Taiz

University
Materials & Manufacturing
Technology (MMT)

Module 1:
Introduction

ir. Hans Ponsen April 2011

Master Engineering & Management

Content of module 1 Taiz
University
Introduction
Learning objectives / Educational concept
Course content and overview
Examination requirements
What is manufacturing? (Chapter 1)
Materials, processes and systems (Chapter 1)
Product attributes (Chapter 5)
Interfaces with other courses
Problems, exercises, discussions

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Lecturer
Taiz

Lecturer : ir. Hans Ponsen University

Last job at the University of Twente (technology and

management), education, education, development,
internationalization.
Technical expert and consultant for manufacturing
and materials engineering in the Netherlands Antilles
(Caribbean).
Experience in industry in the design and
implementation of production lines for the
forming and sheet metal industries.
Research in forming technology (metal
extrusion)
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Educational concept
Taiz
University

Teaching and application of knowledge.

Balanced mix of lectures, group discussions,
video films, problem solving and case studies.
Application of knowledge very important (also
during examination!)
Problems are realistic and can be rather complex.
Case studies and problem solving as teamwork.
The assessment is based for 30% on
student participation during the course.

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Learning objectives (1)
Taiz
University

Knowledge and understanding of structure and

properties of metals, polymers, composites and
ceramics.
Evaluation and testing of the quality of engineering
materials.
Knowledge and understanding of the most
important manufacturing processes.
Understanding the relationships among material
properties and manufacturing process parameters.
Knowledge, understanding and skills to make
quantitative analyses of manufacturing processes.
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Learning objectives (2)
Taiz
University

To be able to select the most appropriate manu-

facturing process for the production of any product
or product part.
Design guidelines related to manufacturing pro-
cesses.
Main objective: Answer the questions
What is the best way to manufacture an arbitrary
product or product part?
How are existing products made?

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Content of the course MMT (1)
Taiz
University

1) Introduction: General information, objectives,

what is manufacturing?, product attributes,
interfaces with other courses.
2) Material properties: Nature of materials, stress-
strain relationships, hardness, fluid properties,
visco-elastic behaviour of polymers.
3) Engineering materials: Metal alloys, ferrous and
non-ferrous materials, polymer technology,
thermoplastics, thermosets, elastomers, ceramics,
composite materials.

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Content of the course MMT (2)
Taiz
University
4) Processes for shapeless materials:
Casting fundamentals and processes, casting quality,
design aspects, powder metallurgy, rapid prototyping
technologies.
5) Shaping of polymers, rubber and composites:
Polymer melts, extrusion, injection moulding,
compression moulding, blow moulding, thermoforming,
design aspects, processes for rubber and composites.
6) Metal forming: Material behaviour in metal forming,
influence of temperature, friction and lubrication, rolling
processes, forging processes, extrusion, wire and bar
drawing.

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Content of the course MMT (3)
Taiz
University

7) a. Sheet metalworking: Cutting operations, bending

operations, other sheet-metal operations, dies and
presses, other machines, bending of tube.
b. Property enhancing and surface processing:
Heat and surface treatment, cleaning, coating.
8) Material removal: Chip formation, force, power and
energy relationships, cutting temperature, turning
operations, drilling, milling, machining and turning
centres, other machining operations.
9) Material removal: tool life, tool materials, cutting fluids,
machineability, tolerances and surface finish, selection
of cutting conditions, design aspects, grinding, electric
discharge and laser beam machining.
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Content of the course MMT (4)
Taiz
University

10) Joining and assembly: Fundamentals of welding,

welding processes, weld quality, weldability,
brazing, soldering, adhesive bonding, mechanical
assembly, design aspects.
11) Manufacturing (support) systems: Numerical
control, industrial robots, group technology, FMS,
production lines, quality control, metrology,
measuring instruments, surface measurement.
12) Summary: Overall overview, guidelines and
recommendations, material and manufacturing
process selection, last consultancy.
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Examination requirements
Taiz
University
Final mark:
- 30% participation in group discussions and work
- 70% written or oral examination

Subjects for the examination:

- Will be specified on Black Board

Expected knowledge and skills :

- You must be able to reproduce the basic knowledge
- You must be able to apply the knowledge about materials
and manufacturing operationally

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What is manufacturing?
Taiz
University

Literal: Manufacture = Manus (hand) + Factus

(make) Made by hand
Technological: Application of physical and chemical
processes to make parts or products,
including assembly of products.
Economical: Transformation of materials into items
of greater value by means of proces-
sing and/or assembly operations.
CIRP definition: Design + production + assembly
(CIRP = International Academy for Production Eng.)
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What is manufacturing?
Taiz
University

Representation of manufacturing
in a technological way

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What is manufacturing?
Taiz
University

Representation of manufacturing
in a economical way

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Importance of manufacturing
Taiz
University
Manufacturing is an important mean to create
material wealth!!!
One job in a manufacturing plant generates about
four other jobs else!!! Question: How?
Data from the USA:
- Manufacturing : ~ 20% of the GNP
- Agriculture, mining : < 5% of the GNP
- Construction, public utilities : ~ 5% of the GNP
- Service sector : ~ 70% of the GNP
(GNP = Gross National Product)

Question: What are the figures for Yemen?

