Chapter 1

General Introduction

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 DEPARTMENT OF INDUSTRIAL ENG.
Manufacturing Process I

FACULTY: Dr. Mazin Obaidat

e-mail: mazin@hu.edu.jo, Room: 3079
Office Hours: Open door ploicy
TEXTBOOKS:
• Manufacturing Processes for Engineering Materials, Serope Kalpakjian
and Steven R. Schmid, Prentice Hall, 5th Edition, 2008
• Fundamentals of Modern Manufacturing – materials, processes and
systems, Mikell P. Groover, Wiley, 2nd Edition, 2002

References:
1. Materials and Processes in Manufacturing, E. Degarmo, J.T. Black and R.A. Kohser,
Wiley, 9th Edition, 2002.
2. Mechanical Metallurgy, G.E. Dieter, McGraw-Hill, 3rd Edition, 1986
3. Material Science and Engineering, W.D. Callister, 6th Edition, Wiley, 2002
 Manufacturing Process I
Handouts: are available at Moodle
http://www.mlms.hu.edu.jo/

Assessment1: Assessment2:
First Exam 25 % First Exam 30 %
Second Exam 25 % Second Exam 30 %
Others 10% Final Exams: 40 %
Final Exams: 50 %

Assessment3:
Mid Exam 20%
Project 20 %
Others 20%
Final Exams: 50 %
 Grading Assessment 2
 25 30 ( Well done )
 20 25 ( Hard worker )
 15 20 ( Slim Chance of passing )
 10 15 ( Drop the course )
 5 10 ( Change your major )
 0 5 ( Stay At home)
 Course Outline
• Introduction to Mechanical Shaping
•Review of Mechanical Properties
• Annealing – Recrystallization
• Forming Process Variables
- hot, warm or cold forming
• Bulk Deformation:
Rolling,
Forging,
Extrusion,
Drawing
• Sheet metalworking:
•Bending,
•Shearing,
•Deep drawing
•Material Removal:
Machining, Cutting Tools
• Powder Metallurgy
 What is Manufacturing?
Manufacture is derived from two Latin words manus
(hand) and factus (make); the combination means
“made by hand”
Made by hand???!!!
“Made by hand” described the fabrication methods that
were used when the English word “ Manufacture” was
first coined around 1567 A.D.
“.
What about the Modern Manufacturing?
Modern manufacturing operations are accomplished by
Mechanized and automated equipment that is supervised by
human workers
 What is Manufacturing?

For our purposes, manufacturing means production of

hardware, which ranges from nuts and bolts to digital
computers and military weapons, as well as plastic and
ceramic products
 Manufacturing is Important Historically

To a significant degree, the history of civilization is

the history of humans' ability to make things

Historically, the importance of manufacturing in the

development of civilization is usually underestimated
• Throughout history, human cultures that were better at
making things were more successful
• Making better tools meant better crafts & weapons
– Better crafts allowed the people to live better
– Better weapons allowed them to conquer other
cultures in times of conflict
 Manufacturing Processes

Manufacturing adds value to the

material by changing its shape or
properties, or by combining it
with other materials that have
been similarly altered

So, a manufacturing plant consists of a set of processes and

systems (and, of course, people) designed to transform a certain
limited range of materials into products of increased value

System Modern There is a strong

Process Manufacturing interdependency among
these three building blocks.
Materials
 Manufacturing
Manufacturing can be defined in two ways:
Technologically
Economically

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 Technologically?
Technologically manufacturing means: is
the application of physical and chemical
processes to alter the geometry and
appearance of the given starting material to
make product or part

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 Economically
Economically: manufacturing is the
transformation of materials into items of
greater value by means of one or more
processing or assembly operations.
Examples:
1.When iron core is converted
into steel – value is added
2.When sand is transferred into
glass-value added
3.When petroleum is refined
into plastic-value is added
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 What is Manufacturing?

It is the process of converting the raw materials

into products. Also it involves activities in which
the manufactured product itself is used to
make other products.
 Products are:
1. Discrete: nails, gears, etc.
2. Continuous: sheet metal, tubes, hose, wire,
etc.
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 Manufacturing capability
Manufacturing capability refers to the technical
and physical limitations of any manufacturing firm
We can identify several dimensions of this
capability:
 Technological processing capability
 Physical product limitations
 Production capacity.

