Range of Materials & Processes in a Tractor

Steel pistons with friction-welded

skirt and crown and chrome/
molybdenum disulfide Silicon microprocessors with
coated piston ring gold-plated connectors
Die-cast aluminum Titanium turbocharger
valve cover compressor wheel
Lexan windshield
Centrifugal cast-iron Forged steel connecting
cylinder bores rods with precision-
fractured joint

Aluminum/copper/nickel
journal bearings

Fiberglass hood
Copper tube,
aluminum fin coolers

High-strength steel bolts

FIGURE 1.1 Model 8430 tractor, with detailed illustration of its

diesel engine, showing the variety of materials and processes
incorporated. Source: Courtesy of John Deere Company.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 History of Manufacturing
TABLE 1.1
H i st or i ca l D evel op m en t of M a t er i a l s a n d M a n u f a ct u r i n g Pr ocesses
Per io d D a t es M et a ls a n d Va r io u s Fo r m in g a n d Jo i n i n g To o ls, m a ch in in g,
ca st in g m a t er ia ls a n d sh a p in g a n d m a n u fa ct u r in g
co m p o sit es syst em s
Befo r e 4 0 0 0 B.C . G o ld , co p p er, m et eo r ic Ea r t h en w a r e, gla zin g, H a m m er in g To o ls o f st o n e, flin t ,
ir o n n a t u r a l fib er s w o o d , b o n e, ivo r y,
co m p o sit e t o o ls
4 0 0 0 –3 0 0 0 B.C . C o p p er ca st in g, st o n e St a m p in g, jew elr y So ld er in g (C u -Au , C o r u n d u m (a lu m in a ,
a n d m et a l m o ld s, lo st - C u -Pb , Pb -Sn ) em er y)
w a x p r o cess, silver,
lea d , t in , b r o n ze
3 0 0 0 –2 0 0 0 B.C . Br o n ze ca st in g a n d G la ss b ea d s, p o t t er ’s W ir e b y slit t in g sh eet R ivet in g, b r a zin g H o e m a k in g, h a m m er ed
A. D .

d r a w in g, go ld lea f w h eel, gla ss vessels m et a l a x es, t o o ls fo r

ir o n m a k in g a n d
Roman Empire: ' 500 B.C . to 476

Renaissance: 14th to 16th centuries

Greece: ' 1100 B.C . to ' 146 B.C .

ca r p en t r y
Egypt: ' 3100 B.C . to ' 300 B.C .

2 0 0 0 –1 0 0 0 B.C . Wr o u gh t ir o n , b r a ss
Middle Ages: ' 476 to 1492

1 0 0 0 –1 B.C . C a st ir o n , ca st st eel G la ss p r essin g a n d St a m p in g o f co in s Fo r ge w eld in g o f Im p r o ved ch isels, sa w s,

b lo w in g ir o n a n d st eel, files, w o o d w o r k in g la t h es
glu in g
1 –1 0 0 0 A.D . Z in c, st eel Ven et ia n gla ss Ar m o r, co in in g, Et ch in g o f a r m o r
fo r gin g, st eel sw o r d s
1 0 0 0 –1 5 0 0 Bla st fu r n a ce, t yp e C r yst a l gla ss W ir e d r a w in g, go ld - Sa n d p a p er, w in d m ill-
m et a ls, ca st in g o f b ells, a n d silver sm it h w o r k d r iven sa w
p ew t er
1 5 0 0 –1 6 0 0 C a st -ir o n ca n n o n , C a st p la t e gla ss, Wa t er p o w er fo r H a n d la t h e fo r w o o d
t in p la t e flin t gla ss m et a lw o r k in g, r o llin g
m ill fo r co in a ge st r ip s
1 6 0 0 –1 7 0 0 Per m a n en t -m o ld Po r cela in R o llin g (lea d , go ld , Bo r in g, t u r n in g, scr ew -
ca st in g, b r a ss fr o m silver ), sh a p e r o lling cu t t in g la t h e, d r ill p r ess
co p p er a n d m et a llic (lea d )
zin c

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 History of Manufacturing (cont.)
T ABLE 1.1
H i st or i ca l D evel op m en t of M a t er i a l s a n d M a n u f a ct u r i n g Pr ocesses ( con t . )
Per io d D a t es M et a ls a n d Va r io u s F o r m in g a n d Jo in in g To o ls, m a ch in in g,
ca st in g m a t er ia ls a n d sh a p in g a n d m a n u fa ct u r in g
co m p o sit es syst em s
1 7 0 0 –1 8 0 0 M a llea b le ca st ir o n , Ex t r u sio n (lea d p ip e),
cr u cib le st eel (ir o n b a r s d eep d r a w in g, r o llin g
' 1750to 1850

a n d r o d s)
1 8 0 0 –1 9 0 0 C en t r igu fa l ca st in g, W in d o w gla ss fr o m St ea m h a m m er, st eel Sh a p in g, m illin g, co p yin g
Bessem er p r o cess, slit cylin d er, ligh t r o llin g, sea m less t u b e, la t h e fo r gu n st o ck s, t u r r et
elect r o lyt ic a lu m in u m , b u lb , vu lca n iza t io n , st eel-r a il r o llin g, la t h e, u n iver sa l m illin g
n ick el st eels, b a b b it t , r u b b er p r o cessin g, co n t in u o u s r o llin g, m a ch in e, vit r ified
Industrial Revolution:

