Chapter 0 General Introduction

Materials in an Automotive Engine Figure I.1 Section of an automotive engine - the Duratec V-6 - showing various components and the materials used in making them. (Source: Courtesy of Ford Motor Company. Illustration by David Kimball.)

Single component Multi-component Components in Products Single component (nail, bolt, fork, coat hanger, etc.) Multi-component (ball point pens, automobiles, washing machines, etc.) All components are manufactured. Manufacturing means, literally, “Made by Hand”.

Components in Products • Some products are a single components (nail, bolt, fork, coat hanger, etc.) • Some products are assemblies of many components (ball point pens, automobiles, washing machines, etc.) • All components are manufactured. • Manufacturing means, literally, “Made by Hand”.

Historical Development of Material and Manufacturing Process

History of Manufacturing (1700-1960)

History of Manufacturing (1960-2000s)

Materials Selection for Paper Clips Questions for consideration: • What material properties are required? • What manufacturing attributes are required? • Would the material and processing strategy change if the desired quantity was 10,000 vs. 1 million per day? Figure I.2 Examples of the wide variety of materials and geometries for paper clips.

Manufacture of Light Bulbs Figure I.3b Manufacturing steps in making an incandescent light bulb. Source: Courtesy of General Electric Company. Figure I.3a Components of a common incandescent light bulb. Source: Courtesy of General Electric Company.

Product Design Process Figure I.4 Depending on the complexity of the product and the type of materials used, the time span between the original concept and the marketing of the product may range from a few months to many years. (b) Product flow in concurrent engineering, from market analysis to selling the product. Source: After S. Pugh, Total Design. Addison-Wesley, 1991. (a) Various steps involved in design and manufacturing a product.

Redesign of Parts Figure I.5 Redesign of parts to facilitate assembly. Source: Reprinted from G. Boothroyd and P. Dewhurst, Product Design for Assembly, 1989. Courtesy of Marcel Dekker, Inc.

Manufacturing Characteristics of Alloys

Baseball Bat Cross-sections Figure I.6 Cross-sections of baseball bats made of aluminum (top portion) and composite material (bottom portion).

Manufacturing Processes: Casting Figure I.7a Schematic illustration of various casting processes

Manufacturing Processes: Forming and Shaping Figure I.7b Schematic illustration of various bulk deformation processes

Manufacturing Processes: Forming and Shaping Figure I.7c Schematic illustration of various sheet metal forming processes

Manufacturing Processes: Forming and Shaping Figure I.7d Schematic illustration of various polymer processing methods

Manufacturing Processes: Joining Figure I.7f Schematic illustration of various joining processes

Manufacturing Processes: Machining Figure 1.7e Schematic illustrations of various machining and finishing processes.

Laser Cutting Figure I.8 Cutting sheet metal with a laser beam. Source: Courtesy of Rofin-Sinar, Inc. and Manufacturing Engineering Magazine, Society of Manufacturing Engineers

Hip Replacement Figure 1.9 Components of a total hip replacement. Source: Courtesy of Zimmer, Inc.

Manufacturing of Hip Replacement Figure 1.10 (b) Manufacturing steps in the production of a forged stem. Hip stems can also be produced by investment casting, metal injection molding, insert injection molding, and assorted other processes. Source: Courtesy of Zimmer, Inc. (a) Manufacturing steps in the production of a roll-formed and machined total hip replacement stem;

Microscopic Components Figure I.11 A movable micro-mirror component of a light sensor. Source: Courtesy of Richard Mueller, University of California at Berkeley. Microscopic gears with dust mite. Source: Courtesy Sandia National Laboratory;

Salt and Pepper Shakers Figure I.12 A salt and pepper mill set. The two metal pieces (at the bottom) for the pepper mill are made by powder-metallurgy techniques. Source: Reproduced with permission from Success Stories on P/M Parts, Metal Powder Industries Federation, Princeton, NJ, 1998.

Automated welding of automobiles Figure I.13 Automated spot welding of automobile bodies in a mass production line. Source: Courtesy of Ford Motor Company.

Application of CAD/CAM to make sunglasses mold Figure I.14 Machining a mold cavity for making sunglasses. (a) Computer model of the sunglass as designed and viewed on the monitor. (b) Machine the die cavity using a computer numerical-control milling machine (c) Final product. Source: Courtesy of Mastercam/CNC Software, Inc.

Hourly Compensation for Production Workers