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 Manufacturing capability

Technological processing capability: it’s

the available set of manufacturing process
 Examples:
Certain plants or firm performing machining
operations, others roll steel sheet, casting,
forging….
Machine job can not produce car.

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 Manufacturing capability
Physical product limitations: one of the most
important thing that identify the capability of
firm is the weight and size of product.
 Examples:
Large and heavy products are difficult to move,
to move these products the firm must be
equipped with cranes of required load.
Smaller parts and products made in large
quantities can be moved by conveyer or other
means. 16
 Manufacturing capability
Production capacity: is the production
quantity that can be produced in a given
time (e.g. month, or year).
 Plant capacity: maximum rate of
production the company can a achieve
under assumed operations conditions.
Shift per hours
Direct labors.

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 Type of Production
Mass Production: the manufacturing of large
quantities of standardized products utilizing assembly
line technology such as mass production of airline and
automobile using special purpose machines. The
concepts of mass production are applied to various
kinds of products to assemblies of such parts such
automobile . (over 100,000 piece/year)
Batch Production: refer to a method of manufacturing
where several of the same item are put together at the
same time. [ is a technique used in manufacturing, in
which the object in question is created stage by stage
over a series of workstations, and different batches of
products are made] Batch production is most common in
bakeries and in the manufacture of sports shoes, 18
pharmaceutical ingredients 100-5000 piece/year
 Type of Production
Job Shop Production: sometimes
called jobbing or one-off production, involves
producing custom work, such as a one-off product
for a specific customer using general purpose
machines (making railings for a specific house,
building/repairing a computer for a specific
customer, making flower arrangements for a
specific wedding etc.) (10-100 piece/year)

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 Product Design Process

It is the process where the product

is passing through many steps, from
the first step (conceptual design) till
its manufacturing (product)

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Product Design Process
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.

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 Important Considerations
Product Design Process
Design requirements, Ex: baseball bat
Bat less 1.5 bound
Made out of approved material
Able to hit baseball without breaking
Manufactured by environmentally
friendly and economical methods
Quality inspection at each stage.
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 Important Considerations
Product Design Process

Flexible production methods

Computer integration
Productivity

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Important Considerations-Product Design Process
 Manufactured by environmentally friendly and economical
methods.
 Consider the effects of water and air pollution, acid rain, ozone
depletion, hazardous waste, and global warming.
 The adverse effects of these activities, their damage to our
environment and to earth ecosystem, ultimately, their effect on the
quality of human life are now well recognized by the public as well
as by the governments.
 In response, a wide range of laws and regulations have been
promulgated by governments.
 These regulations are generally stringent, and their implementation
can have a major impact on the economic operation of
manufacturing .
 These efforts have been most successful when there is value
added, such as in reducing energy requirements ( associated cost)
that have both cost and environmental design benefits. 24
 Important Considerations
Product Design Process
 Much progress has also taken place regarding
1. Design for recycling
2. Design for environment (DFE) or green design
 These comprehensive approaches anticipate the possible
negative environmental impact of materials, products,
and process so that they can be considered at the earliest
stages of design and production.

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Important Considerations-Product Design Process
 Other developments such as sustainable manufacturing and cardle-
to-cardle philosophy.
1. Sustainable manufacturing : which refers to the realization that
natural resources are vital to become economic activity, to ensure
that resources are available for future generations.
2. cardle-to-cardle philosophy. A philosophy that encourages the use
of environmentally friendly materials and design
 Environmentally friendly materials can be:
 Part of a biological cycle, where usually organic materials (such as
wood, and polymers) are used in the design, function probably for their
intended life and can then be disposed of. Such materials degrade
(dissolve) naturally, and in the simple version, lead to new soil
that can sustain life
 Part of industrial cycle, such as aluminum in beverage containers
that serve an intended purpose and are then recycled, so that the
same material is reused continuously.
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 Design Principles for Economic
Production
1. Designs should be as simple as possible to
manufacture, assemble, disassemble, service,
and recycle.
2. Appropriate Material [ material should be chosen
for their appropriate design and manufacturing
characteristics as well as for their service life].
3. Dimensional accuracy.
4. Finishing should be avoided or
minimized.[because they can add significantly to
the cost] 27
 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.

