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WR Prosman

The document provides a weekly report submission for a Manufacturing Processes/Engineering Materials course. It includes the student's full name, student ID, course/class details, topic, and submission date. It then includes a rich picture/mind map explaining the current weekly topic of Engineering Materials. It discusses the classifications, nature, and types of engineering materials. It also includes an explanation of the last week's topic on manufacturing processes from a case study and analysis of the case study with relevant theory. References are provided at the end to support the topic.

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0% found this document useful (0 votes)
35 views5 pages

WR Prosman

The document provides a weekly report submission for a Manufacturing Processes/Engineering Materials course. It includes the student's full name, student ID, course/class details, topic, and submission date. It then includes a rich picture/mind map explaining the current weekly topic of Engineering Materials. It discusses the classifications, nature, and types of engineering materials. It also includes an explanation of the last week's topic on manufacturing processes from a case study and analysis of the case study with relevant theory. References are provided at the end to support the topic.

Uploaded by

Harley Sompie
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 5

Full Name : Timothy Yehezkiel Panjaitan

……………………………………………………………….. Weekly
Student ID 5010221030
: ………………………………………………………………..
Manufacturing Process/C
Report
Course / Class : ………………………………………………………………..
Topic Engineering Materials
: ………………………………………………………………..
3 September 2023/Week 2 Rich Picture / Mind Map explanation about current weekly
Submission Date / # : ……………………………………………………………….. topic or content (lesson learnt), use your own picture!

Structure Material Performance WHAT IS IT?


Property
Substances used to produce
society beneficial products
FACTORS FOR or technical products
Constrains MATERIAL SELECTION

ADDITIONAL
Imperfection Electronics
Biomaterials

CLASSIFICATIONS
Thermoplastic Thermosetting ENGINEERING Metals
Additional
Compounds formed of repeating
structural units called mers
MATERIALS Classification Ceramics

Polymers Elastomers
Polymers

Composites
EXPLANATION Ceramics
Compounds containing metallic, Metals Metal-Polymer
Composite
Metals non metallic, or semi-metallic elements NATURE OF Metal-Ceramic
Composites
Pure metals & combination of metallic SiO2 - Na2O - MgO MATERIALS
elements - Cu Al Ceramics

Polymers
Composites Non-Crystalline
Crystalline Structure
Materials consisting of two or more Bond between
Structure
MARK A
phases that are processed separately, atoms & molecules
Ceramic-Polymer
then bonded together to achieve Composites
superior properties

Explain about last week topic implementation/best practice in a real-life specific Brief analysis (your own argument) about the case study above, and
industry from qualified journal, case study, video, or project overview. consider theoretical framework / basic theory relevant to the topic.
During last week's class, I was given an introduction to the manufacturing From my perspective, first of all, I would say that the theory stated by
process. Essentially it is a designed procedure that results in physical or chemical Groover is true and also was explained last week where in class it was
changes to a starting work material with the intention of increasing the value of said that the manufacturing process could be seen from an economic
the material (Groover, 2012). A study case I’ll be taking regarding a topic comes stand point and a technical standpoint. Adding on to that, efficiency
from a journal regarding manufacturing process selection. From the case it is and effectiveness is one of the main goals of all company. Knowing
stated that there was a company, let’s call it “C company” that specialized in this I would fully agree with the usage of the “PRIMA matrix” from
manufacturing chemical tanks. Of course, when manufacturing certain products the study case. It also sees factors from materials, amount of
there will always be specifications (dimensions) for the product itself and there production, economy, etc.
would also be annual manufacturing requirements (minimum of units
produced). To maximize their manufacturing by looking at the efficiency and
effectiveness of their whole manufacturing process from start to beginning, they
would need to make selections regarding what process they would do. Therefore
here they use a manufacturing process matrix called “PRIMA selection matrix”.
With the help of this matrix, the company could determine the manufacturing
process that fits their product by just looking at a materials and quantity
perspective. Then they would get a series of manufacturing processes such as the
casting process, forming process, plastic & composite process, machining
process, and non-traditional machining process. Another implementation that is MARK C
added is the key candidate process of the “PRIMA matrix”. Where on a certain
process, let’s say when products enter the compression moulding stage, factors
such as economic consideration, typical application, design aspect, and quality
issues must be described and assigned properly to ensure that every process that Journal / Book / Case Study / Reference Link.
will be happening is within the manufacturing standard and boundaries so they Klocke, F.2011.Manufacturing Process I
Aachen: Springer
could get the end result that they want.
Groover, P.2012.Fundamental of Modern Manufacturing
Pennsylvania: John Wiley & Sons
Budinski, K.G & Budinski, M.K.2002. Engineering Materials: Properties and Selection
New Jersey: Pearson Education
MARK B Aslam, R., & Nadeem, E.A.2016. Instructors Engineering Materials MARK D
Lahore: Institute of Chemical Engineering and Technology
Swift, K.G.2013.Manufacturing Process Selection
Oxford: Elsevier

