Lecture 1

Return to Overview Slide

Course MAE 3344Introduction to ManufacturingEngineering and Technology

Professor John J. MillsThe College of Engineering,

The University of Texas at Arlington

Lecture No

Professor John J. Mills: Email: [email protected]; Tel (817) 272-7366

2


Overview of First Week• Introduction

– Statement of course goals– Overall class schedule– Statement of assumptions and policies

• Introductory overview of the larger issues – Definitions - "Manufacturing vs

manufacturing" – Basic concepts – The importance of Manufacturing – Dimensions of Manufacturing – Future trends in Manufacturing

• Summing up

Lecture No


3


Some guiding principles• Important skills for engineers, in order of

importance:

Lecture No


4


What is Manufacturing?

How do we make these?

Lecture No


5


Course Goals• To bring to the students an appreciation for

the complexity, depth and breadth of Manufacturing

• To provide students with an understanding of the importance of manufacturing process to the economy and to design decisions

• To provide students with an understanding of manufacturing processes– Concepts– Examples– Application in the real world– Significance to design

Lecture No


6


Assumptions for Course• Prerequisites:

– Solid Mechanics (course MAE 2312) • Stress-strain relationships • Elastic behavior • Elastic/plastic flow

– Materials science (course MAE 2321) • Basic mechanical, chemical and physical properties of

materials • Relationships between these macroscopic properties and

the electronic, crystalline and microscopic properties

• The student remembers something of forces, energy, power, heat transfer and fluid flow

• Design methods and principles are covered in other courses

Lecture No


7


Overall Approach for Course• Course will consist of a mixture of • Lectures • Labs (On Fridays)

– Tours of local companies – Discussions – Quizzes – Games/simulations

• Homework • Final exam (optional)

Lecture No


8


Course Policies• Attendance only critical for quizzes and final exam. Final

exam will be optional dependent on grade• Material presented will not always be in the book • Quizzes will be mostly based on problems in the book • Late Homework will be accepted by fax or email until the

solutions are posted on the web. • Late homework will be assessed a penalty which will

depend on how late it is. • Lectures will be available on-line as downloadable

programs or as linked world wide web pages • Home page http://www-woolf.uta.edu/mills/mantech/• Dr Mills will answer questions through email • Dr Mills Office Hours are 9:00am-10:am, 2:00 - 4:00pm

Monday, Wednesday and Friday, Room WH 215

Lecture No


9


Course Scoring

• Quizzes count for 40% of total grade (5 @ 80)• Homework counts for 30% of total grade (6 @ 50)• Optional Final counts for 30% of total grade (1@

300)• Some Homework will be scored on the clarity of

your writing • Answers to quizzes and homework and your

grades will be available on the home page – Home page mantech

Lecture No


10


Possible Students• Engineering majors who want to enter

– a manufacturing career – a design career

• Engineering majors looking for general information about Manufacturing

Lecture No


11


The Book and Suggested Reading

The Book – Manufacturing Engineering and

Technology, 4th Edition by S. Kalpakjain, published by Addison Wesley

Lecture No


12


Suggested Reading – 21st Century Manufacturing, by Paul Wright,

published by Prentice Hall, 2001– The New Manufacturing Engineer by M.J.

Terminie, published by The Society of Manufacturing Engineers, 1996

– Designing for Economical Production by H.E. Trucks, published by the Society of Manufacturing Engineers, 1987

– "Handbook of Product Design for Manufacturing," James G. Bralla, Editor, McGraw-Hill, 1986

Lecture No


13


Type of Course• Manufacturing is an "Integration" Course• It integrates your knowledge of:

– Materials – Statics/dynamics – Phase changes/crystal growth – Fluid flow, statistics, control, etc

