IMP

Age of mechanization, automation and computer

integrated manufacturing - today's competitive
manufacturing era of high industrial development
- Advancement of civilizations because of
improvement of materials

ENGINEERING MATERIALS AND

MANUFACTURING TECHNOLOGY
A. Material Science and Engineering
B. Manufacturing Engineering
MANUFACTURING - raw materials to assemble
Deciding material with properties required shapes
- Using the right material for the right job - Country level of manufacturing directly
- Impossible to memories all materials so its related with economic health
better to understand the key factors that - Has design, selection of raw materials and
determines the properties of materials. sequence of process
- More manufacturing industries is more
MATERIALS TEACHING progressive
Scientific approach (knowing the characteristics) - MANUS (hand), FACTUS (make) “made
before advancing to design driven approach by hand”
- Backbone of the industry
CLASSIFICATION OF ENG MATERIALS - As a designer understand the limitations
(tolerances, production rates, economic
❖ Metallics rates)
➢ Metals - Manufacturing staff should know the
➢ Alloys - Manufacturing process
➢ Intermetallic - Materials being processed
➢ compounds - Tools and equipment
- Future methods engineers should know
❖ Polymerics - 5 M’s: Man, Machine, Material,
➢ Plastics Methods, Money (capital)
➢ Rubber
➢ Elastomers ● System of Manufacturing - organizing
➢ Textile people according to their expertise to have
➢ leather an effective and smooth production. Ways
of organizing people and equipment so that
❖ Ceramic production can be performed more
➢ Glasses efficiently
➢ Porcelain ● Division of Labor - Dividing the total work
➢ Semiconductors into tasks and having individual workers
➢ Stoneware each become a specialist at performing only
➢ Cement one task.

PROPERTIES OF MATERIALS 1st INDUSTRIAL REVOLUTION

1. Mechanical: strength, toughness, hardness (1760-1830) - agriculture and handicraft to industry
2. Physical : density, melting point, magnetic and manufacturing
3. Chemical: oxidation, corrosion, toxicity - Started in england to other countries
4. Manufacturing: formability, weldability INVENTIONS:
Engineering materials: ● Watt’s steam engine - first machine
checking of materials that is needed for production ● Machine tools
Deterioration, cost, resource depletion ● Textile industry
Where it came from and how it can affect the product making ● Factory system
2nd INDUSTRIAL REVOLUTION ii. Near-shore outsourcing -
- Control the activities of large population of service provider in a nearby
workers country
- movement’s leaders included Frederick
W. Taylor (1856-1915), Frank Gilbreth 3. Environmentally conscious
(1868-1924) and wife Lillian (1878-1972). manufacturing – manufacturing should be
- Late 1800s green. refers to programs that seek to
determine the most efficient use of materials
● mass production and natural resources in production, and
● Scientific management movement. Father: minimize the negative consequences on the
Frederick W. Taylor (1856–1915) environment
FEATURES: a. DFE (DESIGN FOR
1. Motion study - finding best method ENVIRONMENT) - considering
2. Time study - work standard environment before making products
3. Use of standards in industry - Minimum energy to produce
4. Piece rate system - pay depending on - Minimizes waste of materials
products made - Parts can be recycled
5. Cost accounting(identifying the cost of - Can be disassembled to
product), data collection, record keeping recover
- Minimize hazard and toxic
- How products will be
● Assembly lines/ production lines - one disposed
output to another line to continue the
production. Ex. Mitsumi 4. Microfabrication and nanotechnology
- Introduced by Henry ford Microfabrication – processes needed to
- For mass production make parts and products whose features
● Electrification of factories sizes are in the micrometer range, eg
○ 1881 – first electric power DVDs, CDs
generating station built in New York Nanotechnology – features sizes are in the
City, USA. nanometer scale, eg ultra thin coatings for
○ 1920 – electricity had overtaken catalytic converters, flat screen monitors
steam as the principal power source and cancer drugs.
in the US.
○ 20th century –more technological 8 FORMS OF WASTE:
advances, many developments 1. T - Transportation
resulted in the automation of 2. I – Inventory
manufacturing 3. M - Motion
4. W – Waiting
TRENDS IN MANUFACTURING 5. O – Overproduction
1. Lean production and six sigma 6. O – Overprocessing
Lean production – “doing more work with 7. D – Defects
fewer resources” to have less waste 8. S – Skills (Underutilization of employee
Six Sigma – a quality-focused program that skills or lack of training)
utilizes worker teams to accomplish projects
aimed at improving an organization’s Technical process in manufacturing:
operational performance. Improving workers Starting material - manufacturing process -
ability to enhance operational performance processed part (scrap/waste)
2. Globalization – products being distributed
globally because it is not hard today. Economic process in manufacturing:
enables a freer flow of goods and services, Value added in the process - value added after
capital, technology, and people among improving
regions and countries. Non value adding process - needed to cost
a. Outsourcing – refers to the use of
outside contractors to perform work
that are traditionally accomplished
in-house.
i. Offshore outsourcing -
service provider in a different
country
Manufacturing Industries and Products MATERIALS IN MANUFACTURING
Industry consists of enterprises and organizations
that produce or supply goods and services. Metals – usually alloys, are composed of two or
more
Categories: elements, with at least one metallic element.
Primary industries – cultivate and exploit natural Two basic groups:
resources, such as agriculture and mining. 1. Ferrous – are based on iron, which
Secondary industries – take the outputs of the includes steel (0.02%-2.11% carbon) and
primary industries and convert them into consumer cast iron (2%-4% carbon). Pure iron has
and capital goods. limited commercial use, but when alloyed
Tertiary industries – constitute the service sector of with carbon, iron has more uses and greater
the economy. commercial value.
2. Nonferrous – include other metallic
elements and their alloys like pure metals
and alloys of aluminum, copper, gold,
magnesium, nickel, silver, tin, titanium, zinc,
and other metals.

