Module ME1331:

Engineering Materials, Manufacturing

& Electrical Machines

Manufacturing Methods

Lecture 1: Introduction to Manufacturing

Dr. Alasdair Cairns
Contents
• Module Aims (Manufacturing)

• Module Overview
– Content
– Assignment

• Lecturer Background

• Introduction to Manufacturing
– History
– Industries, Products & Categories
– Trends in Manufacturing
– Design for Manufacture
Module Aims & Learning Objectives (Manufacturing)

Objective:
• To introduce the basic manufacturing methods available to achieve
the required performance

Learning Outcomes
• Knowledge of the fundamental concepts of manufacturing
• Appreciation of appropriate manufacturing methods
 Module Content – Manufacturing Lectures

Overview Metal Forming & Joining & Assembly Particulate

(Week 1) Deformation Processes Processes: Welding, Processes: Powder
(Weeks 4-5) Brazing & Fastening Metallurgy &
(Week 8) Ceramics (Week 10)

Term 1

Solidification Processes: Property Enhancing &

Metal Casting (Weeks 2-3) Surface Treatments Special Processes:
(Week 9) Rapid Prototyping,
Material Removal electrical machines,
Processes: Machining micro and nano
Operations & Tools manufacturing
(Weeks 6-7)
(Week 11)
 Module Content (2) - Assignment

Individual Written Report

Deadline: Friday 14th January 2011

Term 1 Term 2

• Manufacturing is wholly assessed via one assignment

• Worth 25% of the ME1331 module
• To be announced and discussed in one of the lectures

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 Module Content (3) – Reading List

Reading List:

1. ESSENTIAL READING [* Purchased advised]

• Kalpakjian, S. and Schmid, S., “Manufacturing Engineering and Technology”, 6th
Edition)”, Pearson, (2010).
• Schey, J., “Introduction to Manufacturing Processes, 3rd Edition, McGraw-Hill, (2000)

2. RECOMMENDED READING
• Groover, M.P.: “Fundamentals of Modern Manufacturing”, 3rd Edition, Wiley, (2007)
• Brockman, J.B., “Introduction to Engineering”, Wiley, 2009.

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 Contents
• Module Aims (Manufacturing)

• Module Overview
– Content
– Assignment

• Lecturer Background

• Introduction to Manufacturing
– History
– Industries, Products & Categories
– Trends in Manufacturing
– Design for Manufacture

Cairns 2010/2011
 Lecturer Background

Audi RS6 Concept Engine Focus Cosworth Demonstrator Audi R8 Demonstrator Vehicle
(4.2l V8 bi-turbo, 450bhp) (2.0litre, 300bhp) (V10 concept, 650bhp)

• 10 years experience at an automotive consultancy business

– Mahle Powertrain / Cosworth Technology
– Principal Research & Development Engineer
– Exposed to a wide range of engine manufacturing processes

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 MAHLE Produced Engine Components
Oil-mist separator with
control valve
Eco-Oil filter
module Air-mass sensor
Air filter module
Camshaft
Purge valve
Valve guide
Tappet (cam follower,
rocker arm)
Valve
Tumble flap
Valve seat ring
Exhaust gas recirculation
Turbocharger* Intake manifold
(charge air distribution)
Piston ring
Blow-by induction
Piston with pin Fuel filter
bore bushing
Cylinder liner
Piston pin, Connecting rod
Piston pin circlip
Bearing

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3
© MAHLE
 Contents
• Module Aims (Manufacturing)

• Module Overview
– Content
– Assignment

• Lecturer Background

• Introduction to Manufacturing
– History
– Industries, Products & Categories
– Trends in Manufacturing
– Design for Manufacture

Cairns 2010/2011
 What is Manufacturing?

The process of converting raw materials into products

• The term comes from the Latin manu factus, meaning made by hand
 What is Manufacturing?

• Can be considered as a
Technical Process

• Alternatively as an
Economical Process
Three Milestones in Modern Manufacturing

1567 1760 - 1850 1908

First record of the word Industrial Revolution
Ford Model T (the first mass production assembly
“Manufacture” line)
The change from an economy based
The illustration depicts a 16th upon agriculture and handicraft to one
“I will build a car for the great multitude. It will be
century woodcutting operation based upon manufacturing began in
large enough for the family, but small enough for
the UK, where steam power replaced
the individual to run and care for. It will be
water, wind and animal power. A Watt
constructed of the best materials, by the best men
steam engine is shown
to be hired, after the simplest designs that modern
engineering can devise. But it will be so low in price
that no man making a good salary will be unable to
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[Henry Ford]
 Industries & Products (1)

Primary sector: the conversion of natural resources into primary products.

Most products from this sector are considered raw materials for other industries. Major
businesses in this sector include all mining and quarrying industries, forestry, agriculture,
fishing.

Downstream manufacturing industries that package, purify or process the raw materials
close to the primary producers are also normally considered to be part of this sector

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 Industries & Products (2)
Secondary sector: Manufacturing

Converts the output of the primary sector into products.

