Lecture 1

Course MAE 3344 Introduction to Manufacturing Engineering and Technology
Professor John J. Mills The College of Engineering, The University of Texas at Arlington
Return to Overview Slide
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Introduction
Overview of First Week
Statement of course goals Overall class schedule Statement of assumptions and policies
Introductory overview of the larger issues

Definitions - "Manufacturing vs manufacturing" Basic concepts The importance of Manufacturing Dimensions of Manufacturing Future trends in Manufacturing
Summing up

Professor John J. Mills: Email: jmills@mae.uta.edu; Tel (817) 272-7366
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Some guiding principles

Important skills for engineers, in order of importance:

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What is Manufacturing?
How do we make these?

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Course Goals
To bring to the students an appreciation for the complexity, depth and breadth of Manufacturing To provide students with an understanding of the importance of manufacturing process to the economy and to design decisions To provide students with an understanding of manufacturing processes
Concepts Examples Application in the real world Significance to design
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Prerequisites:
Assumptions for Course
Solid Mechanics (course MAE 2312)

Stress-strain relationships Elastic behavior Elastic/plastic flow
Materials science (course MAE 2321)

Basic mechanical, chemical and physical properties of materials Relationships between these macroscopic properties and the electronic, crystalline and microscopic properties
The student remembers something of forces, energy, power, heat transfer and fluid flow Design methods and principles are covered in other courses
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Overall Approach for Course

Course will consist of a mixture of Lectures Labs (On Fridays)
Tours of local companies Discussions Quizzes Games/simulations
Homework Final exam (optional)

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Course Policies
Attendance only critical for quizzes and final exam. Final exam will be optional dependent on grade Material presented will not always be in the book Quizzes will be mostly based on problems in the book Late Homework will be accepted by fax or email until the solutions are posted on the web. Late homework will be assessed a penalty which will depend on how late it is. Lectures will be available on-line as downloadable programs or as linked world wide web pages Home page http://www-woolf.uta.edu/mills/mantech/ Dr Mills will answer questions through email Dr Mills Office Hours are 9:00am-10:am, 2:00 - 4:00pm Monday, Wednesday and Friday, Room WH 215
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Course Scoring
Quizzes count for 40% of total grade (5 @ 80) Homework counts for 30% of total grade (6 @ 50) Optional Final counts for 30% of total grade (1@ 300) Some Homework will be scored on the clarity of your writing Answers to quizzes and homework and your grades will be available on the home page
Home page mantech

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Possible Students
Engineering majors who want to enter
a manufacturing career a design career
Engineering majors looking for general information about Manufacturing

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The Book and Suggested Reading

The Book
Manufacturing Engineering and Technology, 4th Edition by S. Kalpakjain, published by Addison Wesley

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Suggested Reading
21st Century Manufacturing, by Paul Wright, published by Prentice Hall, 2001 The New Manufacturing Engineer by M.J. Terminie, published by The Society of Manufacturing Engineers, 1996 Designing for Economical Production by H.E. Trucks, published by the Society of Manufacturing Engineers, 1987 "Handbook of Product Design for Manufacturing," James G. Bralla, Editor, McGraw-Hill, 1986

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Type of Course
Manufacturing is an "Integration" Course It integrates your knowledge of:
Materials Statics/dynamics Phase changes/crystal growth Fluid flow, statistics, control, etc
By this we mean that you will have to apply your knowledge of these fields

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Materials
Nature of materials
Metals, ceramics, glasses, plastics, composites,
Mechanical properties
Stress strain behavior
Microstructure/properties relationships
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Statics/dynamics

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Phase change/crystal growth

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Fluid flow

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Examples - Casting
Fluid flow Heat Transfer Phase changes Crystal growth in pure metals and alloys

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Examples - Rolling
Vector forces Relationships among force, power and energy Effect of deformation on crystal structure Effect of temperature on microstructure (heat treating) Machine dynamics

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Examples - Material Removal

Shear stress strain behavior Vector forces Relationships among force, power and energy and shearing energy Machine dynamics Thermodynamics and material expansion

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Examples - Powder Processing for metals, ceramics and plastics

Surface science Thermodynamics Effect of heat on microstructure Sintering Flow and rheology of powders
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What is Manufacturing?
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How do we make these?

