©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e INTRODUCTION AND OVERVIEW OF MANUFACTURING  What is Manufacturing?  Materials in Manufacturing  Manufacturing Processes  Production Systems

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Manufacturing is Important  Technologically  Economically

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Manufacturing - Technologically Important Technology - the application of science to provide society and its members with those things that are needed or desired  Technology provides the products that help our society and its members live better  What do these products have in common? They are all manufactured  Manufacturing is the essential factor that makes technology possible

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Manufacturing - Economically Important Manufacturing is one way by which nations create material wealth U.S. economy: Sector % of GNP Manufacturing20% Agriculture, minerals, etc.5% Construction & utilities5% Service sector – retail, transportation, banking, communication, education, and government 70%

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Manufacturing - Technologically Manufacturing as a technical Process: Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a starting material to make parts or products  Manufacturing also includes assembly  Almost always carried out as a sequence of operations

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Manufacturing - Economically Manufacturing as an economic process Transformation of 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

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Manufacturing Industries Industry consists of enterprises and organizations that produce or supply goods and services  Industries can be classified as: 1. Primary industries - those that cultivate and exploit natural resources, e.g., farming, mining 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

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Manufacturing Industries - continued  Secondary industries include manufacturing, construction, and electric power generation  Manufacturing includes several industries whose products are not covered in this book; e.g., apparel, beverages, chemicals, and food processing  For our purposes, manufacturing means production of hardware Nuts and bolts, forgings, cars, airplanes, digital computers, plastic parts, and ceramic products

Methods of Manufacture 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.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e 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  Assembly operations - join two or more components to create a new entity

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 1.4 Classification of manufacturing processes

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Processing Operations Alters a material’s shape, physical properties, or appearance in order to add value  Three categories of processing operations:  Shaping operations - alter the geometry of the starting work material  Property ‑ enhancing operations - improve physical properties without changing shape  Surface processing operations - to clean, treat, coat, or deposit material on exterior surface of the work

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Shaping Processes – Four Categories  Solidification processes - starting material is a heated liquid or semifluid  Deformation processes - starting material is a ductile solid (commonly metal)  Particulate processing - starting material consists of powders  Material removal processes - starting material is a ductile or brittle solid

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Solidification Processes - Casting Starting material is heated sufficiently to transform it into a liquid or highly plastic state  Examples: metal casting, plastic molding

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Open Molds and Closed Molds Figure 10.2 Two forms of mold: (a) open mold, simply a container in the shape of the desired part; and (b) closed mold, in which the mold geometry is more complex and requires a gating system (passageway) leading into the cavity.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 11.1 A large sand casting weighing over 680 kg (1500 lb) for an air compressor frame (photo courtesy of Elkhart Foundry).

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Shell Molding Casting process in which the mold is a thin shell of sand held together by thermosetting resin binder

Expanded Polystyrene Process

Investment Casting

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Permanent Mold Casting Figure Steps in permanent mold casting: (2) cores (if used) are inserted and mold is closed, (3) molten metal is poured into the mold, where it solidifies.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Die Casting Figure Cycle in cold ‑ chamber casting: (1) with die closed and ram withdrawn, molten metal is poured into the chamber

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Centrifugal Casting

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Forming Processes: Deformation Starting workpart is shaped by application of forces that exceed the yield strength of the material  Examples: (a) forging, (b) extrusion

Forming Processes: Deformation Bulk Deformation Sheet Metal Forming

Bulk Deformation Processes Rolling Extrusion Drawing Forging

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 19.2 Some of the steel products made in a rolling mill. Rolled Products Made of Steel

Cutting Deep Drawing Sheet Metal Forming Processes V-Bending

Presses Figure Schematic representation of the various types of press drive mechanisms.

Types of Press Frame Figure (Right) A 200-ton (1800-kN) straight-sided press. (Courtesy of Rousselle Corporation, West Chicago, IL.) Figure (Left) Inclinable gap-frame press with sliding bolster to accommodate two die sets for rapid change of tooling. (Courtesy of Niagara Machine & Tool Works, Buffalo, NY.)

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure Diagram showing details of a drop hammer for impression ‑ die forging. Drop Hammer Details

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure Components of a typical mechanical drive stamping press Stamping Press

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Forming: Particulate Processing Starting materials are powders of metals or ceramics  Usually involves pressing and sintering, in which powders are first compressed and then heated to bond the individual particles

Forming: Material Removal Processes -Machining Excess material removed from the starting piece so what remains is the desired geometry  Examples: machining such as turning, drilling, and milling; also grinding and nontraditional processes Turning: Machining of cylindrical parts Drilling Milling

Forming: Material Removal Processes -Machining Turning examples Standard TurningFacing Threading:

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 21.3 Two forms of milling: (a) peripheral milling, and (b) face milling. Two Forms of Milling

Turning Machine: Lathe

Milling Machine:

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 31.1 Basic configuration of an arc welding process. Joining Processes: Welding, a Permanent Joining Process

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e A pool of molten metal is formed near electrode tip, and as electrode is moved along joint, molten weld pool solidifies in its wake Figure 31.1 Basic configuration of an arc welding process. Arc Welding

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e 31.4 Gas metal arc welding (GMAW). Gas Metal Arc Welding

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Resistance welding, showing the components in spot welding, the main process in the RW group. Resistance Spot Welding

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure A typical oxyacetylene welding operation (OAW). Oxyacetylene Welding

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 32.4 Several techniques for applying filler metal in brazing: (a) torch and filler rod. Sequence: (1) before, and (2) after. Brazing - Soldering: Permanent Joining Processes – Weak Bonding, Lower Temperatures

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure Types of stresses that must be considered in adhesive bonded joints: (a) tension, (b) shear, (c) cleavage, and (d) peeling. Joining Process: Adhesive Bonding