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Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 1
These slides are prepared from “ Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Mikell P.
Groover, Wiley Global Education , 5 th^ (or 6 th) edition, 2012 ” ( the main textbook ) as well as “ Materials Science and Engineering,
W.D. Callister & D.G. Rethwisch, John Wiley & Sons , 9 th^ edition, 2013 ”. Most of the text and images (in all the notes) are adopted
from these books ( mainly from the first textbook ).
These notes/presentations are not enough to prepare you for the assignments and exams, you need to also pay attention to the in-class
discussions and read the textbooks ( related sections/chapters that are discussed in class ).
MECH 421 / 6511
Mechanical Shaping of Metals and Plastics
Mechanical Forming of Metals
When you leave the class today, you are expected to…
Know the course outline and materials ( general information ).
Know “what’s Manufacturing”, “the manufacturing processes”
and why “Manufacturing” is important!
Know the “classification of materials” + “their properties,
advantages and limitations” (overview).
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture (^1 )
Today’s outline and learning outcomes
http://blog.commlabindia.com
Outline
Reviewing of the course outline
Materials classification
Introduction to “manufacturing and shaping of materials”
Course outline Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture (^1 ) Check your moodle to see the course outline. It’s important that you read the whole outline! Let’s check the outline….
An example for the team project (MECH 6511 )
Why Polylactic acid (PLA) for automotive textiles? o Lightweight o Green o Inexpensive o … http://www.shutterstock.com 4 What’s “Manufacturing”? An essential human activity since earliest times Manufacturing is important to most of developed and developing nations: Technologically Economically “The history of civilization is tied with the history of humans' ability to make things”! http://www.business 2 community.com http://www.businesskorea.co.kr Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 Manufacture = manus (hand) + factus (make) = “Made by hand” English word Latin words
(First coined: 1567 A.D.)
Manufactured products - Classification The as-manufactured products can be classified into 2 major groups: Customer goods – products purchased directly by consumers (Cars, cell-phones, TV….) Capital goods ( producer goods ) – those purchased by companies to produce goods and/or provide services (computers, trucks, machine tools, construction equipment) http://www.dqindia.com Directly affect your life Indirectly affect your life Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 7 Materials classification Why we say “engineering materials”? Chemistry, mechanical and physical properties are different Inorganic What about polymers?
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 9 Classified into 2 basic groups: Ferrous metals - based on iron - comprises about 75 % of metal tonnage in the world Steel and cast iron Nonferrous metals - all other metallic elements and their alloys Aluminum, copper, nickel, silver, tin, etc. and also: Superalloys “ Alloys are composed of two or more elements, at least one of which is metallic” Metals / Alloys http://^ Grey Cast Iron Pipe www.metals
- china.com https://en.wikipedia.org/wiki/Cast_iron http://www.dyalloy.com Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 10 “Some metals are important as pure elements (e.g., gold, silver, copper) o Making Pure metals is difficult and they are only used for specific applications: 99.99% Copper (electronics) – Gold – Platinum (thermo-electric applications) Most engineering applications require the enhanced properties obtained by alloying Through alloying, it is possible to increase strength, hardness, and other properties compared to pure metals” Metals / Alloys Gold, platinum, and silver o Called noble metals because chemically inert o Available in limited supplies
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 13 “Strength and hardness of copper is relatively low; to improve strength, copper is frequently alloyed” Bronze - alloy of copper and tin (typical 90 % Cu, 10 % Sn), widely used today and in ancient times Brass - alloy of copper and zinc (typical 65 % Cu, 35 % Zn). Highest strength alloy is beryllium-copper (only about 2 % Be), “which can be heat treated to high strengths and used for springs” Alloys – Copper alloys http://www.dreamstime.com Bronze helmet Why was it important? http://www.indiamart.com Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 14 Gears electrical applications Zipper musical instruments locks doorknobs Valves Decoration stuff Brass applications We will talk amore about metals in weeks 4 - 10 (see the outline) Alloys – Copper alloys - Brass
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 15 “Compounds containing metallic (or semi-metallic) and nonmetallic elements” Ceramics / Glasses Materials Science and Engineering, W.D. Callister & D.G. Rethwisch Typical nonmetallic elements : oxygen, nitrogen, and carbon Crystalline ceramics Includes: traditional ceramics, such as clay , and modern ceramics, such as alumina ( Al 2 O 3 ) Glasses Amorphous - mostly based on silica ( SiO 2 ) Limitation!? Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 16 Properties of Ceramic Materials “High hardness, electrical and thermal insulating, chemical stability, and high melting temperatures (high temperature use…) Low density Brittle, virtually no ductility - can cause problems in both processing and performance of ceramic products Some ceramics are translucent, window glass (based on silica)” “Theoretically, the strength of ceramics should be higher than metals because their covalent and ionic bonding types are stronger than metallic bonding But metallic bonding allows for slip, the mechanism by which metals deform plastically when stressed”. http://www.mse.arizona.edu
