1. Chapter 0
General Introduction

2. 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.)

3. 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”.

4. 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”.

5. Historical Development of Material and Manufacturing Process

6. History of Manufacturing (1700-1960)

7. History of Manufacturing (1960-2000s)

8. 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.

9. 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.

10. 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.

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

12. Manufacturing Characteristics of Alloys

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

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

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

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

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

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

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

20. 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

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

22. 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;

23. 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;

24. 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.

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

26. 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.

27. Hourly Compensation for Production Workers