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 Selecting Materials
A wide variety of materials is now a available, each
having
 its own characteristics
 Composition
 Applications
 Costs
 Advantages
 And limitations

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 Selecting Materials
 Many factors have to be considered when selecting possible
materials to fit a design and manufacturing requirement:
 Dose the material posses the necessary mechanical,
electrical and thermal properties?
 Can the material be formed to the desired shape?
 Will the properties of the material alter with time during
service?
 Will the material adversely affected by the environmental
conditions and resist corrosion and other forms of attack?
 Will the material be acceptable on aesthetic grounds?
 Will the material give sufficient degree of reliability and
quality? And, of course:
 Can the product be made at an acceptable cost? 30
Classification of engineering materials
 Engineering materials can be classified into two or three
classifications:

1. Metallic:
 Ferrous: (iron, steel, cast iron, wrought iron)
 Non ferrous(Al its alloys, Cu its alloys, Mg its alloys

2. Non Metallic. Matrix polymer

 Organic (polymers, wood)
 Inorganic(ceramic, glasses)
Reinforcement
fiber glass
3. Composite materials ?????
 Metal matrix composite
 Ceramic matrix composite
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 Polymer matrix composite
Composite materials

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 Alloys versus composite
• Composite materials: concrete Matrix
consists of two materials or
more, each material has a
surface that separate it from
the other materials
• Alloys: is a mixture of two Reinforcement
iron bar
materials or more showing
metallic properties such as
A+B material
Brass (Cu+Zn), Bronze
(Cu+Sn)
Grain boundaries

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 Classes of Materials
There are 3 major classes:
1. Metals
Usually alloys, which are composed of two or more elements,
at least one of which is metallic

Two basic groups:

a. Ferrous metals - based on iron, comprise  75% of metal
tonnage in the world:
• Steel = iron-carbon alloy with 0.02 to 2.11% C
• Cast iron = alloy with 2% to 4% C
b. Nonferrous metals - all other metallic elements and their
alloys: aluminum, copper, gold, magnesium, nickel, silver,
tin, titanium, etc.
Classification of engineering materials
• Steel : is iron and carbon, theoretically the % of
carbon in steel less than 2%, practically the % of
carbon in steel no more than 1.6%
• Type of steel
 High carbon steel( doesn't exceed =1.6%)
 Mild carbon steel( 1.3% < Carbon% <1.6%)
 Low carbon steel(= 1.3% of carbon).

• We add carbon to iron to become steel in order to

increase hardness

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 Classes of Materials
2. Polymers
A compound formed of repeating structural units called mers,
whose atoms share electrons to form very large molecules

Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without altering
their molecular structure
2. Thermosetting polymers - molecules chemically
transform (cure) into a rigid structure upon cooling
from a heated plastic condition
3. Elastomers - exhibit significant elastic behavior
 Classes of Materials
3. Ceramics
A ceramic is an inorganic, nonmetallic solid material
comprising metal, nonmetal or metalloid atoms primarily held
in ionic and covalent bonds. The crystallinity of ceramic materials
ranges from highly oriented to semi-crystalline, and often
completely amorphous (e.g.,glasses)
- Molecules based on bonding between metallic and
non-metallic elements (including oxides, nitrides, carbides)
- Typically insulating and refractory
Sub-Classes of Materials metalloid is a chemical
element with properties in
Semiconductors (ceramics) between,of metals and nonmetals
Intermediate electrical properties Such Si and B
Composites (all three classes)
Combinations
Bio Materials (all three major classes)
Materials compatible with body tissue
 Selecting Materials
Why do we study materials?
 Many engineers, whether mechanical, civil,
chemical, electrical or mechatronics will be exposed
to design problem, and the reason for this design
problem is selecting the material.
 Ex: transmission gear, the superstructure for building
or an integrated circuit board.
 Always the problem is not selecting the right material
for the right application.

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Criteria to select the proper material

Service conditions must be characterized.

 In rare occasions dose the material posses the ideal
combination of properties- trade off one characteristic
for another.
 Ex: a material having a high strength will have a limited
ductility. In such case a reasonable compromise
between two or more properties may be necessary.

