DM23810

1. Instructor; Prof. Haedo Jeong (Rm 3209)

TEL 2463, hdjeong@pusan.ac.kr

2.Class; Mon/Wed, 09:00-10:15 @ Rm 3315(5)

13:30-14:45 @ Rm 3315(1)

2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

DM23810
1. Aim; To study fundamentals of production,
manufacturing processes and their applications
2.Text; ()
Introduction to Manufacturing Processes
(Mikell P. Groover)
3. Handouts
http://www.cmplab.re.kr/board/
2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

DM23810
4. Review Questions, Problems
. >>> .

5. ; ( ) Handout
6. ; (10%), Quiz (30%), (30%), (30%)
2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

DM23810
9/5,7
9/12,14
9/19,21
9/26, 28
10/3, 5
10/10, 12
10/17, 19
10/24, 26
10/31, 11/1
11/7, 9
11/14
11/16,21
11/23, 28
11/30, 12/5
12/7,12
12/14, 19

Introduction & Overview > Chap1_33

Fundamentals of metal casting; Chap5 _35
Metal casting processes; Chap6_101
metal forming > Chap12_28
Metal forming > Chap13_70
Sheet metal working > Chap14_60
Midterm test
Machining > Chap15_44
Machining > Chap16_77/ Chap17_60
Abrasive > Chap18_49
Nontraditional > Chap19_59
Welding > Chap22_41 / Chap23_105
Brazing and assembly > Chap24_38 /Chap25_43
Special processing > Chap26_34 / Chap27_72
2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
Final Exam

 2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

INTRODUCTION AND
OVERVIEW OF
MANUFACTURING
1. What is Manufacturing
2. Manufacturing Processes
3. Organization of the Book

2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

History & Future

2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

History & Future

, ,

2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Trend of Manufacturing

History of Engineering (Emergence of a New Machine)

2020

Technology leader may be a word leader

1500

Source : Stanford University Learning Laboratory, http://learninglab.stanford.edu

1800

1940

1960

Light Industry

Satellite

Steam Engine

Heavy Industry

Men on the Moon

Bio-Chip

2000

Fusion

Prehistoric age

1980
Electronics

E-Paper

Hubble
Space station

ENIAC

Hydrogen car
Super comp. High-speed train

Solar-energy car

History of Engineering = History of Manufacturing

1980s

Macroscale

Mesoscale

Microscale

2000s

Nanoscale

What is Manufacturing?
The word manufacture is derived from two Latin
words, manus (hand) and factus (make)
Taken together the combination means made by
hand, which is how things were made in 1567 when
the word first entered the English language
Today manufacturing can be defined two ways: R2
Technologically
Economically

2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Technological Definition of
Manufacturing
The 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

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

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) R3
Tertiary industries constitute the service sector (e.g.,
retail, financial, education, transportation, government)
2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

What is Manufacturing?

2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

What is Manufacturing?

.
2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

What is Manufacturing?

Manufactured Products
Final products made by the manufacturing industries
can be divided into two major classes: R4
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

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; R1
However, the manufactured capital goods purchased
by the service sector are the enablers of that sector
Without these manufactured products, the service
industries could not function

2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

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
Soft product variety vs. hard product variety R5
2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

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

2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing Capability
Refers to the technical and physical limitations of a
manufacturing firm and its individual plants
Three dimensions of manufacturing capability:
1. Technological processing capability available
set of manufacturing processes R6
2. Physical product limitations size and weight of
the products that can be made
3. 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

Materials in Manufacturing
Most engineering materials can be classified into one
of three (four) basic categories: R7
1. Metals ferrous (e.g., steel R8, R9 and cast iron)
and nonferrous (e.g., aluminum, copper, nickel)
2. Ceramics crystalline ceramics (e.g., clay,
alumina) and glass
3. Polymers thermoplastics (e.g., polyethylene),
thermosets (e.g., epoxies) R10, and elastomers
(e.g., rubber)
4. Composite materials
2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Manufacturing Processes
A manufacturing process is a designed procedure
that results in physical and/or chemical changes to a
starting work material with the intention of increasing
the value of that material
Usually carried out as a unit operation R11, 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

Two Basic Types of

Manufacturing Operations R12
1. 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
2. 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

 2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Processing Operations
General types:
1. Shaping operations alter the geometry of the
starting work material
2. Property-enhancing operations improve the
physical properties of the material without
changing its shape
3. 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

Shaping Processes
Four categories based on the state of the starting
material: R13
1. Solidification processes
2. Particulate processes
3. Deformation processes
4. Material removal processes

Net shape processes vs. Near-net shape processes:

R14
2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Shaping processes

Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c)
extrusion, (d) machining, (e) joining two pieces.

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

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

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

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

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

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

Assembly Operations
Joining processes form permanent joints R15
Welding
Brazing
Soldering
Adhesive bonding
Mechanical assembly
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

Production Machines
Machine tools R16 power-driven machines used to
operate cutting tools previously operated by hand
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

Categories of Production
Equipment R17
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

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

Production Equipment and

Tooling for Various Processes
Process
Casting
Molding
Forging
Extrusion
Stamping
Machining
Grinding

Equipment
(various types)
Molding machine
Forge hammer
Extrusion press
Stamping press
Machine tool
Grinding machine

Special tooling
Mold
Mold
Forging die
Extrusion die
Stamping die
Cutting tool
Grinding wheel

2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Organization of the Book

I. Engineering materials and product attributes
II. Solidification processes
III. Particulate processing
IV. Metal deformation processes
V. Material removal processes
VI. Property enhancing and surface processing
VII. Joining and assembly processes
VIII.Special processing and assembly processes
IX. Systems topics in manufacturing
2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Organization of the Book

2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

A spectacular scene in steelmaking is charging of a basic oxygen furnace, in which

molten pig iron produced in a blast furnace is poured into the BOF. Temperatures
are around 1650C (3000 F).

A robotic arm performs

unloading and loading
operation in a turning
center using a dual gripper
(photo courtesy of
Cincinnati Milacron).

Metal chips fly in a high

speed turning operation
performed on a computer
numerical control turning
center (photo courtesy of
Cincinnati Milacron).

Two welders perform arc

welding on a large steel
pipe section (photo
courtesy of Lincoln
Electric Company).

Automated dispensing of
adhesive onto component
parts prior to assembly
(photo courtesy of EFD,
Inc.).

Assembly workers on an
engine assembly line
(photo courtesy of Ford
Motor Company).

Assembly operations
on the Boeing 777
(photo courtesy of
Boeing Commercial
Airplane Co.).

A batch of silicon wafers enters a furnace heated to 1000C (1800F) during

fabrication of integrated circuits under clean room conditions
(photo courtesy of Intel Corporation).

Micromanufacturing Processes
Hannover Univ. (Prof. B.N. Chichkov, Germany)

Concurrent Engineering

Conjoined Twins

2D X-rays

From CT scan data to STL files

(Materialises MIMICS, 3 days)

22-hour-long operation
(usually, 97 hours)
Thanks to rapid
prototyping, conjoined
twins could be
successfully separated

Objet Tempo

Water jet-soluble

Rapid Prototyping (80 hr)

Surgical planning

Ref) University of California Los Angeles (UCLA) Mattel Childrens Hospital (2002)