Please write your answer (using English) inside the related boxes, you may add your own additional art drawing at any place to make this resume becomes more
attractive. Your writing should be clear and neat. This form is not necessary to be color printed, a good quality photocopy is accepted.
Full Name : Timothy Yehezkiel Panjaitan
……………………………………………………………….. Weekly
Student ID 5010221030
: ……………………………………………………………….. Report
Course / Class Manufacturing Process/C
: ………………………………………………………………..
Topic Shaping Processes-Solidification (Metal Casting)
: ………………………………………………………………..
Rich Picture / Mind Map explanation about current weekly
Submission Date / # 10 September 2023/Week 3
: ……………………………………………………………….. topic or content (lesson learnt), use your own picture!

Due to this, production is


Expandable Mold
WHAT IS IT?
limited by the time required One of the 3 types of
Mold is sacrificed in order
to make the mold shaping processes
to remove the cast part Z
er O
high
g in O
s u ltin n rate M
s re ctio Pe
the m rmanent
Thu produ old is Mold
of du C A S T IN
rable fabricate F O R G IN
G
d ou
be us
make
m at
ed m erial and
a ny ti can
t METAL MACH
G
IN IN G
mes
Sand Casting
many
casti
ngs
to CASTING
pouring molten metal into a sand
mold, allowing the metal to solidify, Metals for Ferrous Casting Alloys
and then breaking up the mold to
remove the casting
Casting Casting Cast Iron
Steel
Types Permanent Mold Casting
Other Expendable-Mold Casting This method uses a metal mold made
Processes of two sections that are designed for Non-Ferrous Casting Alloys
A more verstaile version of sand an easy and precise opening and Allumunium Alloys
casting. Differences can be seen in closing Magnesium Alloys
the mold material composition Copper Alloys
Zinc Alloys
Shell Molding Slush Casting
Nickel Alloys
MARK A
Vacuum Molding Low-Pressure Casting
Expanded Polystyrene Process Vacuum Permanent-Mold Casting Titanium Alloys
Investment Casting Die Casting
Plaster Mold and Ceramic Mold casting Squeeze Casting Tin-based Alloys

