2- general introductio

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Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Chapter 0

General Introduction


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Materials in an Automotive Engine

Figure I.1 Section of an automotive engine - the Duratec V-6 - showing variouscomponents and the materials used in making them.

(Source: Courtesy of Ford Motor Company. Illustration by David Kimball.)


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Components inProducts

Single component

(nail, bolt, fork, coathanger, etc.)

Multi-component(ball point pens,

automobiles, washingmachines, etc.)

All components aremanufactured.

Manufacturing means,literally, Made by Hand .


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Components in Products

Some products are a singlecomponents (nail, bolt, fork,coat hanger, etc.)

Some products are assemblies

of many components (ball pointpens, automobiles, washingmachines, etc.)

All components aremanufactured.

Manufacturing means, literally,Made by Hand .


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Historical Development of Material and Manufacturing Process


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History of Manufacturing (1700-1960)


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History of Manufacturing (1960-2000s)


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Materials Selection for Paper Clips

Figure I.2 Examples of the wide variety of materials and geometries for paper clips.

Questions for consideration: What material properties are

required? What manufacturing attributes are

required? Would the material and processing

strategy change if the desiredquantity was 10,000 vs. 1 million perday?


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Manufacture of Light Bulbs

Figure I.3a Components of a commonincandescent light bulb.Source : Courtesy of General Electric Company.

Figure I.3b Manufacturing steps inmaking an incandescent light bulb.Source : Courtesy of General ElectricCompany .


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(b) Product flow in concurrentengineering, from market analysis toselling the product. Source : After S.Pugh, Total Design . Addison-Wesley,1991.

Product Design Process

Depending on thecomplexity of theproduct and the typeof materials used, thetime span betweenthe original conceptand the marketing ofthe product mayrange from a fewmonths to manyyears.

Figure I.4

(a) Various steps involved in design andmanufacturing a product.


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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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Manufacturing Characteristics of Alloys


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Baseball Bat Cross-sections

Figure I.6 Cross-sections of baseballbats made of aluminum (top portion)and composite material (bottomportion).


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Manufacturing Processes: Casting

Figure I.7a Schematic illustration of various casting processes


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Manufacturing Processes: Forming and Shaping

Figure I.7b Schematic illustration of various bulk deformation processes


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Figure I.7c Schematic illustration of various sheet metal forming processes


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Figure I.7d Schematic illustration ofvarious polymer processing methods


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Manufacturing Processes: Joining

Figure I.7f Schematic illustration of various joining processes


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Manufacturing Processes: Machining

Figure 1.7e Schematic illustrations of variousmachining and finishing processes.


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Laser Cutting

Figure I.8 Cutting sheet metal witha laser beam. Source: Courtesy ofRofin-Sinar, Inc. and Manufacturing Engineering Magazine, Society of

Manufacturing Engineers


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Hip Replacement

Figure 1.9 Components of atotal hip replacement.Source: Courtesy of Zimmer, Inc.


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Manufacturing of Hip Replacement

(b) Manufacturing steps in the production of aforged stem. Hip stems can also be producedby investment casting, metal injection molding,insert injection molding, and assorted otherprocesses. Source: Courtesy of Zimmer, Inc.

(a) Manufacturing steps in the production of aroll-formed and machined total hip replacement

stem;

Figure 1.10


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Microscopic Components

(b) A movable micro-mirror component ofa light sensor.

Source: Courtesy of Richard Mueller,University of California at Berkeley.

(a) Microscopic gears with dust mite.Source: Courtesy Sandia National Laboratory;

Figure I.11


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Salt and Pepper Shakers

Figure I.12 A salt and pepper mill set. The twometal pieces (at the bottom) for the pepper millare made by powder-metallurgy techniques.Source: Reproduced with permission fromSuccess Stories on P/M Parts , Metal PowderIndustries Federation, Princeton, NJ, 1998.


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Automated welding of automobiles

Figure I.13 Automated spotwelding of automobile bodiesin a mass production line.Source: Courtesy of Ford Motor Company.


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Application of CAD/CAM to make sunglasses mold

Figure I.14 Machining a moldcavity for making sunglasses.

(a) Computer model of the sunglassas designed and viewed on themonitor.

(b) Machine the die cavity using acomputer numerical-control millingmachine

(c) Final product. Source: Courtesy ofMastercam/CNC Software, Inc.


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Hourly Compensation for Production Workers

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