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 19 “Thermoplastic polymers (TP) - can be subjected to multiple heating and cooling cycles without altering molecular structure and significant degradation Thermosetting polymers (TS) - molecules chemically transform into a rigid structure (cure) – cannot reheat Elastomers - shows significant elastic behavior” http://www.recycledplastic.com Polymers - Three categories Plastics Rubbers o “Some elastomers can be stretched by a factor of 10 and yet completely recover o Although their properties are quite different from thermosets , they share a similar molecular structure that is different from the thermoplastics” Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 20 General Properties of Polymers “Low density relative to metals and ceramics Good strength-to-weight ratios for certain (but not all) polymers High corrosion resistance Low electrical and thermal conductivity” - Normally good insulators Plastic insulator Electric fence W.D. Callister
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 21 Limitations of Polymers “Low strength relative to metals and ceramics Low modulus of elasticity (stiffness) Service temperatures are limited to only a few hundred degrees Viscoelastic properties, which can be a distinct limitation in load bearing applications Some polymers degrade when subjected to sunlight and other forms of radiation” Further discussion in weeks 11 & 13 (see the outline) Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 22 “Material consisting of two or more phases that are processed separately and then bonded together to achieve properties superior to its constituents”. Composites
Plywood Bone
Mud and Straw
Reinforced Concrete Fiberglass
A phase = any homogeneous mass of material – unique mechanical, chemical, physical & etc properties What’s a phase?
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 25 Metal Matrix Composites (MMCs) - “mixtures of ceramics and metals, such as cemented carbides and other cermets”. o Cermets : MMC with ceramic contained in a metallic matrix Ceramic Matrix Composites (CMCs) - Al 2 O 3 and SiC imbedded with fibers to improve properties Polymer Matrix Composites (PMCs) - “polymer resins imbedded with filler or reinforcing agent ( e.g., epoxy and polyester with fiber reinforcement, and phenolic with powders )”. Classification of Composite Materials Further discussion in weeks 11 & 13 (see the outline) Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 26 Other important classes of materials Semiconductors ( ceramics ) Intermediate electrical properties Biomaterials ( all three major classes ) Materials compatible with body tissue https://battlenerds.wordpress.com http://time 4 smile.eu Bioinert Bioresorbable Bioactive
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 27 Processing operations – “transform a work material from one state of completion to a more advanced state”. “Operations that change the geometry, properties, or appearance of the starting material” Assembly operations – “join two or more components to create a new entity” Introduction to “Manufacturing of materials” Two basic types of manufacturing processes: http://www.slideshare.net Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 28 Introduction to “Manufacturing of materials” Not covered in this course – (MECH 423 )
https://www.youtube.com/watch?v= 8 _lfxPI 5 ObM
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 31 Solidification processes ( 1 ) Casting process and ( 2 ) casting product http://www.metals-b 2 b.com Not covered in this course – (MECH 423 ) Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 32 Particulate Processing ( 1 ) Starting materials are metal or ceramic powders , which are ( 2 ) pressed and ( 3 ) sintered http://www.epma.com/what-is-powder-metallurgy
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 33 Deformation Processes “Starting workpart is shaped by application of forces that exceed the yield strength of the material”. (a) forging and (b) extrusion http://www.impol.com/products/extruded-products Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 34 Material Removal Processes “Excess material removed from the starting piece so what remains is the desired geometry” (a) turning, (b) drilling, and (c) milling
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 37 Surface Processing Operations Cleaning – “chemical and mechanical processes to remove dirt, oil, and other surface contaminants” Surface treatments – “mechanical working such as sand blasting, and physical processes like diffusion” Coating and thin film deposition – “coating exterior surface of the workpart” Electroplating Painting http://chemwiki.ucdavis.edu Further discussion in the following weeks…. Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 38 Summary Course outline – team project Manufacturing is important to most of developed and developing nations: Technologically Economically Materials classifications: metals/alloys, ceramics/glasses, polymers and composites… Two basic types of manufacturing processes: Processing and Assembly
Dr. E. Rezabeigi - MIE Department - MECH 421 / 6511 - Lecture 1 39 Next Session The nature of materials Materials properties and selection Why Metals and Polymers are important (manufacturing point of view)?
