1. Advanced Manufacturing ME 10405/10505 Professor Jim Waterman
For Today
Objectives of the Course
Who am I?
My approach to the course
Grading, Homework, PBWorks
Outline for the semester
What is Manufacturing – intro to the course

2. Advanced Manufacturing ME 10405/10505
Course Objectives
Provide an overview of modern manufacturing processes
Enable students to select and design efficient and cost effective processes to make things
Provide insights as to what is state of the art now, and what is coming
And leave each of you with a dissatisfaction for the ways things are made today!

3. Advanced Manufacturing ME 10405/10505 Syllabus
Obtain a broad understanding of how things are made:
Taxonomy of manufacturing processes and an examination of current state of the art manufacturing
Emphasis on trends and directions in manufacturing, the relationship of digital data to design and production, and the impact of supply chain on production decisions.
Objectives:
Provide Students with knowledge of modern manufacturing processes, future directions of manufacturing, to include additive (3D printing) techniques, the use of digital data across the entire design/build/support product life cycle.
Students will be able to identify appropriate manufacturing processes for given problems
Students will understand the key factors affecting product quality, productivity and economic production

4. Advanced Manufacturing ME 10405/10505
My Approach
Bring some relevance to the subject
What is happening in industry today
Bring you into the discussion
I want your questions, and your knowledge
We'll learn together
Get you ready to design for manufacture, or design the processes of the future

5. Graded Course Components
Homework % - mostly assigned from the text
Will be assigned about once weekly. Due in one week from assignment
To be submitted in PDF ONLY – to
Mid Term Exam %
Semester Project 30%
A project will be assigned, focusing on expanding your understanding of advanced manufacturing technologies and their application to important uses in today's world.
Grad student projects will likely require the manufacture of a physical product in addition to the research and design aspects involved in product and process design.
Final Exam %

6. Advanced Manufacturing ME 10405/10505 Course Outline – First Half
Text: Introduction to Manufacturing -Mikell P. Groover First Edition
ISBN-13:
ISBN-10:
Intro and Overview of Manufacturing
Engineering Materials
Properties of Engineering Materials
Dimensions Tolerancing and Surfaces
Metal Casting
Glassworking
Plastics
Rubber/Polymer Composites
Powder Metallurgy
Ceramics
Metal Forming and metal working (roll/forge/extrude)
Sheet Metal
Metal Machining(including tool life)
Principles
Machine Tools
Cutting tools tech
Mid Term – Monday, Oct 19

7. Advanced Manufacturing ME 10405/10505 Course Outline – Second Half
Grinding/abrasive processes
Non-traditional Processes
Mechanical Energy processes
Ultrasonic, Water Jet, Electrochemical machining
EDM,Electron Beam/Laser Beam Machining
Chem Machining
Heat Treatment of Metals
Surface Processing - Cleaning,Diffusion/ion implant,Plating/electroforming
Conversion coatings, Vapor deposition
Organic coatings
Welding :Fundimentals/Joints/physics
Processes: Arc, Oxy/fuel, Acetalyene, Fusion, Solid state
Braze/Solder/Adhesive bond
Mechanical Assembly
Rapid Prototype processes
Survey of Additive Manufacturing processes
SLA, Fused Deposition, Powder based
Ink/liquid based
What folks are doing to make additive as fast as current processes!
Micro/Nano fabrication technologies

8. Advanced Manufacturing ME 10405/10505 Course Outline – Second Half
Production Systems and process planning
Automation/Manufacturing Systems
CNC
Cells and work flow/part families/'Flexible Machine Cells'
Lean Manufacturing
Model based design and life cycle data driven mfg/standards.
Quality
Process Capability and Statistical Process Control
Futures
Extrapolating today to tomorrow - we'll do this throughout the semester
Supply Chain considerations – global issues
Final Exam – Weds, December 16

9. What is Manufacturing? Pg. 1-14 of Text
The word manufacture is derived from two Latin words, manus (hand) and factus (make)
Today manufacturing can be defined two ways:
Technologically
Economically
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

10. Technological Definition of Manufacturing
Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products
It also includes assembly of multiple parts to make products
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

11. Economic Definition of Manufacturing
The transformation of materials into items of greater value by means of one or more processing and/or assembly operations
Manufacturing adds value
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

12. Manufacturing Industries
Industries can be classified as:
Primary industries:
Cultivate and exploit natural resources (e.g., agriculture and mining)
Secondary industries:
Take the output of the primary industries and convert them into consumer and capital goods (e.g., manufacturing, construction, power utilities)
Tertiary industries:
Service sector (e.g., retail, financial, education, transportation, government)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

13. Manufactured Products
Final products made by the manufacturing industries can be divided into two major classes:
Consumer goods – products purchased directly by consumers (e.g., cars, personal computers, TVs, tires,, and tennis rackets)
Capital goods – products purchased by companies to produce goods and/or provide services (e.g., aircraft, trucks and buses, machine tools, construction equipment)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