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 Criteria to select the proper
material
Deterioration of material properties
that may occur during operation
service.
 A significant reduction in mechanical strength may
result from exposure to elevated temperature.
The economics.
 What will the finished product cost? A material may be
found that has the ideal set of properties, but still
expensive compromise is still necessary.
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 Important Considerations
selecting materials
 Very many properties of materials have
to be considered when choosing a
material to meet a design requirement.

 These include a wide range of physical,

chemical and mechanical properties
together with forming, or manufacturing
characteristics, cost and availability and,
in addition, more subjective aesthetic
qualities such as appearance and
texture.
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 Important Considerations
selecting materials
Properties of Materials
– Mechanical properties
– Physical properties
– Chemical properties
– Manufacturing properties
Cost versus availability
Service life and recycling
Operational cost :
 Fixed cost : overhead cost (oil, water, electric..)
 Variable cost: cost of material, this cost vary
according to how much product is produced.
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 Properties of materials
Mechanical properties [strength, ductility, toughness,
hardness, elasticity, and creep….]
• These properties can significantly modified by various heat
treatment methods.
• So the mechanical properties should be appropriate for the
conditions under which the product is expected to function.

Physical properties [density, melting point, thermal

expansion, thermal conductivity and electrical and
magnetic properties, also need to be considered].

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 Properties of materials
Chemical properties [ resistance to corrosion,
resistance to oxidation]
 Also can play a significant role in hostile as well as normal
environment.
 Oxidation, corrosion and flammability of the materials are
among the important factors to be considered, as is
toxicity (lead-free solders)

Manufacturing properties determine weather the

material can be processed [ machinability, formability,
castability, weldability] with relative ease.
 The methods used to process materials to the desired
shapes should not adversely affect the product’s final
properties and service life
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 Machinability versus formability
 Machinability : the operation where certain a mount
of the material is removed from the surface as chips.
Or the ability of the material to be shaped by removing
a certain a mount from the surface to reach the
desired shape.
 Formability: it is an operation of forming the material
but without removing a certain a mount from the
surface, it can be done by knocking on or pulling the
material and delivering in another shape [ the mass of
the material before and after the process will be the
same].
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 Properties of materials
Cost versus availability
 If raw materials are not commercially available in the
desired quantities and shape, additional processing may
be required; these steps can contribute significantly to
product cost
 For example, if we need a small round bar of a certain
diameter and it is not commercially available, then we have
to purchase a large diameter bar and reduce its diameter,
by processes such as drawing through a die or machining

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 Properties of materials
Service life and recycling
 Time-and service are dependent phenomena such as wear,
fatigue, creep, corrosion, and dimensional stability are
important considerations as they can significantly affect a
product's performance, and if not controlled, can lead to failure
of product.
 The corrosion caused by compatibility of different materials
used in a product is also important; an example is galvanic
action between mating parts made of dissimilar metals.
 Recycling or proper disposal of the individual components in a
product or the whole product at the end of its useful life is
important as we become increasingly aware to live in clean and
health environment.
 Toxic wastes is a also a crucial consideration and need to have
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proper treatment and disposal
Factors affecting the cost of the materials
1. Availability in the nature.
2. Concentration of the material in the ore.
3. The cost of extracting the material from the
ore.
4. By products [ through extracting the
material, other material can be so benefit,
example extracting petroleum we have
methane gas]

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Manufacturing Characteristics
of Alloys

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 Factors influencing properties and (Manufacturing)
Behavior of Metals
• Atomic Structures
– Crystal structures: bcc, fcc, hcp
– Slip, slip planes:b/a ratio, anisotropy
• Imperfections
– Line: dislocations (strain hardening)
– Point: vacancy, interstitial (alloys, e.g. Fe-C), impurity
(alloys, e.g., Al, Cu)
– Volume: voids, inclusions (e.g. oxides, carbides, sulfides)
– Planar: grain boundaries
• Grains
– Properties depend on size, large grains are softer (why?)
lower strength, hardness, & high ductility and produce rough
surface after stretching (orange peel example)
 Important Considerations: Selecting
Manufacturing Processes
 A wide range of manufacturing processes are used to
produce a variety of parts, shapes and sizes.
 There is usually more than one method of manufacturing a
part from a given material. Each of these processes has its
own advantages, limitations, production rates and cost
 Casting, Forming , Machining, Joining, Nanofabrication
 Selection of a particular manufacturing process depends not
only on the component or part shape to be produced, but also
on many factors such as properties of the martials.
 Brittle and hard materials, can not easily be shaped whereas
they can be cast or machined by various method