Products completed to a point for use by other businesses or for export or sale to domestic
consumers. This sector is often divided into light industry and heavy industry. Many of these
industries consume large quantities of energy and require factories and machinery to convert
the raw materials into goods and products. They also produce waste materials and/or waste
heat that may pose environmental issues.

Example divisions of this sector include Aircraft, Automobile and Marine manufacturers,
Chemical industry, Energy producers (oil, gas, electricity) and Telecommunications.
 Industries & Products (3)
Tertiary sector - also called the service industry:

One of the three main industrial categories of a developed economy.

Involves the provision of services to other businesses as well as final consumers. Services
may involve the transport, distribution and sale of goods from producer to a consumer as
may happen in wholesaling and retailing, or may involve the provision of a service, such as
in tourism or entertainment. The goods may be transformed in the process of providing the
service, as happens in the restaurant industry.

The focus is on people interacting with people and serving the customer rather than
transforming physical goods.
 Industries & Products (4)
Quaternary sector: intellectual services.

Sometimes considered to be a subset of the general service-oriented tertiary

sector of industry.

This includes the high tech industry, with information technology and some forms
of scientific research, as well as education and consulting and the information
industry.
Industry Sectors (Summary)

Primary sector: the conversion of natural resources into primary products

Secondary sector: the manufacture of finished goods or products

Tertiary sector: also called the service industry. One of the three main
industrial categories of a developed economy

Quaternary sector: industry that involves the intellectual services

 Manufacturing within Product Life Cycle

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Three Levels of Manufacturing

Primary manufacturing processes: change the shape or form of materials.

Casting, forging, rolling, etc.

Secondary manufacturing processes: Add or remove geometrical features

from a basic form, obtained with a primary process. Machining, joining etc.

Tertiary manufacturing processes. Surface treatments applied to the

manufactured part. Heat treatment, polishing, painting, etc.
 Seven Types of Manufacturing
1. Solidification (casting) processes. Molten metal, plastic, or glass is cast into a
mould and solidified into a shape.

2. Deformation processes. A material, usually metal, is plastically deformed hot or

cold to give improved properties and change its shape.

3. Machining processes. Material is removed from a workpiece with a sharp tool.

4. Particulate processing. Involves the consolidation of particles of metal, ceramics,

or polymer by pressing and sintering, hot compaction, or plastic deformation. It also
includes the processing of composite materials.

5. Joining processes. Parts are joined together by welding, brazing, soldering,

diffusion bonding, riveting, and adhesive bonding.

6. Heat treatment and surface treatment. Improvement of mechanical properties by

thermal heat treatment.

7. Assembly processes. A number of parts are brought together and combined into
a subassembly or finished product.
 Contents
• Module Aims (Manufacturing)

• Module Overview
– Content
– Assignment

• Lecturer Background

• Introduction to Manufacturing
– History
– Industries, Products & Categories
– Trends in Manufacturing
– Design for Manufacture

Cairns 2010/2011
 Trends in Manufacturing -
Lean Production & Six Sigma
• Aimed at improving both efficiency and quality in manufacturing
• “Lean production”:
• Doing more work with fewer resources
• Evolved from Toyota Production System
• One example is Just-In-Time (JIT) delivery
• “Six Sigma”:
• Utilises established teams specifically assigned at improving operational performance
• One example is Failure Modes and Effects Analysis (FMEA)
• Introduced by Motorola US in the 1980’s
 Trends in Manufacturing -
Globalisation & Outsourcing

• Increased international freedom and hence flow of goods, services, capital,

technology & people
• Developing nations such as China, India & Mexico have increased their
manufacturing capabilities and are becoming increasingly dominant
• Large workforce pool and low labour costs (order of magnitude c.f. UK/US)
• Vast natural resource reserves, especially China (coal, ores etc.)
• Such benefits vastly outweigh increased shipping costs & logistics issues
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 Trends in Manufacturing -
Environmentally Conscious Manufacture

• Energy and material expenditure are inherent to manufacturing

• Globalisation effects must also be counter-acted in the future
• Limited product lifecycle must also be considered
• Increasing emphasis on Design For Environment (DFE)
• Product and process design
• Six Sigma

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 Design for Manufacture

• Impossible to produce a suitable design without prior knowledge of the different

materials and manufacturing methods available
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Design for Manufacture – Best Practice (1)
Design for Manufacture – Best Practice (2)
 Design for Manufacture – Surface Finish

• Surface roughness values must typically be an order of magnitude lower than

any specified tolerance fits
Design for Manufacture – Tolerances

• Sometimes necessary to compromise between functionality and cost

Design for Manufacture – Volumes
Design for Manufacture – Material Waste
Summary

• This course should provide you with a strong overview of modern

manufacturing methods

• Manufacturing awareness will be required throughout both your higher

education and engineering careers
• Knowledge essential to successful product design, development, production
and management

• The course content is designed to flow and requires personal note taking
• What you see is what you will get

• Solidification (casting) lectures next…

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