Ceramic – is a compound containing metallic (or

semi-metallic) and nonmetallic elements. Typical
non metallic elements – oxygen, nitrogen,
Carbon
Traditional ceramics:
1. Clay – used in making bricks
Two major classes of final products:
2. Silica –basis for nearly all glass products
1. Consumer goods – to consume immediately/ for
3. Alumina and silicon carbide – abrasive materials
self usage. products purchased directly by
for grinding
consumers, such as cars, tires, and personal
computers.
Newer ceramics include:
2. Capital goods – used to create or produce for
1. Carbides – used as cutting tool materials like
businesses. are those purchased by companies to
tungsten carbide and titanium carbide
produce goods and/or provide services. These
2. Nitrides – used as cutting tools and grinding
include aircraft, computers, medical apparatus, and
abrasives
construction equipment. Most of these capital
goods are used by service industries
For processing purposes, ceramics can be divided
into:
MANUFACTURED PRODUCTS:
1. Crystalline ceramics – from powders then fired
1. Material
2. Glasses – melted and casted, then formed
2. Components
(process
3. supplies
i.e. traditional glass blowing)

BUILDING BLOCKS OF MANUFACTURING

Polymer – is a compound formed of repeating
Materials, Processes, Systems
structural units called mers, whose atoms share
electrons to form very large molecules. Usually
History of Materials
consists of carbon plus one or more other
The development of materials and man’s ability to
elements, such as hydrogen, nitrogen, oxygen, and
process them is linked to the history of man
chlorine.
● Stone Age
Three categories of polymers:
● Copper and Bronze Age
1. Thermoplastic polymers - subjected to multiple
● Iron Age
heating and cooling cycles without substantially
● Steel Age
altering the molecular structure of the polymer.
● The current age is that of plastics,
Examples are polyvinylchloride (PVC) and nylon.
composite materials, and exotic alloys
2. Thermosetting polymers - chemically transform
Raw Materials
(cure) into a rigid structure on cooling from a
Before raw materials can be turned into industrial
heated plastic condition, e.g. amino resins, epoxies.
goods, they must first be obtained and then
converted using the primary manufacturing
3. Elastomers- exhibit significant elastic behavior,
process.
e.g. natural rubber, silicone, and polyurethane.
Composites– do not really constitute a separate
category of materials; they are mixtures of the other
three types. These consist of two or more phases
that are processed separately and then bonded
together to achieve properties superior to those of
its constituents.

Phase - homogeneous mass of material, such as

an aggregation of grains of identical unit cell
structure in a solid metal.

Matrix – usual structure of a composite, consists of

particles or fibers of one phase mixed in a second
phase. Example applications are boat hulls, tennis
rackets, fishing rods, car bodies, and aircraft
components.

Manufacturing Processes

Material Removal
Common machining operations (mostly applied to
solid metals):

1. Turning – single-point cutting tool removes metal

from a rotating workpiece to reduce its diameter
2. Drilling – rotating drill bit is fed into the work to
create a round hole
3. Milling – workpart is fed past a rotating cutter
with multiple edges
4. Grinding - the reduction of something to small
particles or powder by crushing it.

How are they converted?

Thermal Processing - steelmaking,
smelting.
Chemical Processing - polymer
formation, papermaking.
Mechanical Processing - lumber
manufacturing, crushing rock.

SECONDARY PROCESSING
1. Casting and molding - Pouring or forcing
liquid material into a prepared mold. It
solidifies then is removed from the mold.
2. Forming - Using force to cause a material to
take permanent shape, using a die, mold, or
roll.
3. Separating - Converting a material to size
and shape by removing excess material
through cutting or shearing.
4. Conditioning - Using heat, mechanical force
or chemical action to change the internal
properties of a material. DRYING, HEAT
TREATING, FIRING.
5. Assembling - Temporarily or permanently
holding two or more parts together
6. Finishing - Protecting and/or adding beauty
to the surface of a material.