Advanced Manufacturing
ME 10405/10505
Professor Jim Waterman

For Today
– Objectives of the Course
– Who am I?
– My approach to the course
– Outline for the semester
– What is Manufacturing – intro to the course
Advanced Manufacturing
ME 10405/10505
Professor Jim Waterman

For Today
Objectives of the Course
Who am I?
My approach to the course
Outline for the semester

What is Manufacturing – intro to the course




Advanced Manufacturing
ME 10405/10505
1.
Course Objectives
– Provide an overview of modern manufacturing
processes
– Enable students to select and design processes to
make things
– Provide insights as to what is state of the art now,
and what is coming
Advanced Manufacturing
ME 10405/10505
1.
My Approach
– Bring some relevance to the subject
• What is happening in industry today
– Bring you into the discussion
• I want your questions, and your knowledge
• We'll learn together
– Get you ready to design for manufacture, or
design the processes of the future
Advanced Manufacturing
ME 10405/10505
Course Outline – First Half
Intro and Overview of Manufacturing
Engineering Materials
Properties of Engineering Materials
Dimensions Tolerancing and Surfaces
Metal Casting
Glassworking
Shaping processes for Plastics
Shaping processes for Rubber/Polymer Composites
Powder Metallurgy
Ceramics
Metal Forming
Metal working (roll/forge/extrude)
Sheet Metal
Metal Machining(including tool life)
Principles
Machine Tools
Cutting tools tech
Mid Term
Oct 15
Advanced Manufacturing
ME 10405/10505
Course Outline – Second Half
Grinding/abrasive processes
Non-traditional Processes
Mechanical Energy processes
Ultrasonic, Water Jet, Electrochemical machining
EDM,Electron Beam/Laser Beam Machining
Chem Machining
Heat Treatment of Metals
Surface Processing
Cleaning,Diffusion/ion implant,Plating/electroforming
Conversion coatings, Vapor deposition
Organic coatings
Welding :Fundimentals/Joints/physics
Processes: Arc, Oxy/fuel, Acetalyene, Fusion
Solid state
Braze/Solder/Adhesive bond
Mechanical Assembly
Rapid Prototype processes
Survey of Additive Manufacturing processes
SLA, Fused Deposition, Powder based
Ink/liquid based
Others are developed
Micro/Nano fabrication technologies
Advanced Manufacturing
ME 10405/10505
Course Outline – Second Half
Production Systems/process planning
Survey of Automation/Manufacturing Systems
CNC
Cells and work flow/part families
'Flexible Machine Cells'
Lean
'CIM'
Discussion of life cycle data driven mfg/standards.
Quality
Process Capability
Statistical Process Control
Futures
Extrapolating today to tomorrow (incorporate through the semester?)
Supply Chain considerations – global issues
Final Exam
What is Manufacturing?



The word manufacture is derived from two Latin
words, manus (hand) and factus (make)
Taken together the combination means made by
hand, which is how things were made in 1567 when
the word first entered the English language
Today manufacturing can be defined two ways:
 Technologically
 Economically
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Technological Definition of
Manufacturing


The application of physical and chemical processes
to alter the geometry, properties, and/or appearance
of a given starting material to make parts or products
It also includes assembly of multiple parts to make
products
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Economic Definition of
Manufacturing


The transformation of materials into items of greater
value by means of one or more processing and/or
assembly operations
Manufacturing adds value
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Manufacturing Industries
Industries can be classified as:

Primary industries:
– Cultivate and exploit natural resources (e.g.,
agriculture and mining)

Secondary industries:
– Take the output of the primary industries and convert
them into consumer and capital goods (e.g.,
manufacturing, construction, power utilities)

Tertiary industries:
– Service sector (e.g., retail, financial, education,
©2012 John
Wiley & Sons, government)
Inc. M P Groover, Introduction to
transportation,
Manufacturing Processes
Manufactured Products
Final products made by the manufacturing industries
can be divided into two major classes:

Consumer goods – products purchased directly by
consumers (e.g., cars, personal computers, TVs,
tires,, and tennis rackets)

Capital goods – products purchased by companies to
produce goods and/or provide services (e.g., aircraft,
trucks and buses, machine tools, construction
equipment)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Manufacturing and Gross
Domestic Product (GDP)



In the U.S:
Manufacturing accounts for about 12% of GDP
– And the service sector accounts for more than
75% of GDP
BUT! Manufactured capital goods purchased by the
service sector are the enablers of that sector
 Without these manufactured products, the service
industries could not function
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Production Quantity and Product
Variety


