IME-601 Modules
Manufacturing Processes
BULK PROCESSING MODULE
Outcomes
1. Be able to compare (similarities and differences, advantages and disadvantages)
between the various bulk processes: forging, rolling, bending, shearing, extrusion,
drawing and deep drawing.
2. Be able to connect the scientific principles, engineering challenges, and non-technical
(business, safety etc) for each process
Preparation
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Text Sections. The first two paragraphs of Chapter 17 are a great overview. Other
modules in this course will focus on material properties. Please pay careful attention
to Figure 17.1 and the accompanying text. It is important to differentiate between
bulk and sheet processing. Please pay careful attention to the sloppy use of the term
drawing. The sheet metal process called drawing will be referred to as deep drawing,
and although wire drawing is the most common process pulling material through a
die, we will refer to all pulling through a die processes as drawing. Sections 17.2-17.6
are beyond the scope of this course, and may not be completely correct. The
introduction to Chapter 18 is excellent. However as you read Sections 18.1, 18.3,
18.5, and 18.6 ignore references to true-stress and true-strain, in the presentation
and basic class notes I converted the relevant formulae to properties obtainable from
an engineering stress-strain curve. As you read Chapter 19, please note that all
references to drawing should be labeled deep-drawing.
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The following videos from the text. The hot forging video is a good introduction to
the forging process. As you view this, note the sequence of steps especially those
associated with finish forging. Try to relate finish forging to the role of the riser in
casting. The open die forging video, shows how some parts formed by casting could be
prepared for further machining. Again focus on the steps and the nearer-net-shape
produced. I need to look at the overall forging video in more detail, I am not certain
the connection to microstructure is correct. The bending video shows not only the
current practices but a concise and accurate analysis of the engineering
considerations associated with bending. The Shearing video, provides an excellent
overview of cutting but all references to the slip plane are wrong. The basic
forming video focusing on cutting and forming techniques. Metal formability as it
relates to sheet metal forming is a good overview but note what they call drawing, we
call deep drawing. The YouTube Video on Aluminum Extrusion shows how extrusion
occurs, please focus on pushing through a die, not aging etc. The YouTube video
on Steel Rolling focuses on m-rolling and is good.
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Sheet Metal Forming Experience Provided for Freshmen at Kettering. Focus not
only on how the processes relate to bulk processing in general, but on the details of
the procedures. You may want to compare these to your notes from the reading and
the videos. You may want to refer to these later in the course when ISO and Safety
are discussed.
Presentation and Basic Notes
CASTING MODULE
Outcomes
1. Be able to analyze casting processes based on scientific principles, engineering
challenges, and engineering practice.
2. Be able to determine appropriate casting processes for applications by justifying the
selection as compared to alternatives.
Preparation
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The following Sections from the text: Chapter 10 with the exception of 10.2.3
Analysis of Pouring. Note that we will use SI Units and that the example problems
do not fully meet the standards of this course as units are not included in the
calculations. A comparison of Figures 10.5 and 10.6 showing the cooling curves for
pure metals and alloys is key. Figure 10.8 is one of the best illustrations of Shrinkage
I have seen. Sections 11.4-11.7 should be connected to the relevant parts of Chapter
10 where possible. Review the sections on Sand Casting, Investment Casting, Lost
Foam Casting, Permanent Mold Casting and Die Casting.
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The following Wikipedia Articles were reviewed on 1/11/15. The article on Casting in
General provides a good overview of the casting process. The chart which compares
the different casting processes is great. If you can refer to it as you take notes from
Sections 1 and 2 I think you will learn a lot. Also please pay careful attention to
Section 4. I do not like the work theory as the section better reflects the relevant
scientific principles, engineering challenges, and engineering practices. We will focus
on the following casting processes: Sand Casting Investment (Lost Wax) Casting Lost
Foam / Evaporative Pattern Casting Permanent Mold Casting, and Die Casting . The
images provided in these article are excellent especially when combined with the
processes descriptions. As you read each of these compare what you discover to the
casting process in general and also focus on how each process accomplishes what is
necessary to make a part through casting. The goal of this is to be able to compare
(similarities and differences) of the various casting processes. So that you can make
decisions as to which casting process would be best for a given application.
