HABEEB HATTAB HABEEB

Office: BN-Block, Level-3,

Room-088
Email: hbuni61@yahoo.com
Ext. No.: 7292
H/P No.: 0126610058
University TENAGA Nasio
nal

Lecturer: HABEEB ALANI

University TENAGA National

College Of Engineering
Mechanical Department
Academic Year - 2008
Lecture Note
University TENAGA Nasio
nal

Lecturer: HABEEB ALANI

Introduction To
Manufacturing and
Manufacturing
Systems
University TENAGA Nasio
nal

Lecturer: HABEEB ALANI

Japanese sword reworked for hard and soft metal parts

University TENAGA

Lecturer: HABEEB ALANI

Space Shuttle
University TENAGA

Lecturer: HABEEB ALANI

The Transistor
University TENAGA

Lecturer: HABEEB ALANI

Everyday products
University TENAGA

Lecturer: HABEEB ALANI

Manufacturing
Manufacturing derived
derived from:
from:

Manufacturing
Manufacturing (derived
(derived from
from Latin)
Latin)
== manus
manus (hand)
(hand) ++ factus
factus (made)
(made)
== made
made by
by hand
hand

University TENAGA Nasio

nal

Lecturer: HABEEB ALANI

Definition
Definition of
of Manufacturing:
Manufacturing:

Manufacturing is an industrial activity

that converts raw materials to useful
products by the means of machines.

University TENAGA Nasio

nal

Lecturer: HABEEB ALANI

Development
Development of
of Manufacturing
Manufacturing
depends
depends on:
on:
1

Materials
Materials

Machine-Tools
Machine-Tools

Computer-aided
Computer-aided Design
Design (CAD)&
(CAD)&
Computer-aided
Computer-aided mfg
mfg (CAM).
(CAM).

Robotics
Robotics

Electronic
Electronic
ss

University TENAGA Nasio

nal

Lecturer: HABEEB ALANI

1-1

Evolution
Evolution of
of the
the Enterprise
Enterprise

Evolution
Evolution Steps:
Steps:
1

Hand
Hand Tool
Tool

Animals
Animals

Water
Water Power
Power

Steam
Steam Engines
Engines

Electrical
Electrical Motors
Motors

University TENAGA Nasio

nal

Lecturer: HABEEB ALANI

The
The MFG
MFG System:
System:

INPUT
INPUT

University TENAGA Nasio

nal

PROCESS
PROCESS

Lecturer: HABEEB ALANI

OUTPUT
OUTPUT

INPUT
INPUT

University TENAGA Nasio

nal

Customer
Customer
Demand
Demand

Energy
Energy

Material
Material

Education
Education

Money
Money

RR && DD

Lecturer: HABEEB ALANI

HR
HR

PROCESS
PROCESS

Design
Design
Production
Production
Management
Management

University TENAGA

Lecturer: HABEEB ALANI

OUTPUT
OUTPUT
Consumer
Consumer Goods
Goods
Capital
Capital Goods
Goods
Quality
Quality
Cost
Cost Effectiveness
Effectiveness

University TENAGA

Lecturer: HABEEB ALANI

INPUT
INPUT

Money
Money

-- Working
Working Capital
Capital

--Fixed
Fixed Capital
Capital
buildings)
buildings)

University TENAGA

(Money
(Money for
for employee)
employee)

(For
(For machine
machine tools
tools and
and

Lecturer: HABEEB ALANI

INPUT
INPUT

Energy
Energy

-- Electricity
Electricity

To
Torun
run the
the machines
machines

-- Compressed
To
Compressed air
air
Torun
run the
the pneumatic
pneumatic
systems
systems and
and clean
clean machines
machines and
and products
products
-- Steam
To
Steam
Torun
run the
the turbines
turbines and
and utilized
utilized in
in
produce
produce of
of polystyrene
polystyrene (Expansion
(Expansion OP.)
OP.)