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Definitions
Manufacturing manufacturing

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Definition of "Manufacturing"
Big "M" Manufacturing

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Definition of "manufacturing"
Little m "manufacturing" (production)

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Little "m" manufacturing is all about
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Manufacturing
Societal pressures, Government regulations, company plans and policies, etc
Raw material
Customer needs
Products
manufacturing
People, money, machines and automation Return to Overview Slide

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The manufacturing Process

Materials Science, Statics, Dynamics, Thermodynamics, Fluid dynamics
Raw Material
Material Transformation Processes
Products
Assembly
Machines and Automation

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manufacturing Process Overview

SFF Pressing Injection Molding Blow molding Firing/ Sintering
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Powders
Raw Material
Products
Stamping
Continuous Casting/Rolling
Sheet metal forming
Assembly
Finishing
Rolling
Ingot casting
Molten Material
Forging/ Press forming
Machining
Extruding
Casting Shapes
Single crystal pulling Special
Increasing level of detail

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The ability to create shapes, components and assembled products relies on several physical phenomena
Fundamentals of manufacturing - Concepts
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Fundamentals of manufacturing - Concepts
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The method chosen depends on the material and the shape and properties required

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Liquid to solid phase transformation
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Material Flow

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Stress/strain conditions
Pure Compressive Open die forging
Pure Tensile Drawing

Pure Shear Cutting, machining, turning

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Combined Stress States

Rolling
Mostly compressive with some shear
Forging
Extremely complex stress states
Extrusion
Combination of high compressive and shear stresses
Bending
Mostly shear with tensile and compressive components
Stretching with bending

Mostly shear with only tensile components
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Combined Stress States

Machining
Highly complex stress combination with high levels of shear causing fracture in a controlled manner

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Powder Processing
Takes advantage of the ability of powders to flow like a liquid and fill complex shapes
Can be dry powders or slurries (particles suspended in a liquid The powders can be compacted by
Pressure Extracting the liquid
This forms a green body which is friable and weak Heating to high temperatures causes the powder particles to "sinter" or fuse together and for a strong, nearly 100% dense product

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Glass and Plastic Forming

Similar to metal bulk deformation Silicate glasses have no yield stress but require high temperatures for flow Plastics have a yield stress but require only room or modest temperatures to allow flow behavior

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Wrap up
Introduction
Statement of course goals Overall class schedule Statement of assumptions and policies
Introductory overview of the larger issues

Definitions - "Manufacturing vs manufacturing" Basic concepts


Lecture 1

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Course MAE 3344 Introduction to Manufacturing Engineering and Technology

Return to Overview Slide

Overview of First Week

Introductory overview of the larger issues

Return to Overview Slide

Some guiding principles

Return to Overview Slide

How do we make these?

Assumptions for Course

Solid Mechanics (course MAE 2312)

Materials science (course MAE 2321)

Overall Approach for Course

Homework Final exam (optional)

Return to Overview Slide

Return to Overview Slide

Engineering majors looking for general information about Manufacturing

Return to Overview Slide

The Book and Suggested Reading

Return to Overview Slide

Return to Overview Slide

Return to Overview Slide

Stress strain behavior

Return to Overview Slide

Phase change/crystal growth

Return to Overview Slide

Return to Overview Slide

Return to Overview Slide

Return to Overview Slide

Examples - Material Removal

Return to Overview Slide

Examples - Powder Processing for metals, ceramics and plastics

Return to Overview Slide

How do we make these?

Return to Overview Slide

Return to Overview Slide

Return to Overview Slide

Little "m" manufacturing is all about

Return to Overview Slide

People, money, machines and automation Return to Overview Slide

The manufacturing Process

Material Transformation Processes

Machines and Automation

Return to Overview Slide

manufacturing Process Overview

Sheet metal forming

Forging/ Press forming

Increasing level of detail

Return to Overview Slide

Fundamentals of manufacturing - Concepts

Return to Overview Slide

Fundamentals of manufacturing - Concepts

Return to Overview Slide

Liquid to solid phase transformation

Return to Overview Slide

Return to Overview Slide

Pure Compressive Open die forging

Pure Tensile Drawing

Return to Overview Slide

Combined Stress States

Stretching with bending

Combined Stress States

Return to Overview Slide

Return to Overview Slide

Glass and Plastic Forming