EPP 201 Manufacturing Technology I

Semester I, 2009/2010
Jamaluddin Abdullah Ramdziah Bt. Md. Nasir Indra Putra Al-Manar

Course Plan
Week 1 (JA) 2 (JA) 3 (JA) 4 (JA) Day Tue (7/7) Fri (10/7) Tue (14 /7) Fri (17/7) Tue (21/7) Fri (24 /7) Tue (28/7) Fri (31/7) Tue (4/8) Fri (7/8) Tue (11/8) Fri (14/8)

TEACHING SCHEDULE EPP 201/3: MANUFACTURING TECHNOLOGY I SEMESTER I, 2009/2010 Class Meetings: Tuesday (11-1, DK7), Friday (11-12, DK7) Topics Introductory class & overview of manufacturing (Intro Chap) Fundamental of metallic materials - structures and properties Mechanical and physical properties of metals Alloys and their structures Phase Diagram Iron-Carbon system Ferrous metals and alloys Iron and Steel making Non-ferrous metals and alloys Aluminum, Magnesium, Titanium alloys Shape memory alloys, high temperature alloys, nanomaterials Fundamentals of metal casting Metal-casting processes Metal-casting design and casting defects MID SEMESTER BREAK Rolling of metals flat-rolling process, practice, tools Forging of metals processes Forgeability, economics of forging Extrusion and drawing of metals Sheet-metal Forming Processes: Video - Deep Drawing, Shearing, blanking, punching processes, Bending and stretch forming of sheet metals. Mechanics of sheet metal drawing processes Fundamental of Machining: Video - Mechanics of Cutting, Cutting Forces and Power, Merchant equation Temperature in Cutting SPECIAL BREAK (HARI RAYA) Tool life: Wear and Failure, Taylor's equation for tool life evaluation Cutting-Tool Materials and Cutting Fluids Abrasive Machining, Finishing Operations Video Abrasives and Bonded Abrasives, Grinding Processes Ultrasonic Machining, Deburring Operations Joining Process and Equipment Video Fusion-Welding Processes Solid-State Welding Processes: The Principles, Welding Processes Advantages, Limitations, and Applications Video - Brazing, Soldering, Adhesive-Bonding, Mechanical-Fastening Processes STUDY WEEK EXAM WEEKS Chap 13 Chap 14 Due Assign1 Chap 15, Quiz2 Chap 16 Remark Group Formation Chap 1- 2 Chap 3 Chap 4, Quiz1 Chap 4 Chap 4 Chap 5 Chap 6 Chap 6, Test 1 (2nd hr) Chap 10-11, Assign1 Chap 11 Chap 12

5 (JA) (RN) 6 (RN) 7 8 (RN) 9 (RN) 10 (RN) (IPA)

15/8 23/8 Tue (25/8) Fri (28/8) Tue (1/9) Fri (4/9) Tue (8/9)

11 (IPA)

Fri (11/9) Tue (15/9)

Chap 21

Fri (18/9) 12 13 (IPA) 21/9 27/9 Tue (29/9) Fri (2/10) Tue (5/10)

Test 2

14 (IPA)

Chap 22 Chap 26

15 (IPA)

Fri (9/10) Tue (12/10)

Quiz3 Chap 30 Chap 31

16 (IPA) 17 18 19 20

Fri (15/10) Tue (19/10) Fri (22/10)

Chap 32 Test 2

Note: Reading materials (chap 1- 32) all from the main text. Coursework assessments: Q (10%) + T (20%) + Assignment (10%)

What is manufacturing?

The process of converting raw materials into useful, higher value products. The science and technology of producing high quality goods to fulfill the users needs/wants in the shortest time possible and at acceptable costs. Involves materials, people, machines/tools and information/knowledge that are inter-related, forming a manufacturing system. A complex activity involving a wide variety of resources and activities such as product design, machinery and tooling, process planning, materials, purchasing, production control, support services, marketing, sales, shipping, customer service.

Origin of manufacturing?

Manufacture (latin word manu factus means made by hand. Manufacturing dates back 5000 - 4000 B.C. (Older than recorded history!!!) production of articles made of wood, ceramic, stone and metal by hand skills into highly customized and specific purpose products. Process used - Casting, hammering, carving of metals, woods, etc. First materials used gold, copper, iron followed by silver, lead, tin, bronze and brass. Steel production in year 600-800 was a major milestone, since then many ferrous and non-ferrous metals have been developed Today, engineered materials are being used in advanced applications such supersonic aircraft, computers, spacecraft. Materials with special properties such as advanced ceramics, reinforced plastics, composite materials and nanomaterials being used.

How manufacturing has evolved?

Big companies, many departments, specialized skills and Information Age process, IT, Computer, Global Produce more, automation Mfg earn more, quality Departmentalization secondary, use 1970 -1990 machine tool Mass-production 1960s Automation CAD/CAM/CIM Built-in quality Multi-functional products, short production time, flexible

Highly handcrafted, specific skills for customized products Industrial Revolution (1750 1850)

Machine tool intro, war a pull factor, quality not a concern WWI & II

Materials/Manufacturing engineering is one of the earliest engineering practices of mankind

Materials/Manufacturing engineering is at the leading edge of modern engineering

The Stone Age The Bronze Age The Iron Age The Age

Boneshaker, manufactured in 1868, features solid nature rubber tyres, solid iron frame, wooden wheels and steel rimes, wooden handles and cow hide saddle seat

High strength Al alloy frame for light weight High performance steel spring absorber Carbon fibre reinforced polymeric composite forks

Titanium alloy rim Fibre reinforced synthetic rubber inflated tyre Stainless steel spokes

With rapid development the cutting-edge nanotechnology and micro-electromechanical systems (MEMS), which is regarded the hallmark technology for the next few decades with the promise to revolutionize a wide spectrum of modern technologies and even our life style, production of miniaturised devices and nano-scale components has taken manufacturing to a new challenge

An electrical motor the size smaller than the diameter of a human hair

The US government granted US$847 million for research in 2004. The nanotechnology industry swelled 10 times in the past 5 years and is predicted to reach US$1 trillion in 10 years time.