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Historical perspective (1)
Taiz
University
In broad outlines:
Mans discovery and invention of materials and
processes to make things, since 6000 years ago
Principle of division of labour Adam Smith (~1750)
Industrial Revolution (1770 1850), steam engine,
machine tools, machinery for textile industry
Factory system, UK
American system, interchangeable parts
Whitney (~1800), guns (muskets), USA
Second Industrial revolution mass production,
scientific management, assembly lines, Ford
(~1915), cars, USA
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Industries and products
Taiz
University
Manufacturing industries
- Primary industries: natural resources as mining, fishing,
agriculture, petroleum
- Secondary industries: automotive, computers, electronics
- Tertiary industries (service): banking, tourism, education

Manufactured products
- Consumer goods: cars, TVs, tires, tennis rackets
- Capital goods: aircraft, machine tools, machinery
- Discrete products: pumps, shavers, coffee makers
- Continuous produced products: sheet-metal coils

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Product example
Taiz
University

Electric shaver

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Production quantity and variety
Taiz
University

Production quantity: low (<100), medium

(102-104), high (>104)

Production variety: low, medium, high

soft, hard

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Manufacturing capability
Taiz
University

Technological Processing capability

- Available processes and machines
- Outsourcing of some operations (casting, heat
treatment, etc.)
Physical product limitations
- Size, weight
- Machine dimensions, handling
Production capacity (Plant capacity)
- Production quantity in a given time, output

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Materials in Manufacturing
Taiz
University
Metals
- Ferrous: Steel (iron-carbon, 0,02% - 2,11% C)
Cast iron (iron + 2% - 4% C + silicon)
- Nonferrous: copper, aluminium, nickel, alloys
Ceramics: clay, silica, carbides (Al, Si), nitrides (Ti)
Polymers
- Thermoplastic polymers: PE, PP, PS, PVC
- Thermosetting polymers: phenolics, epoxies
- Elastomers: rubber, neoprene, silicone, PU
Composites: more phases, particles/fibres + matrix
glass reinforced plastic, Kevlar, WC in cobalt
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Materials in Manufacturing
Taiz
University

Venn diagram

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Historical perspective (2)
Taiz

Manufacturing materials and processes: University

Neolithic period (~8000 - 3000 B.C.) in Mesopotamia

Mediterranean, Asia; hammering, gold
Bronze age (3500 - 1500 B.C.), extracting copper
from ores, casting, hammering.
Iron age (since 1000 B.C.), heating, quenching
Industrial Revolution (1770 - 1850), machining like
boring, turning, drilling, milling, shaping.
Assembly methods (since ancient cultures), ships,
weapons, tools, farming equipment
Fusion welding (around 1900)
Rubber and polymer shaping, vulcanization (1939)
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 Manufacturing
Classification of processes
Taiz
Manufacturing processes University

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Processing operations
Taiz
University
1) Shaping operations
- Solidification processes casting of metals,
moulding of plastics
- Particulate processing powder metallurgy
- Deformation processes forging, extrusion
- Material removal processes machining, non-
traditional, grinding
2) Property enhancing processes
- Heat treatments, sintering
3) Surface processing
- Cleaning, coating, plating, deposion

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Casting and moulding processes
Taiz
University

Pouring of the Solidification

liquid or melt

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Particulate processing
Taiz
University

Sintering
Powder
Pressing

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Deformation processes
Taiz
University

Forging Extrusion

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Shaping processes
Taiz
University

General aim: Minimize waste and scrap!!!

- Net shape processes no subsequent machining
- Near net shape processes minimum machining

Turning Drilling Milling

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Manufacturing processes
Taiz
University
1) Processing operations
2) Assembly operations
- Permanent joining: welding, brazing, adhesives
- Mechanical assembly: bolts, screws, rivets, etc.
3) Production machines and tooling
- Machine tools: lathe, milling machine, etc.
- Presses, forge hamers, rolling mills
- Welding machines and equipment
- General and special purpose equipment
- Tooling
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Production systems
Taiz
University
Consist of people, equipment and procedures
Production facilities: factory, production equipment
material handling equipment
Plant layout + Manufacturing systems
Influence of production quantity (low, medium,
high)
Manufacturing support systems
- Manufacturing engineering process planning
- Production planning and control logistics,
ordering materials and parts, scheduling
- Quality control
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Influence of production quantity
Taiz
University
Low quantity production (1 100 units/year)
- Job shop maximum flexibility, fixed-position
layout and often also process layout
- Examples: aircraft, ships, heavy machinery
Medium quantity production (102 104 units/year)
- Batch production process layout or cellular
layout, usually make-to-stock
- Examples: pumps, lathes, gear drives
High quantity production (> 10.000 units/year)
- Flow line production product layout
- Examples: cars, household appliances
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 Plant layouts
Taiz
University

