Manufacturing with Metallic Materials

(MEL202)
Harpreet Singh
Associate Professor
School of Mechanical, Materials & Energy Engineering
Indian Institute of Technology (IIT) Ropar
Room Number: 208
Email: harpreetsingh@iitrpr.ac.in
Phone: +91-1881-242177
Cell: +91-98557-09052

What is Manufacturing?
Manufacture is derived from two Latin words
manus (hand) and factus (make); the
combination means made by hand
Made by hand accurately described the
manual methods used when the word
manufacture was first coined
Most modern manufacturing is accomplished
by automated and computercontrolled
machinery that is manually supervised
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Manufacturing transforms materials into items of

greater value by means of one or more processing
and/or assembly operations
Manufacturing adds value to the material by
changing its shape or properties, or by combining it
with other materials that have been similarly altered

Figure 1.1 (b)

Manufacturing
as an economic
process

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Manufacturing Industries
Industry consists of enterprises and
organizations that produce or supply goods
and services
Industries can be classified as:
1. Primary industries - cultivate and exploit natural
resources, e.g., agriculture, mining , etc.
2. Secondary industries - take the outputs of
primary industries and convert them into
consumer and capital goods - manufacturing is
the principal activity
3. Tertiary industries -service sector of the economy

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Manufacturing Industries - continued

Most secondary industries are companies that do
manufacturing; others are construction and
power generation
However, manufacturing includes several
industries whose production technologies are not
covered in this course; e.g., textiles, beverages
and food processing, chemicals, etc.
For our purposes, manufacturing means
production of hardware, which ranges from nuts
and bolts to digital computers and military
weapons, as well as plastic and ceramic products

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Manufacturing with Metallic

Materials

Product realization with metals, Material properties,

Microstructure, Correlation between microstructure
and properties, interfaces and intermetallics
Property modifications-heat treatment and allied
process, Casting techniques and analysis, Forming
techniques and analysis, Forging technique and
analysis, Machining methods, Conventional and
Non-conventional and their analysis, Assembly and
fabrication techniques, Welding and allied
processes, Product testing and quality control,
Advanced applications in general engineering,
aerospace, automobile and biomedical industries.

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Materials in Manufacturing
Most engineering materials can be
classified into one of three basic categories:
1. Metals
2. Ceramics
3. Polymers

Their chemistries are different, their

mechanical and physical properties are
dissimilar, and these differences affect the
manufacturing processes that can be used
to produce products from them

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

 In addition to the three basic categories, there are:

4.Composites nonhomogeneous mixtures of the other
three basic types rather than a unique category

Figure 1.3
Venn diagram
of three basic
Material types
plus composites

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Metals
Usually alloys, which are composed of two or
more elements, at least one of which is
metallic
Two basic groups:
1. Ferrous metals - based on iron, comprise
75% of metal tonnage in the world:

Steel = ironcarbon alloy with 0.02 to 2.11% C

Cast iron = ironcarbon alloy with 2% to 4% C

2. Nonferrous metals - all other metallic elements

and their alloys: aluminum, copper, gold,
magnesium, nickel, silver, tin, titanium, etc.

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Ceramics
A compound containing metallic (or semimetallic) and nonmetallic elements.
Typical nonmetallic elements are oxygen,
nitrogen, and carbon
For processing purposes, ceramics divide
into:
1. Crystalline ceramics includes:

Traditional ceramics, such as clay (hydrous

aluminum silicates)
Modern ceramics, such as alumina (Al2O3)

2. Glasses mostly based on silica (SiO 2)

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Polymers
A compound formed of repeating structural
units called mers, that link to form very
large molecules
Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without
altering their molecular structure
2. Thermosetting polymers - molecules chemically
transform (cure) into a rigid structure upon
cooling from a heated plastic condition
3. Elastomers - exhibit significant elastic behavior

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Composites
A material consisting of two or more phases that
are processed separately and then bonded
together to achieve properties superior to its
constituents
A phase = a homogeneous mass of material, such
as grains of identical unit cell structure in a solid
metal
Usual structure consists of particles or fibers of
one phase mixed in a second phase
Properties depend on components, physical
shapes of components, and the way they are
combined to form the final material
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Manufacturing Processes
Two basic types:
1. Processing operations - transform a work
material from one state of completion to
a more advanced state
Operations that change the geometry,
properties, or appearance of the starting
material

2. Assembly operations - join two or more

components in order to create a new
entity
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Processing Operations
Alter a workpart's shape, physical properties,
or appearance in order to add value to the
material
Three categories of processing operations:
1. Shaping operations - alter the geometry of the
starting work material
2. Propertyenhancing operations - improve
physical properties of the material without
changing its shape
3. Surface processing operations - performed to
clean, treat, coat, or deposit material onto the
exterior surface of the work
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Shaping Processes Four Categories

