Manufacturing
Processes
(INME
4055)
Pablo
G.
Caceres-‐Valencia
(B.Sc.,
Ph.D.,
U.K.)
GENERAL
INFORMATION
Course
Number
INME
4055
Course
Title
Manufacturing
Processes
Credit
Hours
3
Instructor
Dr.
Pablo
G.
Caceres-‐Valencia
Office
LuccheG
L-‐212,
Extension
2358
Office
Hours
Mo-‐W-‐Fr
from
7-‐10am
e-‐mail
pablo.caceres@upr.edu
Web-‐site
hOp://academic.uprm.edu/pcaceres
Assessment
The
course
will
be
assessed
in
the
following
manner:
q
1st
Exam
30%
q
2nd
Exam
30%
q
Quizzes*
30%
q
Others**
10%
(*)
Date
due
Moodle
Quizzes
and
Pop-‐Quizzes
(max-‐8).
Missed
quizzes
will
be
graded
with
zero.
Lack
of
access
to
Moodle
is
not
an
excuse
for
not
submiGng
your
answers.
(**)
Class
par\cipa\on
and
A^endance.
A'er
the
third
missed
class,
one
point
will
be
deducted
in
the
final
grade
for
each
missed
class
(up
to
10
points).
Grades
Final
Grade
Range
Final
Le^er
Grade
100
–
90
A
89
–
80
B
79
–
70
C
69
–
60
D
59
-‐
0
F
AOendance
A^endance
and
par\cipa\on
in
the
lecture
are
compulsory
and
will
be
considered
in
the
grading.
Students
should
bring
calculators,
rulers,
pen
and
pencils
to
be
used
during
the
lectures.
Students
are
expected
to
solve
problems
during
lecture.
Please
refer
to
the
Bulle\n
of
Informa\on
for
Undergraduate
Studies
for
the
Department
and
Campus
Policies.
TENTATIVES
DATES
Week
Week
08/12
IntroducYon
to
Manufacturing.
08/19
Mechanical
ProperYes.
Q1
08/26
Mechanical
ProperYes/CasYng
09/02
CasYng
and
Molding.
Q2
09/09
Forming
Processes
09/16
Sheet
Metal
Forming
Q3
09/23
Powder
Metallurgy
09/30
Material
Removal
Processes
-‐
Cuang
Exam
1
10/07
Grinding
10/14
Processing
of
Polymers
and
Composite
Q4
Materials
10/21
Joining
and
Fastening
Processes
10/28
Joining
and
Fastening
Processes
Q5
11/04
Processing
of
Ceramic
Materials
11/11
Quality
Assurance
11/18
Quality
Assurance
11/25
Microelectronics
and
Q6
Nanomanufacturing
12/02
Microelectronics
and
12/09
Classes
End
Nanomanufacturing
Q7
-‐
Exam
2
Outcomes
Upon
the
comple\on
of
the
course
the
student
should
be
able
to:
• Describe
basic
mechanical
proper\es
of
metals,
ceramics
and
polymers.
• Evaluate
forces
and
stresses
associated
with
metal
forming
opera\ons.
• Evaluate
forces
and
stresses
associated
with
standard
machining
and
grinding
opera\ons.
• Iden\fy
candidate
processes
to
manufacture
a
given
component.
• Interpret
the
advantages
and
limita\ons
of
powder
metallurgy
processes.
• Dis\nguish
between
the
different
types
of
cas\ngs
and
describe
their
output
product
characteris\cs.
• Iden\fy
specific
polymer
processing
methods
based
on
material
and
component
geometric
proper\es.
• Predict
the
elas\c
proper\es
of
fiber
reinforced
composite
materials
Exams
There
will
be
no
final
exam.
Neatness
and
order
will
be
taking
into
considera\on
in
the
grading
of
the
exams.
Up
to
ten
points
can
be
deducted
for
the
lack
of
neatness
and
order.
You
must
bring
calculators,
class
notes
and
blank
pages
to
the
exams.
Texbooks
Mikell
Groover,
Fundamentals
of
Modern
Manufacturing,
John
Wiley
&
Sons
4th
Edi\on,
2010
Serope
Kalpakjian
and
Steven
R.
Schmid,
Manufacturing
Processes
for
Engineering
Materials,
Pren\ce
Hall,
5th
ed
2007.
