COURSE OUTLINE:

MEE 303 MANUFACTURING TECHNOLOGY (2 Units)

Sand testing and conditioning; pattern and mould making. Metal nucleation and solidification.
Foundry practice, cast testing and analysis fabrication methods, forming from liquid and particle-
stress. Introduction to special manufacturing processes. An introduction to the principle of metal
removal and the physics of metal cutting.The study of tool geometry requirements of modern
processes. Consideration of machine speeds, feeds, tolerance, and surface finish determinate as
related to both manually and numerically controlled machines

MEE 303 MANUFACTURING TECHNOLOGY (2 Units)

1. Introduction and Overview of Manufacturing Technology

2. Casting and Casting Processes
3. Material Removal Processes
4. Special Machining Processes
5. Course Projects

1. INTRODUCTIONAND OVERVIEW OF MANUFACTURING TECHNOLOGY

a. Manufacturing Technology
b. Materials, Processes and Systems in Manufacturing
c. Trends in Manufacturing Technology

1.1 Manufacturing Technology

 Manufacturing is any activity that involves making things

 While Technology refers to the application of science to provide things that were
needed or desire by the society and its members.
 The word manufacture is derived from two Latin words, manus(hand) and
factus(make) which means “made by hand”.
 However, modern manufacturing is accomplished by automated and computer-
controlled machinery.
 Manufacturing as a field of study can be defined in two ways:
 Technologically: Application of physical and chemical processes to alter the
geometry, properties, and/or appearance of a given starting material to make
parts or products. It also includes assembly of multiple parts to make
products.
 Processes to accomplish manufacturing involve a combination of
machinery, tools, power, and labour.
 Manufacturing involves sequence of operations. Each operation brings
the material closer to the desired final state.

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 Starting material Manufacturing Process Processed Part

Scrap and waste

Machinery

Tooling

labour
power
Fig. 1: Manufacturing (Technical process)

 Economically:Manufacturing is the transformation of materials into items of

greater value by means of one or more processing and/or assembly
operations.

Startingmaterial Material in processing Processed Part

N NNNN
addedNN
Value

Manufacturing
Process

Fig. 2: Manufacturing (Economic process)

 Manufacturing and production can be used interchangeably, but production has a

broader meaning than manufacturing. There is crude oil production but crude oil
manufacturing looks odd.
 Types of Industries: Industries are the enterprises and organisations that produce
or supply goods and services.
 Industries can be categorised into three (3)
 Primary industries cultivate and exploit natural resources-agriculture and
mining
 Secondary industries take the outputs of the primary industries and convert
them into consumer and capital goods- manufacturing, construction and
power utilities.
 Tertiary industries constitute the service sector of the economy-banking,
education, information etc.

1.2 Materials, Processes, and Systems in Manufacturing

1. Engineering materials are basically three: metals, ceramics, or polymers. In

addition, there are composites (mixtures of any of three). Differences in their
chemistries, physical and mechanical properties affect the manufacturing processes
that can be used to produce products from them. (Fig. 3)

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  Metals:
Metals used in manufacturing are usually alloys (two or more
elements, with at least one being a metallic element).
Metals and alloys can be divided into two:-
 ferrous:- steel (0.02% to 2.11% carbon) and cast iron (2% to
4% carbon).
 nonferrous:- Nonferrous metal and their alloys. (aluminum,
copper, gold, tin, zinc, etc.).
 Ceramics:
Compounds containing metallic and nonmetallic elements (clay,
alumina, silica, silicon carbide, nitrides).
For processing purposes, ceramics can be divided into
 Crystalline ceramics
 glasses
 Polymers:
Compounds formed of repeating structural units called mers, whose
atoms share electrons to form very large molecules.
Polymers usually contain carbon plus one or other elements, like
hydrogen, nitrogen, oxygen and chlorine.
Polymers are divided into three
 Thermoplastic polymers (polyethylene, polystyrene,
polyvinylchloride, and nylon).
 Thermosetting polymers (phenolics, amino resins, an
epoxies).
 Elastomers (natural rubber, neoprene, silicone, and
polyurethane).
 Composites:
Composites are materials consisting of two or more phases that are
processed separately and then bonded together to achieve properties
superior to those of its constituents.
Wood is a natural composite
Synthetic composite includes
 Glass fibers in a polymer matrix (e.g. fiber-reinforced plastic)
 Polymer fibers in a matrix of another polymer (epoxy-Kevlar
composite).
 Ceramic in a metal matrix (tungsten carbide in a cobalt binder).
Properties of a composite depend on its components, the physical
shapes of the components, and the way they are combined to form the
final material.
2. Manufacturing processes is a procedure that results in physical and/or chemical
changes to a starting work material with the intention of increasing the value of that
material. It can be divided into two: (Fig. 4)
 Processing Operation:-Transforming a work material from one state of
completion to a more advanced state that is closer to the final desired
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 product. It adds value by changing the geometry, properties, or appearance
of the starting material. Three categories of processing operations are
distinguished: Shaping, Property-enhancing, and surface processing.
Shaping Processes: It usually involves application of heat,
mechanical force, or a combination of these to effect a change in
geometry of the work material. It can be categorised into:
Solidification processes (when the starting material is heated liquid
or semifluid that cools and solidifies to form the part geometry),
particulate processing (the starting material is a powder, and the
powders are formed and heated into the desired geometry),
deformation processes (the starting material is a ductile solid that is
deformed to shape the part) and material removal processes (the
starting material is a ductile or brittle solid, from which material is
removed so that the resulting part has the desired geometry).
Property-enhancing Processes: These processes are performed to
improve mechanical or physical properties of the work material. They
do not alter the shape of the part. The most important property-
enhancing processes involve heat treatments (annealing for metals
and glasses, sintering for powdered metals and ceramics)
Surface Processing Operations: Include cleaning(includes both
chemical and mechanical processes to remove dirt, oil, and other
contaminants from the surface), surface treatments ( include
mechanical working such as shot peening and sand blasting, and
physical processes such as diffusion and ion implantation) and
coating and thin film deposition processes (application of coating
material to the exterior surface of the work part:-electroplating,
anodizing, painting, physical vapour deposition and chemical vapour
deposition).
 Assembly Operation: - This is the second basic type of manufacturing
operation in which two or more separate parts are joined to form a new
entity. It could be permanent joining processes (welding, brazing, soldering,
adhesive bonding, rivets, press fitting ad expansion fits) or semi-permanent
joining processes (using screws, bolts and other threaded fasteners).

