ME -215 ENGINEERING

MATERIALS AND PROCESES

Instructor: Veljko Samardzic
Office: MEC 325, Tel.: 973-642-7455
E-mail: samardzi@njit.edu
Lectures: F (Sec-007-1:00 pm-2:25 pm, GITC
1203; Sec-103- 5:45 pm- 7:40 pm GITC 5601)
Labs: Sec-007 W-10:00 am-12:10 pm ME232;
Sec-103- F-7:45 pm- 9:45 pm ME 232;
Office Hours: Tuesday 11:30 m-12:30 pm,
Friday 11:30 m-12:30 pm
ME-215 Engineering Materials and Processes Veljko Samardzic
 Objectives of the of Course
• To combine lectures and laboratory practice as
introduction to: Engineering Materials and
Manufacturing Processes
• Key objectives:
– Introduction to engineering materials and alloy
design;
– Introduction to microstructure-properties relations;
– Introduction to manufacturing processes;
– Laboratory report writing practice.
• Textbook: E. Paul De Garmo, J.T.Black, R.A.
Kohser, Materials and Processes in Manufacturing,
10th edition, NY, 2009
ME-215 Engineering Materials and Processes Veljko Samardzic
 More specifically

• Establish foundation of engineering thinking;

• Expand engineering communication means;
• Expand foundation of engineering knowledge;
• Practice new problem solving techniques;
• Preparation for advanced ME courses;

ME-215 Engineering Materials and Processes Veljko Samardzic

 Tests& Home Assignments

• Three closed book tests will be given ( 5th week,

11th week and final exam);
• Homework is due first 5 minutes of next lecture;
• Laboratory report due one week after completion
of lab practice at the beginning of next lab session;

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 Grading and Performance
• Homework-5%, Laboratory reports& performance-30%,
Test 1-20%, Test 2-20%, Final exam-25%.
• Detailed explanation of lab manual, lab rules and
requirements posted at: ME home page-undergraduate-ME
215. Print it and have it ready for next class;
• Be ready for the lecture and lab practice (read assigned
material prior to class) and bring with you printed material
to the class;

• Submit homework and lab reports on time or you loose;

• HW assignments posted on ME 215 syllabus.

ME-215 Engineering Materials and Processes Veljko Samardzic

 Important Dates in Technologies
Development
• B. Pascal- Mechanical calculator, France,1642
• Industrial revolution, England,1760
• Vertical lathe machine,USA,1840
• H. ford-Conveyer assembly line, USA, 1913
• J. von Newman- Principles of computer programming,
USA,1945
• Industrial robot (cylindrical config.), USA,1959
• EXAPT-Programming language, W. Germany,1966
• Microprocessors, CNC, CIM, 1970
• Intelligent automation, automatic production cells,
PC,USA,1980
• Engineering revolution, 1997 (ongoing)
ME-215 Engineering Materials and Processes Veljko Samardzic
 Impact on Societies
• From Stone age until nowadays tools design and
development controlled the pace of engineering
advancement;
• Bronze age led to rise of empires;
• Printing press (1450) led to expansion of literacy,
knowledge;
• Industrial revolution, 1760, led to the fastest
advances of all aspects of human existence;
• Engineering revolution, 1997, computer based
means for simulation and optimization shortened
the time from the concept and sellable product.
ME-215 Engineering Materials and Processes Veljko Samardzic
 Wheel Evolution

• Dated around 2700 B.C. this ancient wooden wheel is one

of the oldest known wheels in Europe.

ME-215 Engineering Materials and Processes Veljko Samardzic

 Technology

HARDWARE

TECHNOLOGY

SOFTWARE ORGWARE

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 Structural Development of
Technologies

NEW ADVANCED

CONVENTIONAL HIGH-END

TECHNOLOGIES

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 General Technology Classification
TECHNOLOGY

MATERIAL NON-MATERIAL

MECHANICAL BASIC

Processing of raw
ENERGIES
materials
Casting

Sintering
Structure INFORMATION
modification
Forming and TRANSPORTATION
shearing

Material removal OTHER

Non-conventional

Joining

Welding

Protection

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 Basic Manufacturing Processes

Process Operation

Property enhancing Surface enhancing

Shaping
Heat Compose Coating Surface
Treating Materials treatment
Material Removal
Casting & molding

Liquid Semi fluid

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 Manufacturing
• Making goods to satisfy human needs.
• MS-manufacturing system formed by integration
of manufacturing processes;
• PS- production system unifies manufacturing
system and other areas of the plant for
information, design, analysis and control;
• SPS-Service production system( transportation,
banking, finance, savings & loan, insurance,
health care, utilities, education, communication,
entertainment, sporting events, etc).
ME-215 Engineering Materials and Processes Veljko Samardzic
 Manufacturing Systems
• The job shop: machines situated by function and
parts circulated in containers between them;
• The linked cell shop: fluently connected
manufacturing cells by special information control;
• The project shop: product built on the spot of use
(bridge, etc);
• The flow shop: mass production designated shop
with specific manufacturing orientation;
• The continuous process: liquid and gasses
production systems (oil refineries);
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 Flow Shop Assembly Line

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 Manufacturing and Society
• Contributes by 20 % to GNP;
• Employs about 18 % of workforce;
• Accounts for 40 % of the exports of the US;

• Producer goods and Consumer goods;

• Converting materials adds value to them (high
manufacturing efficiency, high quality, better
living standard of employees);
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 The Manufacturing Process
• Raw material/components are subjected to
Manufacturing process (involving
machinery, tooling, power, labor and cost)
• Transformed materials have higher value.
• Raw materials are transformed into:
finished goods and/or components.
• Components are transformed into:
components and/or finished goods.