1. Solidification processes - starting material is a
heated liquid or semifluid that solidifies to form
part geometry
2. Particulate processing - starting material is a
powder, and the powders are formed into desired
geometry and then sintered to harden
3. Deformation processes - starting material is a
ductile solid (commonly metal) that is deformed
4. Material removal processes - starting material is a
solid (ductile or brittle), from which material is
removed so resulting part has desired geometry

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Solidification Processes
Starting material is heated sufficiently to
transform it into a liquid or highly plastic state
Examples: Casting for metals, molding for plastics

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Particulate Processing
Starting materials are powders of metals or ceramics
Usually involves pressing and sintering, in which powders are first squeezed in a die cavity
and then heated to bond the individual particles

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Deformation Processes
Starting workpart is shaped by application of
forces that exceed the yield strength of the
material
Examples: (a) forging, (b) extrusion

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Material Removal Processes

Excess material removed from the starting workpiece
so what remains is the desired geometry
Examples: machining such as turning, drilling, and
milling; also grinding and nontraditional processes

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Waste in Shaping
Processes
It is desirable to minimize waste and scrap in part
shaping
Material removal processes tend to be wasteful
in the unit operation, simply by the way they
work
Casting and molding usually waste little material
Terminology:
Net shape processes - when most of the starting
material is used and no subsequent machining is
required to achieve final part geometry
Near net shape processes - when minimum amount
of machining is required
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

PropertyEnhancing
Processes
Performed to improve mechanical or
physical properties of the work
material
Part shape is not altered, except
unintentionally
Examples:
Heat treatment of metals and glasses
Sintering of powdered metals and
ceramics
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Surface Processing
Operations

1. Cleaning - chemical and mechanical

processes to remove dirt, oil, and other
contaminants from the surface
2. Surface treatments - mechanical working
such as sand blasting, and physical
processes like diffusion
3. Coating and thin film deposition - coating
exterior surface of the workpart
. Several surface processing operations are
used to fabricate integrated circuits
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Assembly Operations
Two or more separate parts are joined to
form a new entity
Types of assembly operations:
1. Joining processes create a permanent joint.

Examples: welding, brazing, soldering, and

adhesive bonding

2. Mechanical assembly fastening by

mechanical methods
. Examples: use of screws, bolts, nuts, other
threaded fasteners; press fitting, expansion
fits

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Production Systems
The people, equipment, and procedures
designed for the combination of materials
and processes that constitute a firm's
manufacturing operations
A manufacturing firm must have systems to
efficiently accomplish its type of production
Two categories of production systems:
1. Production facilities
2. Manufacturing support systems

Both categories include people (people

make these systems work)

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Production Facilities
The factory, production equipment, and
material handling equipment
The facilities "touch" the product
Also includes the way the equipment is
arranged in the factory the plant layout
Equipment usually organized into logical
groupings, called manufacturing systems
Examples: automated production line,
machine cell consisting of an industrial robot
and two machine tools
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Production Facilities and

Product Quantities
A company designs its manufacturing systems
and organizes its factories to serve the particular
mission of each plant
Certain types of production facilities are
recognized as the most appropriate for a given
type of manufacturing (combination of product
variety and production quantity)
Different facilities are required for each of the
three quantity ranges
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Low Quantity Production

Job shop is the term used for this production
facility
Low quantity range = 1 to 100 units/year
A job shop makes low quantities of specialized
and customized products
Products are typically complex, e.g., space
capsules, prototype aircraft, special machinery
Equipment in a job shop is general purpose
Labor force is highly skilled
Designed for maximum flexibility
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Medium Quantity Production

Medium quantity range = 100 to
10,000 units annually
Two different types of facility,
depending on product variety:
Hard product variety: batch production
Soft product variety: cellular
manufacturing

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

High Production
High quantity range = 10,000 to
millions of units per year
Referred to as mass production
High demand for product
Manufacturing system dedicated to the
production of that product

Two categories of mass production:

1. Quantity production
2. Flow line production
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Quantity Production
Mass production of single parts on
single machine or small numbers of
machines
Typically involves standard machines
equipped with special tooling
Equipment is dedicated full-time to
the production of one part type
Typical layouts used in quantity
production = process layout and
cellular layout

Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Flow Line Production

Multiple machines or workstations arranged in
sequence, e.g., production lines
Product is complex and requires multiple
processing and/or assembly operations
Work units are physically moved through the
sequence to complete the product
Workstations and equipment are designed
specifically for the product to maximize efficiency
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Manufacturing Support
Systems
A company must organize itself to design the
processes and equipment, plan and control the
production orders, and satisfy product quality
requirements
These functions are accomplished by manufacturing
support systems people and procedures by which a
company manages its production operations
Typical departments:
1. Manufacturing engineering
2. Production planning and control
3. Quality control
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.

Figure 1.10 Overview of production system and major

topics in Fundamentals of Modern Manufacturing
Adapted from Fundamentals of Modern Manufacturing, M. P. Groover, 2nd Ed., 2002, John Wiley & Sons, Inc.