3. Production Systems are the systems that allow a manufacturing firm to efficiently
accomplish its production. They consist of people, equipment, and procedures
designed for the combination of materials and processes that constitute a firm’s
manufacturing operations. Production systems can be divided into two categories:
Production facilities and manufacturing support systems.(Fig. 5)
 Production Facilities: consist of the factory and the production, material
handling, and other equipment in the factory. The equipment comes in direct
physical contact with the parts and/or assemblies as they being made.
 Manufacturing support systems: These systems design the processes and
equipment, plan and control the production orders, and satisfy product
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 quality requirements. Most of these support systems do not directly contact
the product, but they plan and control its progress through the factory.
Manufacturing support functions are often carried out in the firm by people
organized into; manufacturing engineering, production planning and control
and quality control.
Manufacturing engineering department is responsible for deciding
what processes should be used to make the parts and assemble the
products. It also involves in designing and ordering the machine tools
and other equipment used by the operating departments.
Production planning and control department is responsible for
solving the logistics problem in ordering materials and purchased
parts, scheduling production, and making sure that the operating
departments have the necessary capacity to meet the production
schedules.
Quality control department it develops the means to make sure that
the products conform to specifications and satisfy customer
expectation.

1.3 Trends in Manufacturing Technology

Materials, processes, and systems used in manufacturing are being affected

by several trends motivated by technological and economic factors. Four of these trends
are to be considered. They are; lean production and Six Sigma, globalization,
environmentally conscious manufacturing and microfabrication and nanotechnology.

1. Lean Production and Six Sigma: it can be defined as “doing more work with
fewer resources”. It means that fewer workers and less equipment are used to
accomplish more production in less time, and yet achieved higher quality in
the final product. The major objective in lean production is the elimination of
waste. While Six Sigma can be defined as “a quality-focused program that
utilises worker teams to accomplish projects aimed at improving an
organisation’s operational performance.’ It objective is to reduce variability in
the company’s processes and products to increase customer satisfaction.
2. Globalisation and Outsourcing: Globalisation has enabled a freer flow of
goods and services, capital, technology, and people among regions and
countries. Globalisation is closely related to outsourcing which is the use of
outside contractors to perform work that was traditionally accomplished in-
house. This trend has greatly reduced cost of labour, expand the market
facilities with higher profits.
3. Environmentally Conscious Manufacturing: It refers to programs that seek
to determine the most efficient use of materials and natural resources in
production, and minimise the negative consequences on the environment.
These programs include; green manufacturing, cleaner production,
sustainable manufacturing and design for environment. These programs
could be achieved through:

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  Selection of materials that require minimum energy to produce.
 Selection of processes that minimise waste of materials and
energy.
 Designing parts that can be recycled or reused
 Designing products that can be readily disassembled to recover
the parts.
 Designing products that minimise the use of hazardous and toxic
materials.
 Giving attention to how the product will be disposed of at the end
of its useful life.

4. Microfabrication and Nanotechnology: Another trend in manufacturing is

the emergence of material and products whose dimensions are sometimes so
small that they cannot be seen by the naked eye. In extreme cases, the items
cannot even be seen under an optical microscope. Microfabricationrefers to
the process needed to make parts and products whose features sizes are in the
micrometer range (µ1m=10-3mm=10-6m). While nanotechnology refers to
materials and products whose feature sizes are in the nanometer scale
(1nm=10-3µm=10-6mm=10-9m), a scale that approaches the size of atoms and
molecules.