philosophy. • Sustainable manufacturing : which refers to the realization that natural resources are vital to become economic activity, to ensure that resources are available for future generations. • cardle-to-cardle philosophy. A philosophy that encourages the use of environmentally friendly materials and design • Environmentally friendly materials can be: • Part of a biological cycle, where usually organic materials (such as wood, and polymers) are used in the design, function probably for their intended life and can then be disposed of. Such materials degrade (dissolve) naturally, and in the simple version, lead to new soil that can sustain life • Part of industrial cycle, such as aluminum in beverage containers that serve an intended purpose and are then recycled, so that the same material is reused continuously.

27. Design Principles for Economic Production • Designs should be as simple as possible to manufacture, assemble, disassemble, service, and recycle. 2. Appropriate Material [ material should be chosen for their appropriate design and manufacturing characteristics as well as for their service life]. 3. Dimensional accuracy. 4. Finishing should be avoided or minimized.[because they can add significantly to the cost]

28. Redesign of Parts Figure I.5 Redesign of parts to facilitate assembly. Source: Reprinted from G. Boothroyd and P. Dewhurst, Product Design for Assembly, 1989. Courtesy of Marcel Dekker, Inc.

29. Selecting Materials • A wide variety of materials is now a available, each having • its own characteristics • Composition • Applications • Costs • Advantages • And limitations

30. Selecting Materials • Many factors have to be considered when selecting possible materials to fit a design and manufacturing requirement: • Dose the material posses the necessary mechanical, electrical and thermal properties? • Can the material be formed to the desired shape? • Will the properties of the material alter with time during service? • Will the material adversely affected by the environmental conditions and resist corrosion and other forms of attack? • Will the material be acceptable on aesthetic grounds? • Will the material give sufficient degree of reliability and quality? And, of course: • Can the product be made at an acceptable cost?

31. Classification of engineering materials • Engineering materials can be classified into two or three classifications: • Metallic: • Ferrous: (iron, steel, cast iron, wrought iron) • Non ferrous(Al its alloys, Cu its alloys, Mg its alloys 2. Non Metallic. • Organic (polymers, wood) • Inorganic(ceramic, glasses) 3. Composite materials ????? • Metal matrix composite • Ceramic matrix composite • Polymer matrix composite Matrix polymer Reinforcement fiber glass

32. Composite materials

33. Alloys versus composite concrete Matrix • Composite materials: consists of two materials or more, each material has a surface that separate it from the other materials • Alloys: is a mixture of two materials or more showing metallic properties such as Brass (Cu+Zn), Bronze (Cu+Sn) Reinforcement iron bar A+B material Grain boundaries

34. Classes of Materials There are 3 major classes: 1. Metals Usually alloys, which are composed of two or more elements, at least one of which is metallic • Two basic groups: • Ferrous metals - based on iron, comprise 75% of metal tonnage in the world: • Steel = iron‑carbon alloy with 0.02 to 2.11% C • Cast iron = alloy with 2% to 4% C • Nonferrous metals - all other metallic elements and their alloys: aluminum, copper, gold, magnesium, nickel, silver, tin, titanium, etc.

35. Classification of engineering materials • Steel : is iron and carbon, theoretically the % of carbon in steel less than 2%, practically the % of carbon in steel no more than 1.6% • Type of steel • High carbon steel( doesn't exceed =1.6%) • Mild carbon steel( 1.3% < Carbon% <1.6%) • Low carbon steel(= 1.3% of carbon). • We add carbon to iron to become steel in order to increase hardness

36. Classes of Materials 2. Polymers A compound formed of repeating structural units called mers, whose atoms share electrons to form very large molecules • Three categories: • Thermoplastic polymers - can be subjected to multiple heating and cooling cycles without altering their molecular structure • Thermosetting polymers - molecules chemically transform (cure) into a rigid structure upon cooling from a heated plastic condition • 3. Elastomers - exhibit significant elastic behavior

37. Sub-Classes of Materials Semiconductors (ceramics) Intermediate electrical properties Composites (all three classes) Combinations Bio Materials (all three major classes) Materials compatible with body tissue Classes of Materials 3. Ceramics A ceramic is an inorganic, nonmetallic solid material comprising metal, nonmetal or metalloid atoms primarily held in ionic and covalent bonds. The crystallinity of ceramic materials ranges from highly oriented to semi-crystalline, and often completely amorphous (e.g.,glasses) - Molecules based on bonding between metallic and non-metallic elements (including oxides, nitrides, carbides) - Typically insulating and refractory metalloid is a chemical element with properties in between,of metals and nonmetals Such Si and B

38. Selecting Materials • Why do we study materials? • Many engineers, whether mechanical, civil, chemical, electrical or mechatronics will be exposed to design problem, and the reason for this design problem is selecting the material. • Ex: transmission gear, the superstructure for building or an integrated circuit board. • Always the problem is not selecting the right material for the right application.