To
Touse
use itit in
in Furness,
Furness, welding
welding
operations
operations and
and boilers.
boilers.
-- Gas
Gas

University TENAGA

Lecturer: HABEEB ALANI

PROCESS
PROCESS

Design
Design

-- Creating
Creating plans
plans for
for new
new products
products

--Lowering
Lowering the
the product
product cost
cost at
at maintained
maintained
high
high quality
quality

University TENAGA

Lecturer: HABEEB ALANI

PROCESS
PROCESS
Production
Production

-- Designated
Designated at
at the
the design
design stage
stage
-- Machine
Machine tools
tools types
types
-- Machining
Machining processes
processes
-- People
People are
are selected
selected at
at the
the design
design
stage
stage
University TENAGA

Lecturer: HABEEB ALANI

OUTPUT
OUTPUT
Products
Products

Goods
Goods

-- Customers
Customers goods:
goods: People
People use
use them
them (Food,
(Food,
Cars,
Cars, .)
.)
-- Capital
Capital goods:
goods: Products
Products used
used to
to make
make
other
other consumer
consumer goods
goods (Machine
(Machine tools,
tools,
Plant,
Plant, .)
.)
University TENAGA

Lecturer: HABEEB ALANI

The
The Classification
Classification of
of basic
basic
Manufacturing
Manufacturing

1-2

Mass
Mass production
production
a

University TENAGA

Moderate
Moderate
b

Lecturer: HABEEB ALANI

Job-lot
Job-lot
c

Mass
Mass Production
Production Features:
Features:

-- Goods
Goods are
are produced
produced at
at aa high
high volume
volume for
for
considerable
considerable period
period of
of time
time (( >100.000
>100.000
parts
parts per
per year).
year).
-- Machine
Machine are
are not
not flexible
flexible (They
(They are
are not
not
able
able to
to produce
produce other
other types
types of
of products).
products).

-- Products
Products of
of this
this type
type of
of mfg
mfg are
are the
the
cheapest.
cheapest.
University TENAGA

Lecturer: HABEEB ALANI

Moderate
Moderate production
production Features:
Features:

-- Variable
Variable products
products (depends
(depends on
on the
the sale
sale
order
order and
and the
the market
market demand)
demand) (2,500-100,000
(2,500-100,000
parts
parts per
per year).
year).
-- Multipurpose
Multipurpose machine
machine tools
tools and
and CNC
CNC
machine
machine tools
tools are
are usually
usually used
used in
in this
this
type
type of
of mfg.
mfg.
-- Product
Product Ex.:
Ex.: Tools,
Tools, Moulds,
Moulds, Radio
Radio
transmitters.
transmitters.
University TENAGA

Lecturer: HABEEB ALANI

Job-lot
Job-lot production
production Features:
Features:

-- The
The plant
plant does
does not
not any
any specific
specific type
type of
of
products
products but
but itit is
is able
able to
to produce
produce any
any
type
type of
of product
product that
that the
the market
market is
is in
in
need
need of.
of.
-- Products
Products move
move in
in lots
lots between
between mfg
mfg
processes
processes (10-500
(10-500 parts
parts per
per lot).
lot).
-- Machine
Machine are
are more
more flexible
flexible and
and universal.
universal.
-- Product
Product Ex:
Ex: Airplanes,
Airplanes,Automobile
Automobile parts,
parts,
and
and Plastic
Plastic products
products ..
University TENAGA

Lecturer: HABEEB ALANI

Organization
Organization for
for Manufacturing
Manufacturing
-A
-Aplant
plant needs
needs an
an affective
affective organizing
organizing
method
method for
for manufacturing
manufacturing in
in order
order to
to
manage
manage its
its resources
resources //
1

Employees
Employees

Materials
Materials

Money
Money

Machines
Machines ..

