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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.
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
Single component (nail, bolt, fork, coat hanger, 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.
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.
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, 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, 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.
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.
Figure I.3a Components of a common incandescent light bulb. Source: Courtesy of General Electric Company.
Figure I.3b Manufacturing steps in making an incandescent light bulb. 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.
(b) 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, 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.
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.
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.
Figure 1.10
(a) Manufacturing steps in the production of a roll-formed and machined 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 micro-mirror 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.
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.
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.
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.
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.