ME-215 Engineering Materials and Processes Veljko Samardzic

 Basic Manufacturing Processes

• Surface Processes
– Coating (electro plating, plasma, thermal spray);
– Cleaning (chemical agent, water jet, ice jet, etc)
– Surface treatment (carburizing);

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 Work Piece & it’s Configuration

• By manufacturing goods of prescribed

geometry, size& finish are produced.
• Types of surfaces:
– Plane or flat;
– Cylindrical (Int./Ext.);
– Conical (Int./Ext.);
– Irregular (curved/warped)

ME-215 Engineering Materials and Processes Veljko Samardzic

 Assembly Operations

• Mechanical fastening

• Soldering & brazing

• Welding

• Press, shrink, or snap fittings

• Adhesive bonding

ME-215 Engineering Materials and Processes Veljko Samardzic

 Basic Manufacturing Processes

• Shaping Processes
– Casting (molten metals) or molding (plastic);
– Materials removal: turning, drilling, milling,
grinding and new techniques;
– Particulate processes: pressing and sintering of
metal powder and ceramics;
– Deformation processes: forging, extrusion,
rolling, bending etc.

ME-215 Engineering Materials and Processes Veljko Samardzic

 Manufacturing and Society
• Good natural resources as foundation for
competitive manufacturing sector which
together support a high standard of living.

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 Material Removal
• The best way to create flat surfaces, sharp
corners, external and internal profiles and
process brittle and surface properties altered
materials;
• High accuracy and high quality surface
finish process;
• In most cases economically superior to
concurrent processes.

ME-215 Engineering Materials and Processes Veljko Samardzic

 Turning on a Lathe
• The workpiece is
mounted in a machine
tool (lathe) with a cutting
tool.
• The workpiece is rotated
while the tool is fed at
some feed rate (inches per
revolution). The desired
cutting speed V
determines the rpm of the
workpiece.
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 Material Removal

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 Tool Geometry

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 Forming operations
Rolling

Deep drawing
Forging
Wire and tube
Extrusion drawing

Shear spinning Stretching

Straight bending
Tube Spinning
Contoured
Swaging and flanging
kneading
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 Forming and Shearing

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 Casting and Molding

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 Glass processing diagram

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Schematic of glass fibre manufacturing process.

Aramid Fibre (Kevlar)

Aramids (short for aromatic polyamides) are TP polymers, which
is extruded at 80oC from very small holes to form fibres. Aramid
fibres offer significant improvements in stiffness over glass, but it
is their outstanding toughness and damage tolerance that are most
important. This reinforcement is applied in applications requiring
high impact energy absorption.

ME-215 Engineering Materials and Processes Veljko Samardzic

Carbon Fibre
Carbon fibres have the highest strength and stiffness of any fibrous
composite reinforcement, being applied in applications where these
properties are crucial. The fibres are manufactured from rayon,
polyacrylonitrile (PAN), and petroleum pitch.
1. PAN
manufacturing
process:
2. Pitch
manufacturing
process:
3. Pyrolytic
Deposition
A variety of fibre grades are produced;
Typically, the stiffer the
Carbon (IM) Intermediate Modulus
fibre, the lower the strength
Carbon (HM) High Modulus and strain to failure.
Carbon (UHM) Ultra-high Modulus
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3D structures are formed using a variety of braiding, weaving, and
knitting techniques:

Fibre Spools

Examples of complex structures:

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 Examples of Fabrication
Techniques

2-D Weave
3c Weave

3-D Weave
Braid
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 Materials in Engineering

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 Material Selection
• Optimal combination of properties ( strength,
ductility, hardness, etc.);
• Selected material meets processing requirements;

• Selected material meets operational requirements;

• Lower range price of selected material.

ME-215 Engineering Materials and Processes Veljko Samardzic

 What is the Composite Material?
• A material system made by mixture or
combination of 2 of micro or macro-
constituents different in chemical
composition and insoluble in each other.

ME-215 Engineering Materials and Processes Veljko Samardzic

 Tensile Strain to
Density Young’s Mod Strength Failure
r El sl el
kg/m3 GPa MPa %
E Glass 2570 – 2600 69 – 72 3.45 – 3.79 4.5 – 4. 9
S Glass 2460 – 2490 86 – 90 4.59 – 4.83 5.4 – 5.8
Kevlar 49 1440 131 3.6 – 4.1 2.8
Kevlar 149 1470 186 3.4 2.0
Carbon (IM) 1700 – 1830 276 – 317 2.34 – 7.07 0.8 – 1.9
Carbon (HM) 1750 – 2000 338 – 436 1.9 – 5.52 0.5 – 1.4
Carbon (UHM) 1870 – 2000 440 – 827 1.86 – 3.45 0.4 – 0.5
Spectra 900 (PE) 970 117 2.6 3.5
Spectra 1000 (PE) 970 172 2.9 – 3.3 0.7

* At room temperature
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 Property map 1

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 Property map 2

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 Thermal Stability of Carbon Fibres
• Good high-temperature properties (far
above 2000 ºC)

• When combined
with polymer
matrixes limit of
use is above 200ºC

ME-215 Engineering Materials and Processes Veljko Samardzic