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					     IE 572
  Manufacturing
   Techniques



Y. Doç. Dr. Oğuz Akalın
    Introduction

l   Scheduled for 14 weeks
l   each week 3 hrs lecture session
l   assessment by
    • Two mid-term exams              %30
    • Projects, homeworks, quizes     %30
    • final exam                      %40
Course Schedule
Wk 1
 SESSION 1
 Introduction to Manufacturing Techniques
 The Structure of Metals
Wk 2
 SESSION 2
 Mechanical Behaviour Testing and
 Manufacturing Properties of Materials
Course Schedule
Wk 3
  SESSION 3
  Physical Properties of Materials
       Metal Alloys
       Ferrous Metals and Alloys
       Nonferrous Matel and Alloys
Wk 4
  SESSION 4
  Fundementals of Metal Casting
  Rolling of Metals
  Forging of Metals
  Extrusion and Drawing of Metals
  Sheet-Forming Metal Processes
Course Schedule
Wk 5
  SESSION 5
  Fundementals of Machining
  Cutting Tools
  Turning and Hole Making
  Milling, Broaching and Sawing
Wk 6
  SESSION 6
  Fusion-Welding Processes
  Solid-state Welding Processes
  Brazing, Soldering and Mechanical-fastening Processes
Course Schedule
Wk 7
 SESSION 7
 Surface Roughness and Measurement
 Friction, Wear and Lubrication
Wk 8
 SESSION 8
 Quality Assurance, Testing and Inspection
Course Schedule

Wk 9
 SESSION 9
 Automation of Manufacturing Processes
Wk 10
 SESSION 10
 Computer-Aided Manufacturing
Course Schedule
Wk 11
 SESSION 11
 Computer-Integrated Manufacturing
 Systems
Wk 12
 SESSION 12
 Product Design and Process Selection in
 a Competitive Environment
References

l   “Manufacturing Engineering and
    Technology”, S. Kalpakjian & S.R.
    Schmid, Prentice Hall, Fifth Edition.
                        Chapter 0
General Introduction




Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
 ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
        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.

            Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
             ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
        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”.




Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
 ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
History of Manufacturing (until 1700)




   Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
    ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
History of Manufacturing (1700-1960)




   Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
    ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
History of Manufacturing (1960-2000s)




    Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
     ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
           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.




               Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
                ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
                       Manufacture of Light Bulbs




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




                   Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
                    ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
        Product Design Process
                                                                    Figure I.4 (a) Chart showing the
                                                                    various steps involved in design
                                                                    and manufacturing a product.
                                                                    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) Chart showing general
                                                                    product flow in concurrent
                                                                    engineering, from market analysis
                                                                    to selling the product. Source:
                                                                    After S. Pugh, Total Design.
                                                                    Addison-Wesley, 1991.




Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
 ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
                             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, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
           ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Characteristics of Alloys




    Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
     ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
                   Baseball Bat Cross-sections




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




                 Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
                  ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
       Manufacturing Processes: Casting




Figure I.7a Schematic illustration of various casting processes
       Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
        ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Processes: Forming and Shaping




 Figure I.7b Schematic illustration of various bulk deformation processes
         Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
          ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Processes: Forming and Shaping




Figure I.7c Schematic illustration of various sheet metal forming processes
          Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
           ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Processes: Forming and Shaping




                   Figure I.7d Schematic illustration of
                   various polymer processing methods

      Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
       ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Processes: Machining




      Figure 1.7e Schematic illustrations of various
           machining and finishing processes.
 Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
  ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
     Manufacturing Processes: Joining




Figure I.7f Schematic illustration of various joining processes

     Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
      ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
                           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




Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
 ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
                    Hip Replacement




Figure 1.9 Components of a total hip replacement.
         Source: Courtesy of Zimmer, Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
 ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
               Manufacturing of Hip Replacement




           Figure 1.10 (a) Manufacturing steps in the production of a roll-formed and m
achined total hip replacement stem; (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.

                    Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
                     ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
                    Microscopic Components




Figure I.11 (a) Microscopic gears with dust mite. Source: Courtesy Sandia
National Laboratory; (b) A movable micromirror component of a light sensor.
 Source: Courtesy of Richard Mueller, University of California at Berkeley.




              Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
               ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
       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.




Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
 ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automated welding of automobiles



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




  Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
   ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
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.




       Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
        ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Hourly Compensation for Production Workers




       Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
        ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

				
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