My
lecture
notes
are
available
in
the
web
at
hOp://academic.uprm.edu/pcaceres
See
syllabus
of
the
course
for
recommended
books.
Manufacturing
–
DefiniYon
Process
of
conver\ng
or
processing
raw
materials
into
usable
products.
From
the
La\n:
manufactus
manus
=
hands
factus
=
made
“A
series
of
interrelated
ac@vi@es
and
opera@ons
involving
design,
materials
selec@on,
planning,
produc@on,
quality
assurance,
management,
and
marke@ng
of
discrete
consumer
and
durable
goods”
(CAM-‐I)
Manufacturing
is
one
way
by
which
na\ons
create
material
wealth.
In
2012,
manufacturers
contributed
to
11.9
percent
of
U.S.
Economy
GDP.
For
every
$1.00
spent
in
manufacturing,
another
$1.48
is
added
to
the
economy,
the
highest
mul\plier
Sector
%
of
GNP
effect
of
any
economic
sector.
Manufacturing
12
Manufacturing
supports
an
es\mated
17.2
million
jobs
in
the
U.S.—about
one
in
six
private-‐sector
jobs.
Agriculture
&
Minerals
5
Manufacturers
in
the
U.S.
perform
two-‐thirds
of
all
Construc\on
and
U\li\es
4
private-‐sector
R&D
in
the
na\on,
driving
more
innova\on
than
any
other
sector.
Service
Sector
80
Taken
from
the
Na\onal
Associa\on
of
Manufacturers
Manufacturing
Importance
Importance
of
manufacturing
to
na\onal
economies.
The
trends
shown
are
from
1982
un\l
2006.
Development
Process
(a)
Chart
showing
various
steps
involved
in
designing
and
manufacturing
a
product.
(b)
Chart
showing
general
product
flow,
from
market
analysis
to
selling
the
product,
and
depic\ng
concurrent
engineering.
Proper
Design
Facilitates
Automated
Assembly
Design
–
Materials
–Process
RelaYonship
Product
design,
materials
selec\on,
and
materials
processing
are
highly
interrelated.
For
example:
(a) weight
reduc\on
-‐-‐>
thin
cross-‐sec\ons
-‐-‐>
manufacturing
problems
-‐>
\ght
tolerance
specs.
-‐-‐>
specialized/high
precision
processes
required
-‐-‐>
increased
cost
(b) aluminum
vs.
steel
beverage
cans
-‐-‐>
different
metal
forming
needs.
Various
methods
of
making
a
simple
part:
(a)
cas\ng
or
powder
metallurgy,
(b)
forging
or
upseGng,
(c)
extrusion,
(d)
machining,
(e)
joining
two
pieces.
Shaping
Process
ClassificaYon
(a) Mass
Conserving
(cas\ng,
forming,
powder
processing)
(b) Mass
Reducing
(machining,
grinding)
(c)
Mass
adding
(joining
processes)
ProducYon
QuanYty
(Q)
Annual
ProducYon
QuanYYes
The
quan\ty
of
products
Q
made
by
a
Low
1-‐100
units
factory
has
an
important
influence
on
the
way
its
people,
facili\es,
and
Medium
100-‐10,000
procedures
are
organized.
High
10,000-‐millions
Product
Variety
(P)
It
refers
to
the
produc\on
of
different
models
or
product
type
P
is
less
exact
than
Q
because
it
depends
on
how
much
the
design
changes.
Small
changes
in
design
(Sou
Product
Variety)
or
large
differences
in
design
(
Hard
Product
Variety).
Manufacturing
Work
Flow
-‐
Custom:
Limited
number
of
products
built
to
customer
specifica\ons.
-‐
Intermi^ent/Batch:
from
10
to
1000
units,
uses
general
purpose
machinery.
-‐
Con\nuous:
Same
product
made
repeatedly
by
dedicated
machinery
(custom
built
machine
–
NOT
CUSTOM
built
product).