• By this we mean that you will have to apply your knowledge of these fields

Lecture No


14


Materials • Nature of materials

– Metals, ceramics, glasses, plastics, composites,

• Mechanical properties

• Stress strain behavior

• Microstructure/properties relationships

Lecture No


15


Statics/dynamics

Lecture No


16


Phase change/crystal growth

Lecture No


17


Fluid flow

Lecture No


18


Examples - Casting

– Fluid flow– Heat Transfer– Phase changes– Crystal growth in pure metals and alloys

Lecture No


19


Examples - Rolling

– Vector forces– Relationships among force, power and energy– Effect of deformation on crystal structure– Effect of temperature on microstructure (heat

treating)– Machine dynamics

Lecture No


20


Examples - Material Removal

– Shear stress strain behavior– Vector forces– Relationships among force, power and energy

and shearing energy– Machine dynamics– Thermodynamics and material expansion

Lecture No


21


Examples - Powder Processing for metals, ceramics and plastics– Surface science– Thermodynamics– Effect of heat on microstructure– Sintering– Flow and rheology of powders

Lecture No


22


What is Manufacturing?

How do we make these?

Lecture No


23


Definitions

• Manufacturing• manufacturing

Lecture No


24


Definition of "Manufacturing"

• Big "M" Manufacturing

Lecture No


25


Definition of "manufacturing"

• Little m "manufacturing" (production)

Lecture No


26


Little "m" manufacturing is all about

Lecture No


27


Manufacturing

Cu

stom

er

ne

ed

s

People, money, machines and automation

Societal pressures, Government regulations, company plans and policies, etc

Products

manufacturingRaw

material

Lecture No


28


MaterialTransformation

ProcessesRa

w

Ma

teri

al A

ssembly

Products

Machines and Automation

Materials Science, Statics, Dynamics, Thermodynamics, Fluid dynamics

The manufacturing Process

Lecture No


29


manufacturing Process OverviewP

roducts

Ingotcasting

MoltenMaterial

Powders

CastingShapes

Rolling Forging/Press forming

Stamping

Pressing

Sheet metalforming

ContinuousCasting/Rolling

InjectionMolding

Ma

chinin

g

Fin

ishingR

aw M

ater

ial

Special

Extruding

Single crystalpulling

Firing/Sintering

SFF

Increasing level of detail

Blowmolding

Asse

mb

ly

Lecture No


30


Fundamentals of manufacturing - Concepts

• The ability to create shapes, components and assembled products relies on several physical phenomena

Lecture No


31


Fundamentals of manufacturing - Concepts

• The method chosen depends on the material and the shape and properties required

Lecture No


32


Liquid to solid phase transformation

Lecture No


33


Material Flow

Lecture No


34


Stress/strain conditions

• Pure Compressive– Open die forging

• Pure Tensile– Drawing

• Pure Shear– Cutting, machining, turning

Lecture No


35


Combined Stress States

• Rolling– Mostly compressive with some shear

• Forging– Extremely complex stress states

• Extrusion– Combination of high compressive and shear

stresses• Bending

– Mostly shear with tensile and compressive components

• Stretching with bending– Mostly shear with only tensile components

Lecture No


36


Combined Stress States

• Machining – Highly complex stress combination with high

levels of shear causing fracture in a controlled manner

Lecture No


37


Powder Processing• Takes advantage of the ability of powders to

flow like a liquid and fill complex shapes– Can be dry powders or slurries (particles

suspended in a liquid– The powders can be compacted by

• Pressure• Extracting the liquid

– This forms a green body which is friable and weak

– Heating to high temperatures causes the powder particles to "sinter" or fuse together and for a strong, nearly 100% dense product

Lecture No


38


Glass and Plastic Forming• Similar to metal bulk deformation • Silicate glasses have no yield stress but

require high temperatures for flow• Plastics have a yield stress but require only

room or modest temperatures to allow flow behavior

Lecture No


39


Wrap up• Introduction

– Statement of course goals– Overall class schedule– Statement of assumptions and policies

• Introductory overview of the larger issues – Definitions - "Manufacturing vs

manufacturing" – Basic concepts

Lecture 1

Documents