Explain about last week topic implementation/best practice in a real-life specific Brief analysis (your own argument) about the case study above, and
industry from qualified journal, case study, video, or project overview. consider theoretical framework / basic theory relevant to the topic.
During last week's class, I was taught about engineering materials which where First of all, as we know engineering materials are the beginning of a
more in depth than the one we studied 2 weeks ago. The class covered sub- manufacturing process, it is the behavior of the material when
materials in metals, ceramics, polymers, and composites. All of these materials subjected to the particular forces, temperatures, and other physical
are always used during manufacturing process, since they’re the building blocks parameters of the process that determines the success of the
or the raw materials needed to manufacture a certain products. Products that manufacture. I want to highlight the theory that states “determines
are made with them will have the same characteristic as the materials. Let’s take the success of the manufacture”, this theory in my opinion would
a case from a tooth brush manufacturer, for their toothbrush handle most fully support the case study stated in part B. As in order for the
toothbrush uses plastic giving it a bit of flexibility, but there are some models manufacturer to get an item or a certain product that lives up to their
which use rubber as the material for their handle, resulting in a more plyable standard. They would not only need a good manufacturing system
handle. For manufacturer Choosing the wrong material would result in a bad and manufacturing process but they need the essential item which is
finished product, as when using a material with the wrong characteristic that a the materials. If they can find and use the right material that suits the
producer wanted for the product, would cost in a weird end-result. This is why characteristics they are looking for, then only then can the
the selection of engineering materials are very important. Manufacturer must manufacturing process be started in a good condition.
know about what material they need to use in the product. Not only that, by
knowing the material, manufacturer would know the mechanical and physical
aspect of the material, making it more easier to know how they would want to
process those materials. This study case involves through all other
manufacturing processes, ranging from lamp to even bicycles. Even if we look at MARK C
mass-production company, it is a must for them to always maintain and use the
right materials for their product so their product doesn’t receive backlash from
consumer and have a stagnant or even improvement on their products (This
would help to increase consumer trust on their products). Journal / Book / Case Study / Reference Link.
Groover, P.2012.Fundamental of Modern Manufacturing
Pennsylvania: John Wiley & Sons
Budinski, K.G & Budinski, M.K.2002. Engineering Materials: Properties and Selection
New Jersey: Pearson Education
Aslam, R., & Nadeem, E.A.2016. Instructors Engineering Materials
Lahore: Institute of Chemical Engineering and Technology
MARK B Bolton, W.1987.Engineering Materials 2 MARK D
Oxford: Butterworth-Heinemann
Shackelford, J.2005.Introduction to Material Science for Engineers
New Jersey: Pearson Higher Education

Please write your answer (using English) inside the related boxes, you may add your own additional art drawing at any place to make this resume becomes more
attractive. Your writing should be clear and neat. This form is not necessary to be color printed, a good quality photocopy is accepted.
Full Name : Timothy Yehezkiel Panjaitan
……………………………………………………………….. Weekly
Student ID 5010221030
: ……………………………………………………………….. Report
Course / Class Manufacturing Process/C
: ………………………………………………………………..
Topic Shaping Processes-Material Removal I
: ………………………………………………………………..
Rich Picture / Mind Map explanation about current weekly
Submission Date / # 24 September 2023/Week 5
: ……………………………………………………………….. topic or content (lesson learnt), use your own picture!

WHAT IS IT?
CATEGORIES EXAMPLES Material removal is essentialy the
action to remove excess material
ABRASIVE from the starting workpiece, so that
Non-Traditional
the resulting part is as desired.

CLASSIFICATION
Electron Beam
Grinding
Electrical Beaming

MACHINING One of the classification from


shaping process in processing
operations
MATERIAL
Laser Beam Ultrasonic

Turning

REMOVAL
Drilling

Milling

BENEFITS Categories
Machining based techniques
have a unique mechanic for
VARIABLES Abrasive - Machining - Non-traditional
A couple of variables that
TECHNIQUES
removing materials, this can Non-tradional, this method
help on energy-saving needs to be looked at includes the usage of non
Techniques is a very imporant traditional cuting & grinding
measurement when choosing machining
factor in material removal, as tools. Examples are: lasers,
techniques are when using machines there will electron beams, chemical
1. Machine depth of cut be heat production, this will erosion, electric discharge, or
2. Feed rate affect the result of material electrochemical energy, etc
3. Cutting speed removal
Machining, this includes
4. Cost-effectiveness Abrasive includes the the usage of machine
Negative Effect of usage of hard abrasive operations such as
Heat Production partical to do material turning, drilling, milling, MARK A
1. Dimensional sensitivity removal, examples for etc (Most Common)
2. Tool life this is grinding
3. Surface Roughness