Power
Power

*A
*Agood
good mfg
mfg strategy
strategy is
is needed.
needed.
See
See table
table 1.1
1.1 (Evolution
(Evolution of
of strategy
strategy mfg
mfg sys..
sys..
University TENAGA

Lecturer: HABEEB ALANI

C
Concurrent
oncurrent Engineering
Engineering CE
CE
--ItIt is
is aa philosophy
philosophy that
that promotes
promotes interactive
interactive design
design
and
and manufacturing
manufacturing efforts
efforts to
to develop
develop product
product and
and
processes
processes simultaneously.
simultaneously. CE
CE is
is not
not an
an engineeengineering
ring discipline.
discipline.
-- CE
CE Objective:
Objective: Optimizing
Optimizing the
the use
use of
of company
company
resources
resources and
and reducing
reducing time
time to
to market
market cycle.
cycle.
University TENAGA

Lecturer: HABEEB ALANI

G
General
eneral CE
CE phases
phases for
for aa new
new project:
project:
Ph.-1

Technology
Technology and
and concept
concept development:
development:

Definition
Definition of
of customer
customer requirement
requirement
implementation.
implementation.

Assessment
Assessment of
of primary
primary alternatives
alternatives
processes.
processes.

Development
Development of
of required
required resources.
resources.

Preparation
Preparation of
of product
product plan.
plan.

University TENAGA

Lecturer: HABEEB ALANI

PProduct
roduct

and
and Process
Process Development
Development
and
and Prototype
Prototype validation
validation -CE
-CE Function:
Function:

Ph.-2

This
This is
is the
the phase
phase in
in which
which the
the CE
CE team
team will
will
a

Product
Product improvement
improvement for
for assembly
assembly and
and
mfg
mfg

Development
Development the
the mfg
mfg and
and assembly
assembly
processes
processes

c
d

Establish
Establish baseline
baseline process
process technology
technology
Establish
Establish program
program goals
goals and
and risk-reduction
risk-reduction
plans
plans freezing
freezing

University TENAGA

Lecturer: HABEEB ALANI

Ph.-2

Cont
Cont

Note:

Generally
Generally other
other project
project elements
elements are
are addressed
addressed
II this
this phase
phase Ph.-2 ,, such
such as
as financial
financial business
business
plans,
plans, product
product concept
concept demonstration,
demonstration, freezing
freezing
of
of engineering
engineering content,
content, and
and final
final project
project approval.
approval.
University TENAGA

Lecturer: HABEEB ALANI

Process
Process Validation
Validation and
and Product
Product Design
Design
Confirmation
Confirmation ::

Ph.-3

This
This is
is the
the execution
execution phase
phase where
where
a

The
The Production
Production process
process and
and methods
methods
are
are finalized
finalized
Simulation
Simulation and
and pilot
pilot runs
runs are
are conducted
conducted
to
to test
test critical
critical steps
steps
Machine
Machine and
and equipment
equipment are
are validated
validated
for
for production
production readiness,
readiness, quality
quality and
and
performance
performance

University TENAGA

Lecturer: HABEEB ALANI

Ph.-4

Production
Production and
and continuous
continuous improvement
improvement ::

-- T
This
his face
face is
is the
the Acceleration
Acceleration of
of production
production
floor
floor into
into Full
Full rated
rated capacity.
capacity. This
This means:
means:
Attaining
Attaining high
high product
product quality
quality at
at the
the lowest
lowest
costs.
costs.

University TENAGA

Lecturer: HABEEB ALANI

1-3

Design,
Design, Material
Material and
and Production
Production

--A
According
ccording to
to the
the existing
existing machine
machine tools
tools and
and the
the
designed
designed product
product we
we choose
choose the
the raw
raw materials.
materials.

