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: brian.paul@oregonstate.edu
Phone: 737-7320

Office Hours:
T: 11:30 noon
R: 11:30 13:00

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 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?

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 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/

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 Lab Instruction
Mr. Barath Palanisamy (Instructor)
E-mail: palanisb@onid.orst.edu
Ms. Negar Abolhassani (co-Instructor)
E-mail: abolhasn@onid.orst.edu

Steve Etringer (Technician)

E-mail: etringer@engr.orst.edu

Lab
126 Rogers Hall

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 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

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 Grading

Homework (6): 15%

Midterm: 25%

Final: 35%

Laboratory (9): 25%

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 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
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 Introduction to Materials & Processes

Material-Geometry-Process Relationships
Manufacturing Materials
Manufacturing Processes
How do we characterize processes?

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 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

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 Material-Process-Geometry Relationships

Function Role of
Prod Engr

Material Geometry

Role of
Process Mfg Engr

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 Complexity in Manufacturing

Materials: 106
metals, ceramics, polymers, composites

Processes: 105
process conditions are ~

Properties: 102
applications are ~

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 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

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 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
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 Manufacturing & Globalization

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 Tracking Manufacturing Problems

Exploding tires, 2004 Melamine in milk, 2008

Toxic toys, 2007 Medicines, 2006

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 Transformations

China over 2000 years

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 Materials in Manufacturing

Most engineering materials can be classified

into one of four basic categories:
1. Metals
2. Ceramics
3. Polymers
4. Composites

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 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
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 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
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 Solidification Processes
Starting material is heated sufficiently to transform it
into a liquid or highly plastic state
Examples: casting for metals, molding for plastics

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 Deformation Processes
Starting workpart is shaped by application of forces
that exceed the yield strength of the material
Examples: (a) forging, (b) extrusion

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 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

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 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
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 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

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 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

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 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
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 How do we characterize processes?

Quality
Dimensional bulk and surface
Properties bulk and surface
Economics
Cycle time
Materials utilization
Flexibility
Tooling development
Setup time
Cycle time

29 IE 337: Materials & Manufacturing Processes

 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

30 IE 337: Materials & Manufacturing Processes

 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
31 IE 337: Materials & Manufacturing Processes
 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
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 Comparing Processes

33 IE 337: Materials & Manufacturing 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

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 Next Class

Metals

From Chapters 2 and 3

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