Explain about last week topic implementation/best practice in a real-life specific Brief analysis (your own argument) about the case study above, and
industry from qualified journal, case study, video, or project overview. consider theoretical framework / basic theory relevant to the topic.
During last week's class (before the practicum), I was taught about metal casting From my prespective of view, i would say that metal casting is
which is essentially a way to create a part or a new product through the means of incredibly needed by manufacturing company wheter they work on
liquidizing metals and shaping it before it cools down. There are many categories automotive even to aerospace. Every single manufacturing that uses
of metal casting each with their own advantage and disadvantages, this range metal casting for their parts, would ofcourse need or use the most
from a cheaper price per item to production speed of the casting. A study case suitable one from the classification of metal casting. Wheter they are
we’ll be looking at here is the usage of metal casting in everyday life. As we know searching for maximum accuracy or even lowest price. They all have
there are many kinds of metal casting types, all with their pros and cons. Due to their own needs and choose the metal casting through analysis on
this companys now must choose the casting that is right for them. For the first which will give them the best output while also minimizing input. It
one we’ll be looking at aerospace industries. Aerospace industries really rely on is not as simple as being said to pour metal into a cast, there needs to
investment casting for their parts, this is due to aerospace fields needing parts be analysis and historical study on which material casting they
that are specific with high performance and high quality. This is align with the should use.
benefit of investment casting which is that it creates part with the highest degree
of correctness, leading to a really specific part and it would also outweigh the
disadvantage, as even though its expensive, it is what they need. Aerospace
fields can’t change to other type of casting that is cheaper but has a lower
accuracy than investment casting. Changing from a company to company
prespective, here will be looking at a company to customer kind of use on metal
casting. There are many company know working on metal casting fields, where MARK C
usually they can do most of the types but speciliaze on one of them. The relation
here is that, these company gives out services for one time casting. Where
customer can purchase a certain type of part that will be created by the company
through the means of metal casting. Companies on this field usually rely on sand Journal / Book / Case Study / Reference Link.
casting as they are cheaper but can still get the job done. One of the Groover, P.2012.Fundamental of Modern Manufacturing
Pennsylvania: John Wiley & Sons
disatvantages of this which is also outweight by the advantage is that the time Klocke, F.2011.Manufacturing Process 1
New York: Springer
for production is longer, if the item ordered is at a huge amount. Examplese of Davim, J.2015.Traditional Machining process
companies that have this kind of service is Cayuga Corporation, Impro Industries, New York: Springer
Ammen, C.1979.The Complete Handbook of Sand Casting
and Meteor Foundry. United States: The MacGraw-Hill Education
MARK B Faccenda, V.2003.Metal Casting Basics Book 2 MARK D
United Kingdom:World Gold Council
Stephens, B.2014.The Miniature Guide to Manufacturing
Toronto:Moulin Publication

Please write your answer (using English) inside the related boxes, you may add your own additional art drawing at any place to make this resume becomes more
attractive. Your writing should be clear and neat. This form is not necessary to be color printed, a good quality photocopy is accepted.
Full Name : Timothy Yehezkiel Panjaitan
……………………………………………………………….. Weekly
Student ID 5010221030
: ……………………………………………………………….. Report
Course / Class Manufacturing Process/C
: ………………………………………………………………..
Topic : Shaping Processes-Material Removal II
………………………………………………………………..
Rich Picture / Mind Map explanation about current weekly
Submission Date / # 1 October 2023/Week 6
: ……………………………………………………………….. topic or content (lesson learnt), use your own picture!
WHAT IS IT?
ECONOMIC Last week we covered all
classification, on material
Material removal is essentialy the
PRODUCT DESIGN removal-II we will go in action to remove excess material
CONSIDERATION depth in abrasive! from the starting workpiece, so that
the resulting part is as desired.

Machinability CLASSIFICATION
Influce of work material Cutting One of the classification from
to the end product Conditions
selecting the proper shaping process in processing
Tolerance & cutting conditions for a operations
Surface Finish given operation
Machining operations
Product Design
are used to produce
parts with defined
geometries to
Consideration
1. If possible, parts should be designed that do
MATERIAL
REMOVAL II
not need machining
tolerances and surface 2. Tolerances should be specified to satisfy
finishes functional requirements

Abrasive Type
3. Surface fi nish should be specified to meet
functional requirments