14. Manufacturing and Gross Domestic Product (GDP)
In the U.S:
Manufacturing accounts for about 12% of GDP
And the service sector accounts for more than 75% of GDP
BUT! Manufactured capital goods purchased by the service sector are the enablers of that sector
Without these manufactured products, many service industries could not function
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

15. Production Quantity and Product Variety
Production quantity = the number of units produced annually of a given product type
Three ranges:
Low production (1 to 100 units per year)
Medium production ( 100 to 10,000 units)
High production (10,000 to millions of units)
Product variety refers to the number of different types of products made
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

16. Production Quantity and Product Variety
Manufacturing plants tend to specialize in a combination of production quantity and product variety that lies inside the diagonal band shown below
How can you increase product variety at higher rates of production?
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

17. Manufacturing Capability
Refers to the technical and physical limitations of a manufacturing firm and its individual plants
Three dimensions of manufacturing capability:
Processing capability – available set of manufacturing processes
Physical product limitations – size and weight of the products that can be made
Production capacity – production quantity that can be produced in a given time period
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

18. Materials in Manufacturing
Most engineering materials fall into one of 3 basic categories:
Metals:
Ferrous (e.g., steel and cast iron)
Nonferrous (e.g., aluminum, copper, nickel)
Ceramics
Crystalline ceramics (e.g., clay, alumina)
Glass
Polymers
Thermoplastics (e.g., polyethylene)
Thermosets (e.g., epoxies)
Elastomers (e.g., rubber)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

19. Manufacturing Processes
A manufacturing process is a procedure that results in physical and/or chemical changes to material to increase the value of that material
Usually carried out as a unit operation, which is a single step in the sequence of steps required to transform the material into as final product
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

20. Two Basic Types of Manufacturing Operations
Processing operations – transforms a work material from one state of completion to a more advanced state that is closer to the final desired product
Usually performed on discrete workparts
Assembly operations – joins two or more components to create a new entity, called an assembly, subassembly, or other term (e.g., weldment)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

21. Manufacturing Taxonomy
You will see this again!
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

22. Processing Operations – where we'll get started
General types:
Shaping operations – alter the geometry of the starting work material
Property-enhancing operations – improve the physical properties of the material without changing its shape
Surface processing operations – performed to clean, treat, coat, or deposit material onto the surface of the work
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

23. Shaping Processes
Four categories based on the state of the starting material:
Solidification processes
Particulate processes
Deformation processes
Material removal processes
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

24. Solidification Processes
Starting material is a heated liquid or semifluid that cools and solidifies to form the part geometry
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

25. Particulate Processes
Starting material is a powder, and the powders are formed to create geometry and heated to strengthen
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

26. Deformation Processes
Starting material is a ductile solid (commonly metal) that is deformed to shape the part
Forging Extrusion
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

27. Material Removal Processes
Starting material is a solid (ductile or brittle), from which material is removed so that what remains has the desired geometry
Turning Drilling Milling
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

28. Property-Enhancing Processes
Involves heat treatments, which include:
Annealing and strengthening processes performed on metals and glasses
Sintering of powdered metals and crystalline ceramics
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

29. Surface Processing Operations:
Cleaning – chemical and mechanical processes to remove dirt, oil, and other contaminants
Surface treatments – mechanical working (e.g., sand blasting) and physical processes (e.g., diffusion)
Coating and thin-film deposition – apply a coating to the exterior surface of the work (e.g., electroplating, painting, physical vapor deposition)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

30. Assembly Operations Permanent Joining processes Welding Brazing
Soldering
Adhesive bonding
Mechanical Fastening
Joints can be disassembled (e.g., threaded fasteners)
Joints are permanent (e.g., rivets)
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

31. Production Machines
Machine tools – power-driven machines used to operate cutting tools
Other production machines developed subsequently:
Presses for stamping operations
Forge hammers
Rolling mills
Welding machines
Insertion machines for assembly
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

32. Categories of Production Equipment
General-purpose machines
More flexible and adaptable to a variety of jobs
Commercially available for any manufacturing company to invest in
Special-purpose machines
Usually designed to produce a specific part or product in very large quantities
Achieve high efficiencies and short cycle times
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

33. Tooling
Production machines usually require tooling that customizes the equipment for a particular part or product
In many cases, the tooling must be designed specifically for the part or product (e.g., a mold)
When used with general-purpose equipment, the tooling can be exchanged at the end of a production run
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

34. Production Equipment and Tooling for Various Processes
Process Equipment Special tooling
Casting (various types) Mold
Molding Molding machine Mold
Forging Forge hammer Forging die
Extrusion Extrusion press Extrusion die
Stamping Stamping press Stamping die
Machining Machine tool Cutting tool
Grinding Grinding machine Grinding wheel
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

35. Some Resources (outside of the book)
The Library of Manufacturing: good companion resource to book for process information
Industry Week website – news, white papers
PBWorks site
Most of you should have an invite already – it will contain assignments, class materials, etc.
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

36. For Next Class Read Textbook Intro to Mfg Overview – pg 1-14
Engineering Materials/Properties of Materials – pg
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes