Manufacturing Processes – Notes

Manufacturing Definition

 The word manufacture is derived from two Latin words manus (hand) and factus (make); the
combination means “made by hand”
 Most modern manufacturing operations are accomplished by mechanized and automated
equipment that is supervised by human workers

Consumer Goods

 Purchased directly by the consumer

o I.e. cars, Legos, clothes, TVs

Capital Goods

 Purchased by companies to produce goods and/or provide services

o i.e. aircrafts, computers, medical equipment, machine tools

Technological Manufacturing

 Application of physical/chemical processes to alter the geometry, properties, and/or

appearance of a starting material to make parts or products

Economics of Manufacturing

 Transformation of materials into items of greater value by one or more processing and/or
assembly operations

Production Quantity Q

o Influences the way people, facilities, and procedures are organized

o Production Range  Annual Quantity Q
o Low Production  1 – 100 units
o Medium Production  100 – 10,000 units
o High Production  10,000 – millions+ units
o As quantity increases, product variety decreases

Materials in Manufacturing

o Most engineering materials can be classified into one of four basic categories:
o Metals
o Ceramics
o Polymers
o Composites
Manufacturing Processes

o Processing Operations
o Transforms a work material from one state of completion to a more advanced state that
is closer to the final desired product. It adds value by changing the geometry, properties,
or appearance of the starting material
o Assembly Operations
o Joins two or more components to create a new entity, called an assembly, subassembly,
or some other term that refers to the joining process

Materials in Manufacturing

o Manufacturing is a transformation process

o The material is transformed
o The behavior of the material when subjected to the forces, temperatures, and other
parameters of the process that determines the success of the operation
o Atom and atomic structure
o The basic structural unit of matter is the atom
o The number of protons identifies the atomic number of an element
o Bonding
o Primary bonds
 Generally associated with formation of molecules
 Involve strong atom-to-atom attractive forces
 Ionic Bonding
o Occurs between metals and non metals
o One or more valence electrons transfer to another atom making
two oppositely charged ions that are then attracted to each
other
 Covalent Bonding
o Sharing of electrons
 Metallic Bonding
o Positively charged metal nuclei are surrounded by a sea of
mobile electrons
 o Secondary bonds
 Generally associated with attraction between molecules
 Dipole forces
 London forces
 Hydrogen bonding
 No transfer or sharing of electrons
 Not as strong as primary bonds

Macroscopic Structures of Matter

 Crystalline structure
o Atoms arrange themselves into orderly arrangements
o Elastic Strain:
 Reversible deformation resulting from shear stress
o Plastic Strain:
 Irreversible deformation (aka slip deformation)
 Twinning
 The atoms on one side of a plane shift to form a mirror image of the
other side
o Point Defects
 Vacancy  an atom is missing
 Self-interstitial  an extra atom
o Line Defects
 Edge Dislocation  edge of an extra plane of atoms that exists in the lattice
 Screw Dislocation  spiral within the lattice structure wrapped around the
imperfection line
o Work Hardening
 The higher shear stress required to overcome entanglements and impediments
results in an increase in the overall strength and hardness of the metal
 Tensile Test

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Effect of Manufacturing Process (Dimensions, Surfaces, Measurment):

 Dimensions  linear or angular sizes of a component specified on the part drawing

 Tolerances  allowable variations from the specified part dimensions that are permitted in
manufacturing
o The difference between the maximum and minimum limits
 Bilateral Tolerance  Variation is permitted in both positive and negative directions from the
nominal dimension
 Unilateral Tolerance  variation from the specified dimension is permitted in only one direction
o Either positive or negative, but not both
 Limit Dimension  permissible variation in a part feature size consists of the max and min
dimensions allowed
 Accuracy  the degree to which a measured value agrees with the true value of the quantity of
interest
 Precision  the degree of repeatability in the measurement process