Ch0.ppt

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Chapter 0
General Introduction

Materials in an Automotive Engine
Figure I.1 Section of an automotive engine - the Duratec V-6 - showing various
components and the materials used in making them. Source: Courtesy of Ford
Motor Company. Illustration by David Kimball.

Components in Products
• Some products are a single
components (nail, bolt, fork, coat
hanger, etc.)
• Some products are assemblies of
many components (ball point pens,
automobiles, washing machines, etc.)
• All components are manufactured.
• Manufacturing means, literally, “Made
by Hand”.

History of Manufacturing (until 1700)

History of Manufacturing (1700-1960)

History of Manufacturing (1960-2000s)

Materials Selection for Paper Clips
Figure I.2 Examples of the wide variety of materials and geometries for paper clips.
Questions for consideration:
• What material properties are
required?
• What manufacturing attributes are
required?
• Would the material and processing
strategy change if the desired
quantity was 10,000 vs. 1 million
per day?

Manufacture of Light Bulbs
Figure I.3a Components of a common
incandescent light bulb. Source: Courtesy
of General Electric Company.
Figure I.3b Manufacturing steps in
making an incandescent light bulb.
Source: Courtesy of General Electric
Company.

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.
(b) Chart showing general
product flow in concurrent
engineering, from market analysis
to selling the product. Source:
After S. Pugh, Total Design.
Addison-Wesley, 1991.
Product Design Process

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.

Manufacturing Characteristics of Alloys

Baseball Bat Cross-sections
Figure I.6 Cross-sections of baseball
bats made of aluminum (top portion)
and composite material (bottom
portion).

Manufacturing Processes: Casting
Figure I.7a Schematic illustration of various casting processes

Manufacturing Processes: Forming and Shaping
Figure I.7b Schematic illustration of various bulk deformation processes

Figure I.7c Schematic illustration of various sheet metal forming processes

Figure I.7d Schematic illustration of
various polymer processing methods

Manufacturing Processes: Machining
Figure 1.7e Schematic illustrations of various
machining and finishing processes.

Manufacturing Processes: Joining
Figure I.7f Schematic illustration of various joining processes

Laser Cutting
Figure I.8 Cutting sheet metal with
a laser beam. Source: Courtesy of
Rofin-Sinar, Inc. and Manufacturing
Engineering Magazine, Society of
Manufacturing Engineers

Hip Replacement
Figure 1.9 Components of a total hip
replacement. Source: Courtesy of Zimmer, Inc.

Manufacturing of Hip Replacement
Figure 1.10 (a) Manufacturing steps in the production of a roll-formed and machined
total hip replacement stem; (b) Manufacturing steps in the production of a forged stem.
Hip stems can also be produced by investment casting, metal injection molding, insert
injection molding, and assorted other processes. Source: Courtesy of Zimmer, Inc.

Microscopic Components
Figure I.11 (a) Microscopic gears with dust mite. Source: Courtesy Sandia
National Laboratory; (b) A movable micromirror component of a light sensor.
Source: Courtesy of Richard Mueller, University of California at Berkeley.

Salt and Pepper Shakers
Figure I.12 A salt and pepper mill set. The two
metal pieces (at the bottom) for the pepper mill
are made by powder-metallurgy techniques.
Source: Reproduced with permission from
Success Stories on P/M Parts, Metal Powder
Industries Federation, Princeton, NJ, 1998.

Automated welding of automobiles
Figure I.13 Automated spot
welding of automobile bodies in
a mass production line. Source:
Courtesy of Ford Motor
Company.

Application of CAD/CAM to make sunglasses mold
Figure I.14 Machining a mold
cavity for making sunglasses.
(a) Computer model of the sunglass
as designed and viewed on the
monitor.
(b) Machine the die cavity using a
computer numerical-control milling
machine
(c) Final product. Source: Courtesy of
Mastercam/CNC Software, Inc.

Hourly Compensation for Production Workers

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