Lab Safety
No short pants
No open toe shoes
Safety goggles
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
INTRODUCTION AND
OVERVIEW OF MANUFACTURING
1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production Systems
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
What is Manufacturing?
The word manufacture is derived from two Latin
words manus (hand) and factus (make); the
combination means “made by hand”
“Made by hand” described the fabrication methods
that were used when the English word
“manufacture” was first coined around 1567 A.D.
Most modern manufacturing operations are
accomplished by mechanized and automated
equipment that is supervised by human workers
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Manufacturing - Technological
Application of physical and chemical processes to alter
the geometry, properties, and/or appearance of a
starting material to make parts or products
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Manufacturing - Economic
Transformation of materials into items of greater value by
one or more processing and/or assembly operations
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Manufactured Products
Final products divide into two major classes:
1. Consumer goods - products purchased directly by
consumers
Cars, clothes, TVs, tennis rackets
2. Capital goods - those purchased by companies to
produce goods and/or provide services
Aircraft, computers, communication equipment,
medical apparatus, trucks, machine tools,
construction equipment
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Production Quantity Q
The quantity of products Q made by a factory has an
important influence on the way its people, facilities, and
procedures are organized
Annual quantities can be classified into three ranges:
Production range Annual Quantity Q
Low production 1 to 100 units
Medium production 100 to 10,000 units
High production 10,000 to millions of
units
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Materials in Manufacturing
Most engineering materials can be classified into one of
three basic categories:
1. Metals
2. Ceramics
3. Polymers
Their chemistries are different, and their mechanical and
physical properties are different
In addition, there is a fourth category:
4. Composites
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Classification of
engineering
materials
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
1. Metals
Usually alloys, which are composed of two or more
elements, at least one of which is metallic. Two basic
groups:
1. Ferrous metals - based on iron, comprises about
75% of metal tonnage in the world:
Steel and cast iron
2. Nonferrous metals - all other metallic elements and
their alloys:
Aluminum, copper, nickel, silver, tin, etc.
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
2. Ceramics
Compounds containing metallic (or semi-metallic) and
nonmetallic elements.
Typical nonmetallic elements are oxygen, nitrogen,
and carbon
For processing, ceramics divide into:
1. Crystalline ceramics – includes traditional
ceramics, such as clay, and modern ceramics,
such as alumina (Al2O3)
2. Glasses – mostly based on silica (SiO2)
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
3. Polymers
Compound formed of repeating structural units called
mers, whose atoms share electrons to form very large
molecules. Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without altering
molecular structure
2. Thermosetting polymers - molecules chemically
transform into a rigid structure – cannot reheat
3. Elastomers - show significant elastic behavior
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
4. Composites
Material consisting of two or more phases that are
processed separately and then bonded together to
achieve properties superior to its constituents
Phase - homogeneous material, such as grains of
identical unit cell structure in a solid metal
Usual structure consists of particles or fibers of
one phase mixed in a second phase
Properties depend on components, physical
shapes of components, and the way they are
combined to form the final material
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Manufacturing Processes:
Two Basic Types
1. Processing operations - transform a work material
from one state of completion to a more advanced
state
Operations that change the geometry, properties, or
appearance of the starting material
2. Assembly operations - join two or more components to
create a new entity
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Classification of
Manufacturing
Processes
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Processing Operations
Alter a material’s shape, physical properties, or
appearance in order to add value
Three categories of processing operations:
1. Shaping operations - alter the geometry of the
starting work material
2. Property‑enhancing operations - improve
physical properties without changing shape
3. Surface processing operations - clean, treat,
coat, or deposit material on surface of work
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Four Categories of
Shaping Processes
1. Solidification processes - starting material is a heated
liquid or semifluid
2. Particulate processing - starting material consists of
powders
3. Deformation processes - starting material is a ductile
solid (commonly metal)
4. Material removal processes - starting material is a
ductile or brittle solid
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Solidification Processes
Starting material is heated sufficiently to transform it into a
liquid or highly plastic state
(1) Casting process and (2) cast product
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Particulate Processing
(1) Starting materials are metal or ceramic powders, which
are (2) pressed and (3) sintered
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Deformation Processes
Starting work part is shaped by application of forces that
exceed the yield strength of the material: (a) forging and (b)
extrusion
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Material Removal Processes
Excess material removed from the starting piece so what
remains is the desired geometry: (a) turning, (b) drilling, and (c)
milling
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Car Manufacturing
What processes are involved in make a car?
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Property‑Enhancing Processes
Processes that improve mechanical or physical
properties of work material
Examples:
Heat treatment of metals and glasses
Sintering of powdered metals and ceramics
Part shape is not altered, except unintentionally
Example: unintentional warping of a heat treated
part
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Surface Processing Operations
Cleaning - chemical and mechanical processes to
remove dirt, oil, and other surface contaminants
Surface treatments - mechanical working such as
sand blasting, and physical processes like diffusion
Coating and thin film deposition - coating exterior
surface of the work part
Examples:
Electroplating
Painting
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
Assembly Operations
Two or more separate parts are joined to form a new
entity
Types of assembly operations:
1. Joining processes – create a permanent joint
Welding, brazing, soldering, adhesive bonding
2. Mechanical assembly – fastening by mechanical
methods
Threaded fasteners (screws, bolts and nuts);
press fitting, expansion fits
©2016 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 6/e