Automa\on
becomes
more
cost-‐effec\ve
Primary
and
Secondary
Manufacturing
Primary
processes
convert
minerals
or
raw
materials
into
standard
stock
• bauxite
ore
à
aluminum
• petroleum
à
polyester
resin
• wood
à
lumber
Secondary
processes
convert
standard
stock
into
usable
parts
• aluminum
rod
à
fuel
valve
• polyester
resin
à
medical
tubing
• lumber
à
furniture
Secondary
Manufacturing
Processes
• Cas\ng
and
Molding:
processes
hold
liquid
or
semi-‐liquid
materials
in
a
mold
cavity
un\l
the
material
hardens
• Forming:
use
a
shaping
device
and
pressure
to
cause
a
material
to
take
on
a
new
shape
and
size
• Separa\ng
/
Material
Removal:
processes
remove
material
to
produce
a
desired
shape
and
surface
finish
• Condi\oning:
it
uses
heat,
chemical
reac\ons,
or
mechanical
means
to
change
the
proper\es
of
a
material
• Assembling
/
Joining:
join
two
or
more
parts
or
assemblies
through
mechanical,
thermal,
or
chemical
means
• Finishing:
modify
the
surface
of
a
material
to
improve
appearance
or
performance
Micromanufacture
Example
Gear
assembly
driven
by
resonant
combdrives.
(a)
A
view
of
the
en\re
assembly.
(b)
Details
of
the
gear
assembly.
Source:
R.
Muller,
University
of
California
at
Berkeley.
Example
of
Primary
Manufacturing:
Steel
To
make
steel,
you
start
with
iron
ore,
a
rock
that
contains
a
high
concentra\on
of
iron.
Common
iron
ores
include:
HemaYte
-‐
Fe2O3
-‐
70
%
iron
MagneYte
-‐
Fe3O4
-‐
72
%
iron
Limonite
-‐
Fe2O3
+
H2O
-‐
50
to
66
%
iron
Siderite
-‐
FeCO3
-‐
48
%
iron
Iron
is
plen\ful
-‐-‐
5
percent
of
the
Earth's
crust
is
iron,
and
in
some
areas
it
concentrates
in
ores
that
contain
as
much
as
70
%
iron.
A
blast
furnace
is
charged
(from
the
top)
with
iron
ore,
coke
(charcoal
made
from
coal)
and
limestone
(CaCO3).
Huge
quan\\es
of
air
blast
in
at
the
bo^om
of
the
furnace.
The
calcium
in
the
limestone
combines
with
the
silicates
to
form
slag.
At
the
bo^om
of
the
blast
furnace,
liquid
iron
(pig
iron)
collects
along
with
a
layer
of
slag
on
top.
To
create
1
ton
of
pig
iron,
you
start
with
2
tons
of
ore,
1
ton
of
coke
and
half-‐ton
of
limestone.
The
fire
consumes
5
tons
of
air.
The
temperature
reaches
almost
3000
degrees
F
(about
1600
degrees
C)
at
the
core
of
the
blast
furnace!
COKE:
Metallurgical
grade
coal
is
converted
to
coke
by
a
coking
process
that
drives
off
impuri\es
to
leave
almost
pure
carbon.
The
coking
process
consists
of
hea\ng
coking
coal
(1000-‐1100ºC)
in
the
absence
of
oxygen
to
drive
off
the
vola\le
compounds
(pyrolysis).
This
process
results
in
a
hard
porous
material
-‐
coke.
The
coking
process
is
\me
consuming,
between
12-‐36
hours
in
the
coke
ovens.
The
most
commonly
applied
process
for
conver\ng
pig
iron
into
steel
is
the
Basic
Oxygen
Furnace.
In
the
BOF,
the
liquid
pig
iron
+
steel
scrap
(less
than
30%)
and
flux
are
combined
and
a
lance
is
introduced
in
the
vessel
that
blows
99%
pure
oxygen,
that
causes
the
temperature
to
rise
to
1700°C.
The
scrap
melts,
impuri\es
are
oxidized,
and
the
carbon
content
is
reduced
by
90%,
resul\ng
in
liquid
steel.
Other
processes
can
follow
–
secondary
steel-‐making
processes
–
where
the
proper\es
of
steel
are
determined
by
the
addi\on
of
other
elements,
such
as
boron,
chromium
and
molybdenum,
amongst
others,
ensuring
the
exact
specifica\on
can
be
met.
BOFs
produce
about
70%
of
the
world’s
steel.
A
further
29%
of
steel
is
produced
in
Electric
Arc
Furnaces.
Example
of
Primary
Manufacturing:
Steel
ConYnuous
CasYng
The world of materials
Metals:
Materials
that
are
inorganic
substances
which
are
composed
normally
of
combina\ons
of
"metallic
elements“
and
may
also
contain
some
non
metallic
elements
(alloys).