Fixed-position layout Process layout

Cellular layout Product layout

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Production System
Taiz
University

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Mutual relationships
Taiz
University

Function

Material Shape

Process

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Product attributes
Taiz
University
Mechanical properties, e.g. tensile strength
Physical properties, e.g. thermal expansion
Dimensions, e.g. mm
Tolerances: bilateral, unilateral tolerances
limit dimensions
Geometric attributes: angularity, circularity,
concentricity, cylindricity, flatness, parallellism,
perpendicularity, roundness, squareness and
straightness (See table 5.1)
Surface quality, e.g. roughness

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 Specification of tolerances
Taiz
University

Bilatertal Unilateral Limit

tolerance tolerance dimensions

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 Taiz
University

Geometric
tolerances
a. Flatness
b. Circularity
c. Cylindricity
d. Perpendicularity
e. Concentricity

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Surfaces
Taiz
University
Importance of surface quality
- Aesthetic reasons
- Safety aspects
- Influence on friction and wear
- Influence on mechanical and physical properties
- Important for assembly
- Better electrical contact
Surface technology is concerned with
- Surface texture
- Surface integrity
- Relationship with manufacturing processes
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Characteristics of surfaces
Taiz
A microscopic view shows: University

- Substrate bulk material

- Altered layer different structure
- Surface texture exterior part with roughness
- In addition: Mostly an oxide film

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Surface texture
Taiz
Surface texture Deviations from the surface University

- Roughness: small deviations

- Waveness: deviations with much larger spacing
- Lay: predominant direction or pattern of the surface
- Flaws: irregularities like cracks, inclusions, etc.

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 Taiz
University

Possible lays

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Surface roughness (1)
Taiz
University
Definition of (average) surface roughness
Arithmetic average (AA) of the vertical Lm
y
deviations from the normal surface
over a specified surface length.
Ra L
0 m
.dx

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Surface roughness (2)
Taiz
University
Approximation form:
n
yi
Ra
i 1 n
Units for Ra: m (10 -6 m)
Cutoff length Filter to separate the waviness from
the roughness deviations
Usually: Cutoff length = 0,8 mm = 1/5.L m
Surface finish = surface roughness denoting good
quality and smoothness

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Symbols for surface texture
Taiz
University

Symbols on
engineering drawings

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Final remarks
Taiz
University
Final remarks related to product attributes:
Surface integrity
- Changes in the subsurface layer
- Alterations like cracks, craters, hardness changes
inclusions, residual stresses, etc. (See Table 5.2)
- Different reasons: mechanical, thermal,etc.
Effect of manufacturing processes on
- Tolerance limits: See Table 5.4
- Surface roughness values: See Table 5.5

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Tolerance limits
Taiz
University

Table 5.4

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Surface roughness values
Taiz
University

Table 5.5
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Manufacturing Process Selection
Taiz

Aspects: University

Batch size: Single product, medium size or mass

production
Geometric requirements: Shape and tolerances
Manufacturing phase: Primary or secondary
Tools: General purpose or product specific
Assembly: Pay attention to assembly aspects
during process selection for part manu-
facturing
Minimize costs: Costs per product + Costs per
batch + Once-only costs
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Interfaces with other courses
Taiz
University
Product design: Selection of the product material
and the manufacturing process is related to the
product shape and product function.
Production systems: Selection of a manufacturing
process is related to the optimum batch size and
has consequences for the plant layout.
Management and cost accounting: If more manu-
facturing scenarios are possible, the final choice
will be made based on minimum costs.
Total Quality Management: All decisions related to
manufacturing are dealing with quality aspects.
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 Problem 1.1
Taiz
University
Subject: Manufacturing in Yemen
1) What is the GNP value in Yemen?
2) Which percentages of the GNP of Yemen are
coming from agriculture, mining, manufacturing,
oil and services?
3) What are the specific industries of Yemen in the
primary, secondary and tertiary categories?
4) What are the most important manufacturing
industries of Yemen, processing metals and/or
plastics?

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Case study 1.2
Taiz
University
Subject: Manufacturing of golf balls
1) What are the functional requirements for golf
balls?
2) With which type of materials can you realize
these requirements in the best way?
3) Which type of manufacturing processes would
be required to make a golf ball?

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Case study 1.3
Taiz
University

1) What are the functional requir-

ments for a safe?
2) With which type of materials can
you realize these requirements
in the best way?
3) Which type of manufacturing
processes would be required to
make a safe?

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Video films
Taiz
University

- Manufacturing of golf balls, series How its made,

Source: Discovery/Teleac, about 5 minutes
- Manufacturing of safes, series How its made,
Source: Discovery/Teleac, about 5 minutes

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