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The following videos from the text provide great examples of: Sand
Casting, Investment Casting, and Foam Casting. As you view these I suggest you
elaborate on the notes you took from the reading.
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The Casting Experiences Provided for Freshmen at Kettering. Focus not only on
how the processes relate to casting in general, but on the details of the procedures.
You may want to compare these to your notes from the reading and the videos. You
may want to refer to these later in the course when ISO and Safety are discussed.
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The following videos from the text should also be examined.
Presentation and Basic Notes
ELECTRONIC MANUFACTURING MODULE
Outcomes
1. Be able to explain the scientific principles, engineering challenges, current
engineering practices and non-technical issues associated with electronics
manufacturing
2. Be able to explain all steps in building from the ground-up
Preparation
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Chapters 33 and 34 of the text describe electronic manufacturing from the
ground-up. The introductory section from Chapter 33 describing the 3D nature of an
integrated circuit. As you examine Figure 33.1 and the description in Section 33.1
think about how a piece of Si is continually changed by the different layers. Figure
33.3 and the preceding text is an excellent overall perspective of making an IC and
getting it on a circuit board. Try to connect the content of Figure 34.1 and the
descriptive text to Figure 33.1 and the Section 34.1, As you examine Figure 34.2
please zoom in as much as possible to see the different sizes and types of components
on circuit boards. I found the historical note 34.1 a great concise summary describing
the evolution of printed circuit boards.
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The following You Tube Videos should help you better understand electronic
manufacturing from the ground up. As you watch the IC Fabrication Video, pay
attention to the full process and try to relate it to Section 33.1. The packaging
video shows how the IC is placed into a chip package so that it can be placed on a
circuit board. The historical perspective is great. Finally the Circuit Board
manufacturing video is a detailed description of circuit board manufacturing.
Presentation and Basic Notes
JOINING MODULE
Outcomes
1. Be able to compare (similarities and differences, advantages and disadvantages)
between joining process categories: adhesive bonding, brazing, soldering, and
welding.
2. Be able to compare (similarities and differences, advantages and disadvantages)
between different joining within each of the following process categories: adhesive
bonding, brazing, soldering, and welding.
3. Be able to connect the scientific principles, engineering challenges, and non-technical
(business, safety etc) for each process and process category.
Preparation
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Chapters 28-30 describe the various joining processes we will be discussing, The
introduction in Chapter 28 is good except I disagree that welding is limited to skilled
trades welding is becoming automated. The bullet point regarding defects will be
discussed throughout this module. Although the description of fusion welding
processes is excellent, the description of non fusion processes is not as robust. Liquid
can form and disappear in diffusion welding. You should become familiar with the
subject matter presented in section 28.2.. In Section 28.3 focus on melting and
solidification, power density, and energy required to melt. The two f factors are an
attempt to oversimplify heat transfer and efficiency of melting; keep a big picture
perspective do not focus on the math associated with the two f factors. We will
expand on the subject matter in Section 28.4 in the presentation. As you read section
29.1 focus on comparing similarities and differences between the various types of arc
welding. Focus on power source, weld pool protection and practicality. As you read
section 29.2 focus on comparing the various processes to spot welding, Regarding
Sections 29.3 and 4 we will look at oxy-fuel as a power source for welding, brazing,
and soldering. The only specialized process we will mention is thermit welding. We
will discuss some of the processes in Section 29.5 (diffusion and friction stir welding)
but not to the detail of the arc and resistance welding processes. However Section
29.6 and forward is important. As you read this try to connect design to quality and
quality to power source, melting efficiency, weld pool protection, and practicality. The
very beginning of Chapter 30 is excellent, however the difference between brazing
and soldering is not the 450C/840F threshold. We will discuss this is the
presentation. Pay particular attention to the use of brazing paste in Figure 30.5.. The
remainder of the chapter is excellent. The connection between adhesive bonding and
the other processes is great. We will not focus on mechanical fastening.
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The following videos from the text provide great examples of: Resistance Welding, I
think it will help put the subject matter referred to in Section 29.3 more relevant. I
also suggest the viewing the following You Tube videos welding in general , arc
welding , mig welding , tig welding , this should help you compare the different
processes discussed in Section 29.1
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Welding and Brazing Experiences Provided for Freshmen at Kettering. Focus not
only on how the processes relate to welding and brazing in general, but on the details
of the procedures. You may want to compare these to your notes from the reading and
the videos. You may want to refer to these later in the course when ISO and Safety
are discussed.