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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
 Deformation Processes
• Starting workpart is shaped by application of forces that
exceed the yield strength of the material
• Examples: (a) forging, (b) extrusion
 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 machining processes
 Particulate Processing
• Starting materials are powders of metals or ceramics
• Usually involves pressing and sintering, in which powders
are first squeezed in a die cavity and then heated to bond
the individual particles
 Waste in manufacturing Processes

It is desirable to minimize waste and scrap in part

shaping
– Material removal processes tend to be wasteful in
the unit operation, simply by the way they work
– Casting and molding usually waste little material
The Materials Selection Process
Pick Application: Determine required
Properties : mechanical, electrical, thermal,
magnetic, optical, deteriorative.
Properties: Identify candidate Material:
alloys, composition.
Material : Identify required Processing
Processing: changes structure and overall
shape
ex: casting, forming, joining.
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 Near Net-shape manufacturing
 Because not all manufacturing operations produce finished
products or products to desired specifications, additional
finishing operations may be necessary.
 For example, a forged part may not have the desired dimensional
accuracy; thus additional operations such as machining may be
necessary.
 Likewise, it may be difficult to produce a product using only one
manufacturing process, a part that, by design, has a number of
holes in it, necessitating additional process such as drilling.
 Also, the holes produced by drilling process may not have the
proper roundness, dimensional accuracy, or surface finish, thus
necessitating the need for additional operations, such as honing.
 These additional operations can contribute significantly to the
cost of a product
 Net-shape manufacturing
 Consequently, net-shape or near-net-shape manufacturing has
become an important concept in which the part is made also close to
the final desired dimensions, tolerances, and specifications.

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
 Typical examples of near-net shape manufacturing
 Near-net-shape forging or casting or metal injection molding
 Computer Integrated
Manufacturing
 CIM: software and hardware are integrated from
product concept through product distribution in
the marketplace. It has the capability of:
1. Improved responsiveness to rapid changes in
market demand and product modification.
2. Better use of materials, machinery and
reduction in inventory.
3. Better control of production.
4. Manufacturing high quality products at low cost.

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 Lean Production and Agile
Manufacturing
Lean Production
 Minimizing the waste in production process. Dealing
with problems as soon as they appear.

Agile manufacturing (flexibility):

 Ensuring flexibility. Respond to changes in product
demand.
Benchmarking:
 A measurement of the quality of an organization’s
polices, products, strategies..., and their comparison
with standard measurement.
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 The objectives of benchmarking
1. Determine what and where improvements
are called
2. Analyze how other organizations achieve
their high level performance.
3. Use this information to improve performance.

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 Quality Assurance and Total
Quality Management
QA:
 Is a systematic process of checking to see whether
the product or service developed is meeting
specified requirements.
Product integrity:
 Is a term that is generally used to define the degree
to which a product: is suitable for its intended
purpose, responds to a real market demand,
functions reliably during its life expectancy.

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 Quality Assurance and Total
Quality Management
TQM :
 A comprehensive and a structured approach that
seeks to improve quality of products or service
through ongoing refinement in response to continuous
feed back.
 It must be the responsibility of everybody involved in
designing, manufacturing, and marketing of a product.

Experimental Design:
 A technique in which the factors involved in a
manufacturing process and their interactions are 64
studied simultaneously.
 Quality Assurance and Total
Quality Management

Product liability:
 The consequences of product failure, including
failures during possible misuse of products, must be
fully understood by those involved with product
design, manufacturing, and marketing.

Human-factors engineering and ergonomics:

 Deals with human versus machine interactions and
thus are important aspects of design and manufacture
of safe products.
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General Trends in Manufacturing:
World-class Matrix
High Quality
Low Cost
Minimum Time

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