Production quantity = the number of units produced
annually of a given product type
 Three ranges:
 Low production (1 to 100 units per year)
 Medium production ( 100 to 10,000 units)
 High production (10,000 to millions of units)
Product variety refers to the number of different types
of products made
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Production Quantity and Product
Variety

Manufacturing plants tend to specialize in a
combination of production quantity and product
variety that lies inside the diagonal band shown
below
How would you 'break' the curve?
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Manufacturing Capability


Refers to the technical and physical limitations of a
manufacturing firm and its individual plants
Three dimensions of manufacturing capability:
1. Technological processing capability – available
set of manufacturing processes
2. Physical product limitations – size and weight of
the products that can be made
3. Production capacity – production quantity that
can be produced in a given time period
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Materials in Manufacturing
Most engineering materials fall into one of 3 basic categories:
Metals:
Ferrous (e.g., steel and cast iron)
Nonferrous (e.g., aluminum, copper, nickel)
Ceramics
Crystalline ceramics (e.g., clay, alumina)
Glass
Polymers
Thermoplastics (e.g., polyethylene)
Thermosets (e.g., epoxies)
Elastomers (e.g., rubber)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Manufacturing Processes


A manufacturing process is a designed procedure
that results in physical and/or chemical changes to a
starting work material with the intention of increasing
the value of that material
Usually carried out as a unit operation, which is a
single step in the sequence of steps required to
transform the material into as final product
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Two Basic Types of
Manufacturing Operations
1.
2.
Processing operations – transforms a work
material from one state of completion to a more
advanced state that is closer to the final desired
product
 Usually performed on discrete workparts
Assembly operations – joins two or more
components to create a new entity, called an
assembly, subassembly, or other term (e.g.,
weldment)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Manufacturing Taxonomy
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Processing Operations

General types:
1. Shaping operations – alter the geometry of the
starting work material
2. Property-enhancing operations – improve the
physical properties of the material without
changing its shape
3. Surface processing operations – performed to
clean, treat, coat, or deposit material onto the
surface of the work
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Shaping Processes

Four categories based on the state of the starting
material:
1. Solidification processes
2. Particulate processes
3. Deformation processes
4. Material removal processes
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Solidification Processes

Starting material is a heated liquid or semifluid that
cools and solidifies to form the part geometry
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Particulate Processes

Starting material is a powder, and the powders are
formed to create geometry and heated to strengthen
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Deformation Processes

Starting material is a ductile solid (commonly metal)
that is deformed to shape the part
Forging
Extrusion
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Material Removal Processes

Starting material is a solid (ductile or brittle), from
which material is removed so that what remains has
the desired geometry
Turning
Drilling
Milling
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Property-Enhancing Processes

Involves heat treatments, which include:
 Annealing and strengthening processes performed
on metals and glasses
 Sintering of powdered metals and crystalline
ceramics
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Surface Processing Operations:



Cleaning – chemical and mechanical processes to
remove dirt, oil, and other contaminants
Surface treatments – mechanical working (e.g., sand
blasting) and physical processes (e.g., diffusion)
Coating and thin-film deposition – apply a coating to
the exterior surface of the work (e.g., electroplating,
painting, physical vapor deposition)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Assembly Operations


Permanent Joining processes
 Welding
 Brazing
 Soldering
 Adhesive bonding
Mechanical Fastening
 Joints can be disassembled (e.g., threaded
fasteners)
 Joints are permanent (e.g., rivets)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Production Machines


Machine tools – power-driven machines used to
operate cutting tools
Other production machines developed subsequently:
 Presses for stamping operations
 Forge hammers
 Rolling mills
 Welding machines
 Insertion machines for assembly
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Categories of Production
Equipment


General-purpose machines
 More flexible and adaptable to a variety of jobs
 Commercially available for any manufacturing
company to invest in
Special-purpose machines
 Usually designed to produce a specific part or
product in very large quantities
 Achieve high efficiencies and short cycle times
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Tooling



Production machines usually require tooling that
customizes the equipment for a particular part or
product
In many cases, the tooling must be designed
specifically for the part or product (e.g., a mold)
When used with general-purpose equipment, the
tooling can be exchanged at the end of a production
run
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Production Equipment and
Tooling for Various Processes
Process Equipment
Casting (various types)
Molding Molding machine
Forging Forge hammer
Extrusion Extrusion press
Stamping Stamping press
Machining Machine tool
Grinding Grinding machine
Special tooling
Mold
Mold
Forging die
Extrusion die
Stamping die
Cutting tool
Grinding wheel
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes
Some Resources (outside of the
book)
I.
II.
The Library of Manufacturing: good companion
resource to book for process information
– http://thelibraryofmanufacturing.com/index.html
Industry Week website – news, white papers
– http://www.industryweek.com/
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to
Manufacturing Processes