Presentation and Basic Notes
MACHINING MODULE
Outcomes
1. Be able to analyze machining and material processes based on scientific principles,
engineering challenges, and engineering practice.
2. Be able to determine appropriate machining and material processes for applications
by justifying the selection as compared to alternatives.
3. Be able to identify an appropriate sequence of operations.
4. Be able to do cost-benefit analyses related to machining and material processes.
Preparation
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The introductory section from Chapter 20 in the text, provides a good overview of
machining/material removal processes. The definition of machining (p522-3) and
figures 20.1 and 20,2 provide concise summary of machining and where machining
fits into material removal processes in general. I thing the disadvantages listed on
page 524, could be opportunities for measuring productivity. Section 20.1 should be
read in its entirety. Pay careful attention to Figures 20.3, 20.5 and equation 20.1.
Limit the focus in 20.2 to pages 531-2 (chip formation). Section 20.4 should be read in
its entirety, connect equation 20.1 with the equations for power and energy
consumption. Chapter 21 should be read up to and including Section 21.6. This is
probably the best introduction to machining I have seen. Read the introduction to
Chapter 22 and Section 22.1. We will connect tool life, to section 20.4 and eqn 20.1.
Chapter 23 should be reviewed. Connecting economic considerations will be a key
part of the project.
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The following videos from the text provide great examples of: Basic Lathe
Operations (Turning, Drilling/Boring/Reaming, Facing and Parting), the 2 types of
hole making , the versatility of Milling As you view these I suggest you elaborate on
the notes you took from the reading.
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Machining Experiences Provided for Freshmen at Kettering. Focus not only on how
the processes relate to machining in general, but on the details of the procedures. You
may want to compare these to your notes from the reading and the videos. You may
want to refer to these later in the course when ISO and Safety are discussed.
Presentation and Basic Notes
POLYMER PROCESSING MODULE
Outcomes
1. Be able to compare (similarities and differences, advantages and disadvantages)
between the various polymer processing techniques
2. Be able to connect the scientific principles, engineering challenges, and non-technical
(business, safety etc) for each polymer processing technique.
Preparation
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Chapter 13 of the text focuses on Polymer Processing, the introduction (before
Section 13.1) is an excellent overview. I think that Section 13.1 can be summarized as
follows: 1) viscosity (or syrupiness) decreases exponentially with temperature, and
the viscosity for a pseudo-plastic at constant temperature decreases as strain rate
increases. Although Section 13.2 is a great description of polymer extrusion, Section
13.2.2 is beyond the scope of this course. As you examine Figure 13.4 and the
associated text compare the process with die casting, and extrusion (bulk processing).
As you examine Figure 13.9 and the associated text consider the shrinkage
associated with casting. Sections 13.3 and 13,4 should be read in their entirety. As
you examine the figures and associated text consider the versatility of polymer
processes. Section 13.6 should be read in its entirety as injection molding is one of the
most important manufacturing processes. As you read this section compare injection
molding to extrusion and die casting. Sections 13.9 and 13.10 should be read in their
entirety. As you examine the casting of polymers compare it to the casting of metals.
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Prior to viewing the injection molding video from the text please review the polymer
extrusion videos from YouTube: extrusion basics, and extrusion applications.
Although the injection molding video, from the text starts out slow within 30 or so
seconds you will see the application of the fundamental principles of injection
molding applied. The thermoforming video on YouTube is one of the best descriptions
of thermoforming I have seen. Although the YouTube Video on blow molding has no
sound, the close captioning is great.
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Polymer Processing Experience Provided for Freshmen at Kettering. Focus not only
on how the processes relate to polymer processing in general, but on the details of the
procedures. You may want to compare these to your notes from the reading and the
videos. You may want to refer to these later in the course when ISO and Safety are
discussed.