On
On the
the other
other hands,
hands, according
according to
to the
the existing
existing
materials
materials and
and required
required quality
quality we
we choose
choose the
the
machine
machine tools.
tools.
University TENAGA

Lecturer: HABEEB ALANI

-- Efficiency
Efficiency of
of production
production ::

-- IInn order
order to
to attain
attain aa high
high production
production
rate
rate with
with aa low
low labor
labor cost,
cost, Automatic
Automatic
features
features have
have been
been built
built gradually
gradually in
in
different
different machine
machine tools.
tools. Nowadays
Nowadays
we
we deal
deal with
with fully
fully automatic
automatic machine
machine
tools
tools and
and computer
computer aided
aided design
design and
and
manufacturing
manufacturing (CAD/CAM).
(CAD/CAM). But
But the
the
problem
problem is
is that
that maintenance
maintenance of
of such
such
automatic
automatic machines
machines is
is very
very expensive.
expensive.
University TENAGA

Lecturer: HABEEB ALANI

Cont.. Efficiency of production

-- T
The
he quality
quality and
and accuracy
accuracy must
must
be
be maintained
maintained for
for the
the whole
whole mfg
mfg
processes
processes so
so at
at the
the output
output we
we
produce
produce parts
parts that
that can
can be
be quickly
quickly
assembled
assembled (interchangeable).
(interchangeable).

University TENAGA

Lecturer: HABEEB ALANI

-- EEconomical
conomical production
production is
is determined
determined by:
by:
A
Afunctional
functional simple
simple design
design that
that has
has
appropriate
appropriate quality
quality (no
(no more
more or
or less).
less).
1

A
Amaterial
material choice
choice that
that represents
represents the
the
best
best compromise
compromise among
among physical
physical
properties,
properties, cost,
cost, and
and machinability.
machinability.

The
The selection
selection of
of mfg
mfg processes
processes that
that
provide
provide the
the plant
plant with
with required
required quality
quality
and
and accuracy
accuracy (no
(no more
more accuracy
accuracy than
than
necessary)
necessary) at
at the
the lowest
lowest possible
possible cost.
cost.
3

University TENAGA

Lecturer: HABEEB ALANI

Engineering
Engineering Materials
Materials
Materials
Materials
Metallic
Metallic

Non-Metallic
Non-Metallic

Ferrous
Ferrous

Organic
Organic

Non-Ferrous
Non-Ferrous

NonNon- Organic
Organic

University TENAGA

Lecturer: HABEEB ALANI

Materials
Materials Application
Application Chain
Chain
PProcessing
rocessing
SStructure
tructure

* SELECTION
is the Critical Step
for Technologists.

PProperties
roperties
PPerformance
erformance
SSelection
election
FField
ield Application
Application
University TENAGA

Lecturer: HABEEB ALANI

Mechanical
Mechanical Properties
Properties

Stress & Strain

Dislocations &

Deformation
Elasticity & Plasticity
Elastic Constants
University TENAGA

Lecturer: HABEEB ALANI

Tests
Tests

Mechanical Testing
Mechanical Properties
Strengthening
Mechanisms
Failure Analysis

University TENAGA

Lecturer: HABEEB ALANI

Electrical
Electrical Properties
Properties
Electrical Properties

Resistivity & Conductivity

Electronic-Band Structure
Semiconductivity
Refraction & Reflection
Transmission

University TENAGA

Lecturer: HABEEB ALANI

The Evolution of Materials

University TENAGA

Lecturer: HABEEB ALANI

Classes
Classes of
of Materials
Materials
Basic
Basic
Metals
Metals
Ceramics
Ceramics
Polymers
Polymers
Advanced
Advanced

Composites
University TENAGA Semiconductors
Lecturer: HABEEB ALANI Biomaterials
Biomaterials
Semiconductors
Composites

Metals
Metals

Materials that are normally combinations

of "metallic elements".

Metals usually are good conductors of

heat and electricity.

Metals are quite strong but malleable

and tend to have a lustrous look when
polished

University TENAGA

Lecturer: HABEEB ALANI

Ceramics
Ceramics

Ceramics are generally

compounds between Metallic
and NONmetallic elements
and include such compounds
as:
-Oxides
-Nitrides
-Carbides

Ceramic materials developed for gas

turbine rotors are used in aircraft and
diesel engine parts.

