IE 337 W10 Lecture 1 Introduction

IE 337: Materials & Manufacturing
Processes
Lecture 1:
Introduction
Chapter 1 & 5
Course Instructor
Brian K. Paul
PhD 1995, Penn State
Office:
322 Rogers Hall
E-mail: [email protected]
Phone: 737-7320
Office Hours:
T: 11:30 noon
R: 11:30 13:00
2
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?
3
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/
4
Lab Instruction
Mr. Barath Palanisamy (Instructor)
Ms. Negar Abolhassani (co-Instructor)
Steve Etringer (Technician)

Lab
126 Rogers Hall
5
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
6
Grading
Homework (6): 15%
Midterm: 25%
Final: 35%
Laboratory (9): 25%
7
Learning Outcomes
1. State basic properties of materials and apply these

properties to manufacturing process and product
design.
2. Compare and contrast the design and production
advantages of traditional mechanical manufacturing
processes (casting, forming, machining, and joining).
3. Evaluate material-process-geometry relationships in
manufacturing processes.
4. Differentiate advanced mechanical manufacturing
processes e.g. micro-scale and nano-scale
technologies.
8 IE 337: Materials & Manufacturing Processes
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
9
Introduction to Materials & Processes
Material-Geometry-Process Relationships
Manufacturing Materials
Manufacturing Processes
10
What is Manufacturing?
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
11
Material-Process-Geometry Relationships
Function Role of
Prod Engr
Material Geometry
Role of
Process Mfg Engr

Complexity in Manufacturing
Materials: 106
metals, ceramics, polymers, composites
Processes: 105
process conditions are ~
Properties: 102
applications are ~
13
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
14
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
15
Manufacturing & Globalization
16
Tracking Manufacturing Problems
Exploding tires, 2004 Melamine in milk, 2008
Toxic toys, 2007 Medicines, 2006

17
Transformations
China over 2000 years
18
Materials in Manufacturing
Most engineering materials can be classified

into one of four basic categories:
1. Metals
2. Ceramics
3. Polymers
4. Composites
19
Processing Operations
Three categories of processing operations:
1. Shaping operations - alter the geometry of the

starting work material
2. Propertyenhancing operations - improve physical

properties of the material without changing its shape
3. Surface processing operations - clean, treat, coat, or

deposit material onto the exterior surface of the work
20
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
21
Solidification Processes
Starting material is heated sufficiently to transform it
into a liquid or highly plastic state
Examples: casting for metals, molding for plastics
22
Deformation Processes
Starting workpart is shaped by application of forces
that exceed the yield strength of the material
Examples: (a) forging, (b) extrusion
23
Material Removal Processes
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

24
Assembly Operations
Two or more separate parts are joined to

form a new entity
Types of assembly operations:

1. Joining processes create a permanent joint.
Examples: welding, brazing, soldering, and adhesive
bonding
2. Mechanical assembly fastening by mechanical
methods
Examples: use of screws, bolts, nuts, other threaded
fasteners; press fitting, expansion fits
25
PropertyEnhancing 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
26
Surface Processing
1. Cleaning - chemical and mechanical processes to

remove dirt, oil, and other contaminants from the
surface
2. Surface treatments - mechanical working such as
sand blasting, and physical processes like diffusion
3. Coating and thin film deposition - coating exterior
surface of the workpart
Several surface processing operations used to

fabricate integrated circuits
27
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
28
Quality
Dimensional bulk and surface
Properties bulk and surface
Economics
Cycle time
Materials utilization
Flexibility
Tooling development
Setup time
Cycle time

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

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
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
32
Comparing Processes

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
44
Next Class
Metals
From Chapters 2 and 3
45

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What are the key categories of manufacturing materials discussed?

What are the key categories of manufacturing materials discussed?

What are the key categories of manufacturing processes discussed?

What are the key categories of manufacturing processes discussed?

IE 337: Materials & Manufacturing

Labs: 126 Rogers

Steve Etringer (Technician)

Homework (6): 15%

Laboratory (9): 25%

1. State basic properties of materials and apply these

Make-up Work & Absences use memorandum format

12 IE 337: Materials & Manufacturing Processes

Wilbur & Orville Wright, 1903

Exploding tires, 2004 Melamine in milk, 2008

Toxic toys, 2007 Medicines, 2006

China over 2000 years

Most engineering materials can be classified

Three categories of processing operations:

1. Shaping operations - alter the geometry of the

2. Propertyenhancing operations - improve physical

3. Surface processing operations - clean, treat, coat, or

Solidification Processes - starting material is a

Deformation Processes - starting material is a ductile

Material Removal Processes - starting material is a

Assembly Processes - two or more separate parts

Excess material removed from the starting workpiece

Turning Drilling Milling

Two or more separate parts are joined to

Types of assembly operations:

Performed to improve mechanical or physical

1. Cleaning - chemical and mechanical processes to

Several surface processing operations used to

2. Properties Identify candidate Material(s)

3. Material Identify required Processing

29 IE 337: Materials & Manufacturing Processes

30 IE 337: Materials & Manufacturing Processes

It is desirable to minimize waste and scrap in part

33 IE 337: Materials & Manufacturing Processes

The key design responsibility of a

From Chapters 2 and 3

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