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Steel pistons with friction-welded skirt and crown and chrome/ molybdenum disulfide Silicon microprocessors with coated piston ring gold-plated connectors Titanium turbocharger Die-cast aluminum compressor wheel valve cover Lexan windshield Centrifugal cast-iron cylinder bores Forged steel connecting rods with precisionfractured joint
FIGURE 1.1 Model 8430 tractor, with detailed illustration of its diesel engine, showing the variety of materials and processes incorporated. Source: Courtesy of John Deere Company.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
History of Manufacturing
TABLE 1.1 H i st or i ca l D evel op m en t of M a t er i a l s a n d M a n u f a ct u r i n g Pr ocesses
Per io d D a t es M et a ls a n d ca st in g G o ld , co p p er, m et eo r ic ir o n C o p p er ca st in g, st o n e a n d m et a l m o ld s, lo st w a x p r o cess, silver, lea d , t in , b r o n ze Br o n ze ca st in g a n d d r a w in g, go ld lea f G la ss b ea d s, p o t t er s w h eel, gla ss vessels Va r io u s m a t er ia ls a n d co m p o sit es Ea r t h en w a r e, gla zin g, n a t u r a l fib er s F o r m in g a n d sh a p in g H a m m er i n g Jo in in g To o ls, m a ch in in g, a n d m a n u fa ct u r in g syst em s To o ls o f st o n e, flin t , w o o d , b o n e, ivo r y, co m p o sit e t o o ls So ld er in g (C u -Au , C u -Pb , Pb -Sn ) C o r u n d u m (a l u m i n a , em er y) Befo r e 4 0 0 0 B.C .
4 0 0 0 3 0 0 0 B.C .
St a m p in g, jew elr y
3 0 0 0 2 0 0 0 B.C . Egypt: ' 3100 B.C . to ' 300 B.C . Greece: ' 1100 B.C . to ' 146 B.C . Roman Empire: ' 500 B.C . to 476 Middle Ages: ' 476 to 1492 Renaissance: 14th to 16th centuries
A. D .
W ir e b y slit t in g sh eet m et a l
R ivet in g, b r a zin g
H o e m a k in g, h a m m er ed a x es, t o o ls fo r ir o n m a k in g a n d ca r p en t r y
2 0 0 0 1 0 0 0 B.C . 1 0 0 0 1 B.C .
Wr o u gh t ir o n , b r a ss C a st ir o n , ca st st eel G la ss p r essin g a n d b lo w in g Ven et ia n gla ss C r yst a l gla ss St a m p in g o f co in s Fo r ge w eld in g o f ir o n a n d st eel, glu in g Im p r o ved ch isels, sa w s, files, w o o d w o r k in g la t h es Et ch in g o f a r m o r Sa n d p a p er, w in d m illd r iven sa w H a n d la t h e fo r w o o d
1 1 0 0 0 A.D . 1 0 0 0 1 5 0 0
Ar m o r, co in in g, fo r gin g, st eel sw o r d s W ir e d r a w in g, go ld a n d silver sm it h w o r k Wa t er p o w er fo r m et a lw o r k in g, r o llin g m ill fo r co in a ge st r ip s R o llin g (lea d , go ld , silver ), sh a p e r o lling (lea d )
1 5 0 0 1 6 0 0
1 6 0 0 1 7 0 0
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
1 8 0 0 1 9 0 0
Industrial Revolution:
1 9 0 0 1 9 2 0
Tu b e r o llin g, h o t ex t r u sio n
G ea r ed la t h e, a u t o m a t ic scr ew m a ch in e, h o b b in g, h igh -sp eed -st eel t o o ls, a lu m in u m o x id e a n d silico n ca r b id e (syn t h et ic) Tu n gst en ca r b id e, m a ss p r o d u ct io n , t r a n sfer m a ch in es
1 9 2 0 1 9 4 0
D ie ca st in g
WWI
D evelo p m en t o f p la st ics, ca st in g, m o ld in g, p o lyvin yl ch lo r id e, cellu lo se a cet a t e, p o lyet h ylen e, gla ss fib er s Acr ylics, syn t h et ic r u b b er, ep o x ies, p h o t o sen sit ive gla ss Acr ylo n it r ileb u t a d ien e-st yr en e, silicon es, flu o r o ca r b o n s, p o lyu r et h a n e, flo a t gla ss, t em p er ed gla ss, gla ss cer a m ics
Tu n gst en w ir e fr o m m et a l p o w d er
1 9 4 0 1 9 5 0
WWII
Ex t r u sio n (st eel), Su b m er ged a r c sw a gin g, p o w d er w eld in g m et a ls fo r en gin eer in g parts C o ld ex t r u sio n (st eel), ex p lo sive fo r m in g, t h er m o m ech a n ica l p r o cessin g G a s m et a l a r c, ga s t u n gst en a r c, a n d elect r o sla g w eld in g; ex p lo sio n w eld in g
1 9 5 0 1 9 6 0
C er a m i c m o l d , n o d u la r i r o n , sem ico n d u ct o r s, co n t in u o u s ca st in g
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
1 9 6 0 1 9 7 0
Pla sm a -a r c a n d elect r o n -b ea m w eld in g, a d h esive b o n d in g La ser b ea m , d iffu sio n b o n d in g (a lso co m b in ed w it h su p er p la st ic fo r m in g), su r fa cem o u n t so ld er in g
1 9 7 0 1 9 9 0 Space Age
C o m p a ct ed gr a p h it e, va cu u m ca st in g, o r ga n ica lly b o n d ed s a n d , a u t o m a t io n o f m o ld in g a n d p o u r in g, r a p id so lid ifica t io n , m et a l-m a t r ix co m p o sit es, sem iso lid m et a lw o r k in g, a m o r p h o u s m et a ls, sh a p e-m em o r y a llo ys (sm a r t m a t er ia ls), co m p u t er sim u la t io n
Pr ecisio n fo r gin g, iso t h er m a l fo r gin g, su p er p la st ic fo r m in g, d ies m a d e b y co m p u t er-a id ed d esign a n d m a n u fa ct u r in g, n et -sh a p e fo r gin g a n d fo r m in g, co m p u t er sim u la t io n
So u r ce: J.A. Sch ey, C .S. Sm it h , R .F. Tyleco t e, T.K. D er r y, T.I. W illia m s, S.R . Sch m id , a n d S. Ka lp a k jia n .