39. Criteria to select the proper material • Service conditions must be characterized. • In rare occasions dose the material posses the ideal combination of properties- trade off one characteristic for another. • Ex: a material having a high strength will have a limited ductility. In such case a reasonable compromise between two or more properties may be necessary.

40. Criteria to select the proper material • Deterioration of material properties that may occur during operation service. • A significant reduction in mechanical strength may result from exposure to elevated temperature. • The economics. • What will the finished product cost? A material may be found that has the ideal set of properties, but still expensive compromise is still necessary.

41. Important Considerationsselecting materials • Very many properties of materials have to be considered when choosing a material to meet a design requirement. • These include a wide range of physical, chemical and mechanical properties together with forming, or manufacturing characteristics, cost and availability and, in addition, more subjective aesthetic qualities such as appearance and texture.

42. Important Considerationsselecting materials • Properties of Materials • Mechanical properties • Physical properties • Chemical properties • Manufacturing properties • Cost versus availability • Service life and recycling • Operational cost : • Fixed cost : overhead cost (oil, water, electric..) • Variable cost: cost of material, this cost vary according to how much product is produced.

43. Properties of materials • Mechanical properties [strength, ductility, toughness, hardness, elasticity, and creep….] • These properties can significantly modified by various heat treatment methods. • So the mechanical properties should be appropriate for the conditions under which the product is expected to function. • Physical properties [density, meltingpoint, thermalexpansion, thermalconductivity and electrical and magneticproperties, also need to be considered].

44. Properties of materials • Chemical properties [ resistance to corrosion, resistance to oxidation] • Also can play a significant role in hostile as well as normal environment. • Oxidation, corrosion and flammability of the materials are among the important factors to be considered, as is toxicity (lead-free solders) • Manufacturing properties determine weather the material can be processed [ machinability, formability, castability, weldability] with relative ease. • The methods used to process materials to the desired shapes should not adversely affect the product’s final properties and service life

45. Machinability versus formability • Machinability: the operation where certain a mount of the material is removed from the surface as chips. Or the ability of the material to be shaped by removing a certain a mount from the surface to reach the desired shape. • Formability: it is an operation of forming the material but without removing a certain a mount from the surface, it can be done by knocking on or pulling the material and delivering in another shape [ the mass of the material before and after the process will be the same].

46. Properties of materials • Cost versus availability • If raw materials are not commercially available in the desired quantities and shape, additional processing may be required; these steps can contribute significantly to product cost • For example, if we need a small round bar of a certain diameter and it is not commercially available, then we have to purchase a large diameter bar and reduce its diameter, by processes such as drawing through a die or machining

47. Properties of materials • Service life and recycling • Time-and service are dependent phenomena such as wear, fatigue, creep, corrosion, and dimensional stability are important considerations as they can significantly affect a product's performance, and if not controlled, can lead to failure of product. • The corrosion caused by compatibility of different materials used in a product is also important; an example is galvanic action between mating parts made of dissimilar metals. • Recycling or proper disposal of the individual components in a product or the whole product at the end of its useful life is important as we become increasingly aware to live in clean and health environment. • Toxic wastes is a also a crucial consideration and need to have proper treatment and disposal

48. Factors affecting the cost of the materials • Availability in the nature. • Concentration of the material in the ore. • The cost of extracting the material from the ore. • By products [ through extracting the material, other material can be so benefit, example extracting petroleum we have methane gas]

49. Manufacturing Characteristics of Alloys

50. Factors influencing properties and (Manufacturing) Behavior of Metals • Atomic Structures • Crystal structures: bcc, fcc, hcp • Slip, slip planes:b/a ratio, anisotropy • Imperfections • Line:dislocations (strain hardening) • Point:vacancy, interstitial (alloys, e.g. Fe-C), impurity (alloys, e.g., Al, Cu) • Volume:voids, inclusions (e.g. oxides, carbides, sulfides) • Planar:grain boundaries • Grains • Properties depend on size, large grains are softer (why?) lower strength, hardness, & high ductility and produce rough surface after stretching (orange peel example)