Examples
of
metallic
elements
are
iron,
copper,
aluminum,
nickel,
\tanium.
Non
metallic
elements
such
as
carbon,
nitrogen
and
oxygen
may
also
be
contained
in
metallic
materials.
These
elements,
when
combined,
usually
have
electrons
that
are
non
localized
and
as
a
consequence
have
generic
types
of
proper\es.
Metals
usually
are
good
conductors
of
heat
and
electricity.
Metals
have
a
crystalline
structure
in
which
the
atoms
are
arranged
in
an
orderly
manner.
Also,
they
are
quite
strong
but
malleable
and
tend
to
have
a
lustrous
look
when
polished.
Metals
and
alloys
are
commonly
divided
into
two
classes:
ferrous
metals
and
alloys
and
non
ferrous
metals
and
alloys
that
do
not
contain
iron
or
only
a
rela\vely
small
amount
of
iron.
Metals
Historical
Timeline
9000 - 3500BC Use of native (pure) copper (Copper Age)
3500 - 1500BC Tin added to copper forms bronze, a stronger alloy (Bronze Age)
1500BC - 100AD Iron smelting in Egypt, begins the Iron Age.
500 - 1600AD High quality iron and steel processing, (Feudal Era)
1750 – 1850 Commercial production of high quality steels.
1850 – 1900 Hall’s ore reducing process produces cheap aluminum in large quantities.
1900 - 1935 Aircraft moves from fabric to high strength aluminum alloy.
1935 - 1955 Specialty alloys produce turbines for more efficient power production.
1955 – 1970 Human body parts.
1970 – 1995 Superalloys developed for jet-engines
Ceramics:
Ceramics
are
generally
compounds
between
metallic
and
nonmetallic
elements
chemically
bonded
together
and
include
such
compounds
as
oxides,
nitrides,
and
carbides.
Ceramic
materials
can
be
crystalline,
non-‐crystalline,
or
mixtures
of
both.
Typically
they
have
high
hardness
and
high-‐temperature
strength
but
they
tend
to
have
mechanical
bri^leness.
They
are
usually
insula\ng
and
resistant
to
high
temperatures
and
harsh
environments.
Ceramics
can
be
divided
into
two
classes:
tradi\onal
and
advanced.
Tradi\onal
ceramics
include
clay
products,
silicate
glass
and
cement;
while
advanced
ceramics
consist
of
carbides
(SiC),
pure
oxides
(Al2O3),
nitrides
(Si3N4),
non-‐silicate
glasses
and
many
others.
Ceramics
Historical
Timeline
Early man discovers that clay can be molded and dried to form a brittle heat
26000BC
resistant material
6000BC Ceramic firing is first used in ancient Greece
4000BC Glass is discovered in ancient Egypt
50BC – Optical glass (lenses and mirrors), window glass and glass blowing production
50AD begins in Rome.
600AD Porcelain is created by the Chinese
Refractory materials (able to withstand extremely high temperatures) are
1870
introduced during the industrial revolution.
1960 Discovery of laser opens the field of fiber optics
1965 Development of a photovoltaic cell, which converts light into electricity
1987 Discovery of a superconducting ceramic oxide with a critical temperature of 92K
1992 Era of the Smart Materials
PlasYcs:
Plas\cs
or
polymers
are
substances
containing
a
large
number
of
structural
units
joined
by
the
same
type
of
linkage.
These
substances
ouen
form
into
a
chain-‐like
structure
and
are
made
of
organic
compounds
based
upon
carbon
and
hydrogen.
Usually
they
are
low
density
and
are
not
stable
at
high
temperatures.
Polymers
in
the
natural
world
have
been
around
since
the
beginning
of
\me.
Starch,
cellulose,
and
rubber
all
possess
polymeric
proper\es.
Man-‐made
polymers
have
been
studied
since
1832.
Today,
the
polymer
industry
has
grown
to
be
larger
than
the
aluminum,
copper
and
steel
industries
combined.
Polymers
already
have
a
range
of
applica\ons
that
far
exceeds
that
of
any
other
class
of
material
available
to
man.
Current
applica\ons
extend
from
adhesives,
coa\ngs,
foams,
and
packaging
materials
to
tex\le
and
industrial
fibers,
composites,
electronic
devices,
biomedical
devices,
op\cal
devices,
and
precursors
for
many
newly
developed
high-‐tech
ceramics.