Information Age
1 9 9 0 2 0 0 0 s
Fr ict io n st ir w eld in g, lea d -fr ee so ld er s, la ser b u t t w eld ed (t a ilo r ed ) sh eet -m et a l b la n k s, elect r ica lly co n d u ct in g a d h esives
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
Manufacturing Importance
GDP per capita, 1000 US$ 40 USA Australia Kuwait 20 Canada 10 Bangladesh Ethiopia 0 0 5 10 15 20 25 30 35 Contribution of manufacturing to GDP, % Mexico Germany Thailand China 40 45 Japan France
30
FIGURE 1.2 Importance of manufacturing to national economies. The trends shown are from 1982 until 2006. Source: After J.A. Schey with data from the World Development Report, World Bank, various years.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
Development Process
Computer-aided design (CAD)
Production drawings; instruction manuals Computer-aided manufacturing and process planning (CAM and CAPP)
Market
Specification Iterations
Production
Detail design
Manufacture
Product (a)
Sell (b)
FIGURE 1.3 (a) Chart showing various steps involved in designing 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 a product may range from a few months to many years. (b) Chart showing general product ow, from market analysis to selling the product, and depicting concurrent engineering. Source: After S. Pugh.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
Poor
Good
Poor
Good
Easy to feed
Insertion difficult
FIGURE 1.4 Redesign of parts to facilitate automated assembly. Source: Reprinted from G. Boothroyd and P. Dewhurst, Product Design for Assembly, 1989, by courtesy of Marcel Dekker, Inc.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
All-Aluminum Automobile
Robotically applied, advanced arc-welding processes provide consistent, high-quality assembly of castings, extrusions, and sheet components Die-cast nodes are thin-walled to maximize weight reduction yet provide high performance
Advanced extrusion bending processes support complex shapes and tight radii (a) (b)
Strong, thin-walled extrusions exhibit high ductility, energy absorption, and toughness
FIGURE 1.5 (a) The Audi A8 automobile, an example of advanced materials construction; (b) The aluminum body structure, showing various components made by extrusion, sheet forming, and casting processes. Source: Courtesy of ALCOA, Inc.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
Methods of Manufacture
Before After
Joined
(a)
(b)
(c)
(d)
(e)
FIGURE 1.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
Classification
Examples in nature
Applications Aircraft
10 m Human height Casting Forging Mouse Machining Ant Mesomanufacturing Grain of sand Integrated circuit package Chemical blanking Gear for MEMS LIGA Virus Features in integrated circuit Automobile
Scales in Manufacturing
Macromanufacturing
1m
0.1 m 0.01 m 5 1 cm
Machinery gears
Human cell
10 mm
1 mm 0.1 m 5 100 nm
10 nm 1 nm 5 10
Atoms
FIGURE 1.7 Illustration of the range of common sizes of parts and the capabilities of manufacturing processes in producing these parts.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
(a)
(b)
(c)
FIGURE 1.8 Machining a mold cavity for making sunglasses. (a) Computer model of the sunglasses as designed and viewed on the monitor. (b) Machining the die cavity using a computer numerical control milling machine. (c) Final product produced from the mold. Source: Courtesy Mastercam / CNC Software, Inc.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
Flexible Manufacturing
FIGURE 1.9 General view of a exible manufacturing system, showing several machines (machining centers) and an automated guided vehicle (AGV) moving along the aisle. Source: Courtesy of Cincinnati Milacron, Inc.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7
FIGURE 1.5 (a) The Audi A8 automobile, an example of advanced materials construction; (b) The aluminum body structure, showing various components made by extrusion, sheet forming, and casting processes. Source: Courtesy of ALCOA, Inc.
Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. 0-13-227271-7