Grinding Picturized
Abrasive includes the usage of hard
1. Machined features such as sharp corners, abrasive partical to do material It use traditional ceramics for
edges, and points should be avoided Grinding removal abrasive products, such as grinding
2. Deep holes should be avoided
wheels and sandpaper. Using
3. Machined parts should be designed so they
can be produced from standard available Material removal using alumina and silicon carbide
stock abrasive is part of
4. and Many more traditional material EXAMPLES
Grinding removal process Grinding, Honing,
Centerless Grinding
Operations
1. Surface Grinding Combination Superfinishing, Polishing,
2. Cylindrical Grinding Parameter Grinding Wheel Parameter Buffing, Lapping, etc
3. Centerless Grinding
(Cutting Condition + Grinding Wheel Parameter)
1. Surface Finish
1. Abrasive Material Guidelines Grinding
2. Grain Size material removal process
Surface Grinding 4. Creep Feed Grinding 2. Forces and Energy
3. Temprature at Work Surface
3. Bonding Materials
1. Application Guidelines
2. Grinding Fluid accomplished by abrasive particles MARK A
Cylindrical Grinding
4. Wheeel Structure & Wheel Grade that are contained in a bonded
4. Wheel Wear 5. Grinding Wheel Specification grinding wheel rotating at very high
surface speeds.

Explain about last week topic implementation/best practice in a real-life specific Brief analysis (your own argument) about the case study above, and
industry from qualified journal, case study, video, or project overview. consider theoretical framework / basic theory relevant to the topic.
In last week class we got to learn more in depth regarding material removal on a From my prespective of view, i would say that material removal is
certain part. Where in one single part there could be done severa types of also an essential part in manufacturing process. We can see that not
material removal techniques using various machine in order to get the expected everytime end product can be created solely by the means of metal
end product. Industries nowadays uses every kind of material removal casting, therefore manufacturing companies would use these
techniques in order to achieve not only the end product that they want, but also material removal techniques/machines in order to achieve the
effeciency of the whole process, this includes material removal. What effeciency wanted end-product. Another thing to add is that i find it incredibly
here means is that parts of product created through the means of material brialliant for the start of companies that focus on material removal.
removal is made with the least possible time and least amount of money, As many other manufacturing companies would ofcourse want to
minimizing input and maximizing output. When we first think of material work with them to achieve a more effecient production process. This
removal, we might look at big manufacturing companies such as Toyota, Honda, could as a company with the focus of material removal, would have
and Kawasaki creates their own parts using mass production, one of the process better technologies and layout that would reduce bottleneck during
there of course the material removal. One thing to note here is that every production.
material removal techniques that they do now are mostly run through robots, as
it is no longer manpowered any more, this not only help with effeciency &
effectivity, but also with safety reason. But, as time goes on we now see
companies that actually have a sole focus on material removal, let’s take a look
at “Eagles Technologies” a company located in the US that have a service
dedicated to material removal. From saw cutting, drilling, precision deburring, MARK C
and laser ablation, they have it all. What’s more incredible is that eventhough
they are not as big as Toyota, Honda, Kawasaki. All of their machine is already
robotic and not human powered. By making a company with a focus on material
removal, this helps other companies to use their services and have a better Journal / Book / Case Study / Reference Link.
production system. As companies like this have one goal in common which is Groover, P.2012.Fundamental of Modern Manufacturing
Pennsylvania: John Wiley & Sons
reduction of production bottleneck. Stephens, B.2014.The Miniature Guide to Manufacturing
Toronto:Moulin Publication
Klocke, F.2011.Manufacturing Process 1
New York: Springer
Davim, J.2015.Traditional Machining process
New York: Springer

MARK B Bolton, W.1988. Production Technology - Processes, materials, and planning


London: Heinemann Professional Publishing Ltd
MARK D
Tukuru, O. I., et al. (2023). An overview of material removal processes and its industrial
application. E3S Web of Conferences, 391, 1–17. https://doi.org/10.1051/e3sconf/202339101078

Please write your answer (using English) inside the related boxes, you may add your own additional art drawing at any place to make this resume becomes more
attractive. Your writing should be clear and neat. This form is not necessary to be color printed, a good quality photocopy is accepted.

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