Materials and Processes

Manufacturing: Derived Latin word, manus (hand) and factus (make)

Technologically and Economically

Technological Definition of Manufactoring

The application of physical and chemical processes to transform raw materials into finished products. The assembly of multiplr parts to amke products.

Economic Definition of Manufacturing

Manufacturing adds value byt transforming materials.

Manufactoring Industries

Split into three categories: Primary, Secondary, Tertiary

Primary Industry

Cultivate ans exploit natural resources (ex: agriculture and mining)

Secondary Industry

Convert into consumer and capital goods (ex: manufacturing, construction, power utilities)

Manufactured Products

Final products made by the manufacturing industries (two maajor clases)

Consumer Goods:

Products purchased directly by consumers

Tertiary Industry

Service sector (ex: retail, financial, education, transportation, government)

Capital Goods

Products purchased by companies to produce goods and/or provide services (ex: buses, aircraft, construction equipment)

Manufacturing and Gross Domestic Products (GDP)

U.S., manufacturing accounts for about 12% of GDP and the service sector accounts for more than 75% of GDP. Without these manufactured products, the service industries could not function

Production Quantity

Number of units produced annually of a given product type:

Low production: (1 to 100 units per year)

Medium production (100 to 10,000)

High Production: (10,000 to millions of units)

Product Variety

Number of different types of products made

Manufactoring Capability

Technocal and physical limiitations of a manufactured firm and its individual plants

Three dimensions:

Technological processing capability

Physical product limitation

Production capacity

Technological processing capability

available set of manufacturing processes

Physical product limitations

size and weight of the products that can be made

Production capacity

production quantity that can be produced in a given time period

Materials in Manufacturing

Metlas, Ceramics, Polymers

Metals

ferrous (ex: steel and cast iron))

and nonferrous (ex: aluminum, copper, nickel)

Ceramics

Crystalline ceramics (ex: clay, alumina) and glass (amorphous)

Polymers

thermoplastics (e.g., polyethylene), thermosets (e.g., epoxies), and elastomers (e.g., rubner)

Manufactoring Processes

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

Two Basic Types of Manufacturing Operations

Processing Operations, Assesmbly Operations

Processing Operations:

Transforms a work material from one state of completion to more advanced state. Usually performed on discrete workparts

Assembly Operations

joins two or more components to create a new entity, calles an assesmbly, subassembly, or other term (ex: weldment)

Processing Operations

General Types:

1) Shaping operations

2) Property-enhancing operations

3) Surface processing operations

Shaping Operations

alter the geometry of the starting work material

Property-enhancing operations

improve the physical properties of the material without

Surface processing operations

performed to clean, treat, coat, or deposit material onto the surface of the work

Shaping Processes (4 categories)

1. Solidification processes

2. Particulate processes

3. Deformation processes

4. Material removal processes

Solidification Processes (Casting)

Starting material is a heated liquid or semifluid that cools and solidifies to form the part geometry

Particulate Processes (Powder Metallurgy)

Starting material is a powder, and the powders are formed to create geometry and heated to strengthen

Deformation Processes

Starting material is a ductile solid (commonly metal) that is deformed to shape the part