Polymers
Historical
Timeline
The Mayans are assumed to be among the first to find an application for polymers, as balls were
1500s
made from local rubber trees.
Charles Goodyear discovers vulcanization by combining natural rubber with sulfur and heating it to
1839
270 degrees Fahrenheit (automobile tires)
The oldest recorded synthetic plastic is fabricated by Leo Bakeland (bakelite). It was used for
1907
electrical insulation.
Staundinger published his classic paper entitled “Uber Polimerization”. It begins the development of
1920
modern polymer theory.
1927 Large scale production of vinyl-chloride resins begins. (PVC – pipes, bottles).
Polystyrene is invented (videocassettes). Expanded polystyrene (Styrofoam) is used in cups,
1930
packaging and thermally insulating materials,
1938 Wallace Carothers of the Dupont Company produces Nylon (ropes and clothes)
1941 Polyethylene (PE) is developed. It is used for everything from packaging film to piping to toys.
1970 James Economy develops Ekonol (Liquid Crystal Polymer used in electronic devices)
S Kwolek develops Kevlar. High strength polymer used in bullet proof vests and fire proof garments
1971
for firefighting and auto racing (300oC)
1976 Polymer/Plastic industry bigger (per volume) than steel industry.
Semiconductors
(Electronic
Materials):
Semiconductors
are
materials
which
have
a
conduc\vity
between
conductors
(generally
metals)
and
nonconductors
or
insulators
(such
as
most
ceramics).
Semiconductors
can
be
pure
elements,
such
as
silicon
or
germanium,
or
compounds
such
as
gallium
arsenide
or
cadmium
selenide.
In
a
process
called
doping,
small
amounts
of
impuri\es
are
added
to
pure
semiconductors
causing
large
changes
in
the
conduc\vity
of
the
material.
Due
to
their
role
in
the
fabrica\on
of
electronic
devices,
semiconductors
are
an
important
part
of
our
lives.
Imagine
life
without
electronic
devices.
The
developments
in
semiconductor
technology
during
the
past
50
years
have
made
electronic
devices
smaller,
faster,
and
more
reliable.
Semiconductors
Historical
Timeline
1600 William Gilbert is the first person to use the term electricity
1824 John Berzelius isolates and identifies silicon.
1833 Faraday discovers that electrical resistivity decreases as temperature increases in silver sulfide.
1873 William Smith discovers the photoconductivity of selenium.
1927 Arnold Sommerfeld and Felix Bloch apply quantum mechanics to solids.
1943 Karl Lark-Horovitz uses high quality germanium to make diode detectors.
Schockley, Brattain and Bardeed invent the transistor. The semiconductor electronic industry is
1947
born.
Robert Noyce, founder of Intel Corporation develops a planar process for making semiconductors
1958
called Monolithic IC Technology
W.P. Dumke shows that semiconductors such as GaAs can be used to make lasers
1962
(optoelectronics).
1970 The first charge coupled devices (CCD’s) are made.
1980 Explosion in the use of personal computers.
GaN light emitting diodes are made which can produce blue light. Possible application are flat
1993
screen displays and high density memory storage.
Composites:
Composites
consist
of
a
mixture
of
two
or
more
materials.
Most
composite
materials
consist
of
a
selected
filler
or
reinforcing
material
and
a
compa\ble
resin
binder
to
obtain
the
specific
characteris\cs
and
proper\es
desired.
Usually,
the
components
do
not
dissolve
in
each
other
and
can
be
physically
iden\fied
by
an
interface
between
the
components.
Fiberglass,
a
combina\on
of
glass
and
a
polymer,
is
an
example.
Concrete
and
plywood
are
other
familiar
composites.
Many
new
combina\ons
include
ceramic
fibers
in
metal
or
polymer
matrix.
Biomaterials
Biomaterials
are
used
in
components
implanted
into
the
human
body
for
replacement
of
diseased
or
damaged
body
parts.
For
Example:
Hip
replacement
designs.
Intraocular
Lens
3 basic materials - PMMA, acrylic, silicone
ArYficial
Hip
Joints
The
biological
phenomenon
of
microorganisms
SubsYtute
Heart
Valves
tending
to
move
in
response
to
the
environment's
magne\c
characteris\cs
is
known
as
magnetotaxis
BF Organic
image matter
HAADF image
Magnetite (Fe3O4)
crystals
400 nm
50 nm