Typically they are insulating and

resistant to high temperatures and harsh
environments.
University TENAGA

Lecturer: HABEEB ALANI

Plastics
Plastics

Plastics (or polymers) are generally

compounds based upon carbon and
hydrogen (Organic Compounds).
They are very large molecular structures.
Usually they are low density and are not
stable at high temperatures.

Using advanced polymer materials, organic light emitting diode (OLEDs) displays produce bright, highcontrast display panels with a wide viewing angle. OLED panels are emissive, eliminating the need for
the backlight required in display technologies such as liquid crystal displays (LCDs).

University TENAGA

Lecturer: HABEEB ALANI

Semiconductors
Semiconductors

SEMIconductors have electrical properties

intermediate between Metallic conductors
and Ceramic insulators.
Also, the electrical properties are strongly
dependent upon small amounts of
Impurities.

University TENAGA

Lecturer: HABEEB ALANI

Composites
Composites

Composites consist of more than one

material type.
Fiberglass, a combination of glass and a
polymer, is an example. Concrete and
plywood are other familiar composites.
Many new combinations include ceramic
fibers in a metal or polymer matrix.

University TENAGA

Lecturer: HABEEB ALANI

Composites
Composites

University TENAGA

Lecturer: HABEEB ALANI

Composites
Composites

Hand bag

Ghost airplane

Graphite Matrix
Composite Shaft
Liquid Metal
FacePlate

Golf Clubs
University TENAGA

Lecturer: HABEEB ALANI

BioMaterials
BioMaterials

Materials compatible with an organism

(e.g. Humans) that can be used to make
implants, prostheses, and surgical
instruments.

Designed not to provoke rejection by our bodies

(skin, blood, bone, etc.), they can be natural
(collagen, cellulose, etc.) or synthetic (metallic,
alloy, ceramic, plastic, and others).
Dental crowns and
contact-lenses
use biomaterials.

University TENAGA

Lecturer: HABEEB ALANI

Data
Data Organization
Organization of
of Materials
Materials
Kingdom

Materials

Family

Class

Ceramics

Steels

Polymers

Cu-alloys

Metals

Al-alloys

Natural

Ti-alloys

Foams

Ni-alloys

Composites

Zn-alloys

Member

1000
2000
3000
4000
5000
6000
7000
8000

Attributes
Density
Mechanical props.
Thermal props.
Electrical props.
Optical props.
Corrosion props.
Supporting information
-- specific
-- general

A material record
or properties

University TENAGA

Lecturer: HABEEB ALANI

Structured
information

Unstructured
information

Metallography:

to see microstructures

metal

mount

Steel (Fe-C)
Nickel Alloy 242
University TENAGA

Lecturer: HABEEB ALANI

Materials
Materials Information
Information for
for Design
Design
The goal of design:
To create products that perform their function effectively, safely, at acceptable cost
What do we need to know about materials to do this?
Stat/Math
analysis

Data
capture

More than just test data.

Selection of
material and process

Economic analysis
and business case

Mechanical Properties
Bulk Modulus
Compressive Strength
Ductility
Elastic Limit
Endurance Limit
Fracture Toughness
Hardness
Loss Coefficient
Modulus of Rupture
Poisson's Ratio
Shear Modulus
Tensile Strength
Young's Modulus

Test

Test data

Characterization
University TENAGA

4.1 55 0.06 40 24 2.3 100 0.00950 0.38 0.85 45 2.5 -

4.6 GPa
60 MPa
0.07
45 MPa
27 MPa
2.6 MPa.m1/2
140 MPa
0.026
55 MPa
0.42
0.95 GPa
48 MPa
2.8 GPa

$
Potential
applications

Design data

Successful
applications

Selection and implementation

Lecturer: HABEEB ALANI

Next Lecture:
Nature And Properties
of Materials
University TENAGA Nasio
nal

Lecturer: HABEEB ALANI

THANK YOU
University TENAGA Nasio
nal

Lecturer: HABEEB ALANI