Manufacturing Engineering

General Introduction

Materials in an Automotive Engine

Figure I.1 Section of an automotive engine - the Duratec V-6 - sho ing various com!onents and the materials used in ma"ing them. Source# $ourtes% of Ford Motor $om!an%. Illustration &% David 'im&all.

$om!onents in (roducts
) Some !roducts are a single com!onents *nail+ &olt+ for"+ coat hanger+ etc., Some !roducts are assem&lies of man% com!onents *&all !oint !ens+ automo&iles+ ashing machines+ etc., All com!onents are manufactured. Manufacturing means+ literall%+ -Made by Hand..

) )

/istor% of Manufacturing *until 1011,

/istor% of Manufacturing *1011-1261,

/istor% of Manufacturing *1261-3111s,

Materials Selection for (a!er $li!s

5uestions for consideration# ) 6hat material !ro!erties are re7uired8 ) 6hat manufacturing attri&utes are re7uired8 ) 6ould the material and !rocessing strateg% change if the desired 7uantit% as 11+111 vs. 1 million !er da%8

Figure I.3 E4am!les of the ide variet% of materials and geometries for !a!er cli!s.

Manufacture of 9ight :ul&s

Figure I.;a $om!onents of a common incandescent light &ul&. Source# $ourtes% of General Electric $om!an%.

Figure I.;& Manufacturing ste!s in ma"ing an incandescent light &ul&. Source# $ourtes% of General Electric $om!an%.

(roduct Design (rocess

Figure I.< *a, $hart sho ing the various ste!s involved in design and manufacturing a !roduct. De!ending on the com!le4it% of the !roduct and the t%!e of materials used+ the time s!an &et een the original conce!t and the mar"eting of the !roduct ma% range from a fe months to man% %ears. *&, $hart sho ing general !roduct flo in concurrent engineering+ from mar"et anal%sis to selling the !roduct. Source# After S. (ugh+ Total Design. Addison-6esle%+ 1221.

=edesign of (arts

Figure I.> =edesign of !arts to facilitate assem&l%. Source: =e!rinted from G. :oothro%d and (. De hurst+ Product Design for Assembly+ 12?2. $ourtes% of Marcel De""er+ Inc.

Manufacturing $haracteristics of Allo%s

:ase&all :at $ross-sections

Figure I.6 $ross-sections of &ase&all &ats made of aluminum *to! !ortion, and com!osite material *&ottom !ortion,.

Manufacturing (rocesses# $asting

Figure I.0a Schematic illustration of various casting !rocesses

Manufacturing (rocesses# Forming and Sha!ing

Figure I.0& Schematic illustration of various &ul" deformation !rocesses

Manufacturing (rocesses# Forming and Sha!ing

Figure I.0c Schematic illustration of various sheet metal forming !rocesses

Manufacturing (rocesses# Forming and Sha!ing

Figure I.0d Schematic illustration of various !ol%mer !rocessing methods

Manufacturing (rocesses# Machining

Figure 1.0e Schematic illustrations of various machining and finishing !rocesses.

Manufacturing (rocesses# @oining

Figure I.0f Schematic illustration of various Aoining !rocesses

9aser $utting
Figure I.? $utting sheet metal ith a laser &eam. Source: $ourtes% of =ofin-Sinar+ Inc. and Manufacturing Engineering Magazine, Societ% of Manufacturing Engineers

/i! =e!lacement

Figure 1.2 $om!onents of a total hi! re!lacement. Source: $ourtes% of Bimmer+ Inc.

Manufacturing of /i! =e!lacement

Figure 1.11 *a, Manufacturing ste!s in the !roduction of a roll-formed and machined total hi! re!lacement stemC *&, Manufacturing ste!s in the !roduction of a forged stem. /i! stems can also &e !roduced &% investment casting+ metal inAection molding+ insert inAection molding+ and assorted other !rocesses. Source: $ourtes% of Bimmer+ Inc.

Microsco!ic $om!onents

Figure I.11 *a, Microsco!ic gears ith dust mite. Source# $ourtes% Sandia Dational 9a&orator%C *&, A mova&le micromirror com!onent of a light sensor. Source: $ourtes% of =ichard Mueller+ Eniversit% of $alifornia at :er"ele%.

Salt and (e!!er Sha"ers

Figure I.13 A salt and !e!!er mill set. Fhe t o metal !ieces *at the &ottom, for the !e!!er mill are made &% !o der-metallurg% techni7ues. Source: =e!roduced ith !ermission from Success Stories on P/M Parts+ Metal (o der Industries Federation+ (rinceton+ D@+ 122?.

Automated elding of automo&iles

Figure I.1; Automated s!ot elding of automo&ile &odies in a mass !roduction line. Source: $ourtes% of Ford Motor $om!an%.

A!!lication of $ADG$AM to ma"e sunglasses mold

Figure I.1< Machining a mold cavit% for ma"ing sunglasses. *a, $om!uter model of the sunglass as designed and vie ed on the monitor. *&, Machine the die cavit% using a com!uter numerical-control milling machine *c, Final !roduct. Source: $ourtes% of MastercamG$D$ Soft are+ Inc.

/ourl% $om!ensation for (roduction 6or"ers