Presentation and Basic Notes
POWDER PROCESSING & ADDITIVE
MANUFACTURING MODULE
Outcomes
1. Be able to describe the series of steps required for powder processing and additive
manufacturing
2. Be able to connect the scientific principles, engineering challenges, current
engineering practice and non-technical issues associated with each individual step
and overall process
Preparation
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Chapters 15 and 16 of the text focus on Powder Processing (Metals and Ceramics
respectively). Consider all the associated steps: 1) atomization, 2) blending, 3)
compaction, and 4) sintering. Figure 15.12 is one of the best illustrations of sintering
I have seen. Compare the powder processing of metals and ceramics. For example
compare a blend to a slurry. Chapter 32 of the text is a good overview of additive
manufacturing, which has become known as 3-D printing. The following YouTube
videos give you a great overview and set of applications
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As you watch the text video giving an overview of powder metallurgy pay careful
attention to the controlled porosity and compare it to the shrinkage associated with
casting. The YouTube Video on melt atomization describes how starting with molten
metal one can form metal powders.
Presentation and Basic Notes
Materials
CHEMICAL PROPERTIES AND CORROSION MODULE
Outcomes
1. Be able to compare the behavior of batteries with corrosion in action.
2. Be able to determine, and explain the determination of the two half reactions
3. Be able to explain the various corrosion prevention techniques based on Outcomes 1
and 2
Preparation
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Section 4.5 of the text starts with a description of how the potential associated with
the half reactions are calculated. The content on Pg 93 helps link this module to the
manufacturing modules.
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The following YouTube Video is one of the best overviews of Corrosion based on
Chemical Reactions that I have seen. This is a great introduction to this module with
a practical example.
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The You Tube Video showing the formation of copper through the reaction of zinc
and copper sulfate is a good introduction to the basic battery/corrosion reaction. This
should be followed by a review of the Cu/Zn battery. Understanding half reactions is
key to understanding the chemical reactions responsible for corrosion.
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Presentation and Basic Notes
ELECTRICAL PROPERTIES MODULE
Outcomes
1. Be able to compare the behavior of conductors, insulators and semiconductors.
2. Be able to compare the following material properties: conductivity, dielectric constant,
mobility, and resistivity. Further be able to explain the properties and behavior of
devices created from these materials.
3. Be able to explain how Band Theory describes the behavior of insulators, metals and
semiconductors.
4. Be able to explain how AC frequency effects capacitance.
Preparation
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Section 4.4 of the text is an OK introduction for this module. However, as you read
Section 4.4 please ignore all references to superconductivity.
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The YouTube video on Electrical Conductivity is a good example showing how to
calculate electrical conductivity. As you review this video please pay as much
attention to the results as to the mathematical techniques. Please review the
following video regarding the difference between conductors, insulators, and
semiconductors; based on band theory. This video clearly shows why the sea of
electrons model is wrong. The following video explaining extrinsic semiconductors,
shows how doping a semiconductor can increase its conductivity. The following video
describing capacitors is one of the best basic explanations I have seen.
Presentation and Basic Notes
MECHANICAL PROPERTIES OF MATERIALS MODULE
Outcomes
1. Be able to explain and demonstrate how to determine the key mechanical properties
of materials from a stress-strain curve.
2. Be able to use these mechanical properties to determine the specifications for bulk
processing methods.
3. Be able to explain how hardness testing can best be used for quality control.
Preparation
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The first paragraph of Chapter 3 should be given special attention. Section 3.1 is
key to this module. As you examine Figure 3.2 and the descriptive text, pay careful
attention to necking and elastic recovery. The description of true stress and true
strain is worth reading, However, please note that the formulae for bulk processing
have been converted to engineering stress and engineering strain. Because of this I
do not suggest paying much attention to Figure 3.4 or the associated descriptive text.
The same is true about Figure 3.5, Table 3.4 and Example 3.3. As you read Section
3.2 pay careful attention to the empirical nature of hardness numbers.
Presentation and Basic Notes
THERMAL PROPERTIES OF MATERIALS MODULE
Outcomes
1. Be able to compare the following thermal properties of a material: heat capacity, heat
of fusion, thermal conductivity, thermal diffusivity, and thermal expansion.
2. Be able to qualitatively and quantitatively relate the thermal properties of a material
to manufacturing processes.
Preparation
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Please read Chapter 4.2 from the text. It provides a good introduction to the
presentation.
Presentation and Basic Notes