ga lva n ized st eel, p o lyest er, st yr en e, elect r o p la t in g gr in d in g w h eel

p o w d er m et a llu r gy, cellu lo id , r u b b er
o p en -h ea r t h st eel ex t r u sio n , m o ld in g
1 9 0 0 –1 9 2 0 Au t o m a t ic b o t t le Tu b e r o llin g, h o t O x ya cet ylen e; G ea r ed la t h e, a u t o m a t ic
m a k in g, b a k elit e, ex t r u sio n a r c, elect r ica l- scr ew m a ch in e, h o b b in g,
b o r o silica t e gla ss r esist a n ce, a n d h igh -sp eed -st eel t o o ls,
t h er m it w eld in g a lu m in u m o x id e a n d
silico n ca r b id e (syn t h et ic)
1 9 2 0 –1 9 4 0 D ie ca st in g D evelo p m en t o f Tu n gst en w ir e fr o m C o a t ed elect r o d es Tu n gst en ca r b id e, m a ss
p la st ics, ca st in g, m et a l p o w d er p r o d u ct io n , t r a n sfer
m o ld in g, p o lyvin yl m a ch in es
ch lo r id e, cellu lo se
a cet a t e, p o lyet h ylen e,
WWI

gla ss fib er s
1 9 4 0 –1 9 5 0 Lo st -w a x p r o cess fo r Acr ylics, syn t h et ic Ex t r u sio n (st eel), Su b m er ged a r c Ph o sp h a t e co n ver sio n
en gin eer in g p a r t s r u b b er, ep o x ies, sw a gin g, p o w d er w eld in g co a t in gs, t o t a l q u a lit y
p h o t o sen sit ive gla ss m et a ls fo r en gin eer in g co n t r o l
parts
WWII

1 9 5 0 –1 9 6 0 C er a m ic m o ld , Acr ylo n it r ile- C o ld ex t r u sio n (st eel), G a s m et a l a r c, ga s Elect r ica l a n d ch em ica l

n o d u la r ir o n , b u t a d ien e-st yr en e, ex p lo sive fo r m in g, t u n gst en a r c, a n d m a ch in in g, a u t o m a t ic
sem ico n d u ct o r s, silicon es, t h er m o m ech a n ica l elect r o sla g w eld in g; co n t r o l
co n t in u o u s ca st in g flu o r o ca r b o n s, p r o cessin g ex p lo sio n w eld in g
p o lyu r et h a n e, flo a t
gla ss, t em p er ed gla ss,
gla ss cer a m ics

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 History of Manufacturing (conc.)
TABLE 1.1
His t o r ic a l De v e lo p m e n t o f M a t e r ia ls a n d M a n u f a c t u r in g P r o c e s s e s ( c o n t . )
Per io d D a t es M et a ls a n d Va r io u s F o r m in g a n d Jo in in g To o ls, m a ch in in g,
ca st in g m a t er ia ls a n d s h a p in g a n d m a n u fa ct u r in g
co m p o sit es syst em s
1 9 6 0 –1 9 7 0 Sq u eeze ca st in g, Acet a ls, H y d r o f o r m in g , Pla sm a -a r c a n d Tit a n iu m ca r b id e,
sin gle-cr yst a l p o lyca r b o n a t e, co ld h yd r o st a t ic ex t r u sio n , elect r o n -b ea m syn t h et ic d ia m o n d ,
t u r b in e b la d es fo r m in g o f p la st ics, elect r o fo r m in g w eld in g, a d h esive n u m er ica l co n t r o l,
r ein fo r ced p la st ics, b o n d in g in t egr a t ed cir cu it ch ip
fila m en t w in d in g
1 9 7 0 –1 9 9 0 C o m p a ct ed gr a p h it e, Ad h esives, co m p o sit e Pr ecisio n fo r gin g, La ser b ea m , C u b ic b o r o n n it r id e,
Space Age

va cu u m ca st in g, m a t er ia ls, iso t h er m a l fo r gin g, d iffu sio n b o n d in g co a t ed t o o ls, d ia m o n d

o r ga n ica lly b o n d ed sem ico n d u ct o r s, su p er p la st ic fo r m in g, (a lso co m b in ed t u r n in g, u lt r a p r ecisio n
sa n d , a u t o m a t io n o f o p t ica l fib er s, d ies m a d e b y w it h su p er p la st ic m a ch in in g, co m p u t er-
m o ld in g a n d p o u r in g, st r u ct u r a l cer a m ics, co m p u t er-a id ed d esign fo r m in g), su r fa ce- in t egr a t ed m a n u fa ct u r in g,
r a p id so lid ifica t io n , cer a m ic-m a t r ix a n d m a n u fa ct u r in g, m o u n t so ld er in g in d u st r ia l r o b o t s,
m et a l-m a t r ix co m p o sit es, n et -sh a p e fo r gin g a n d m a ch in in g a n d t u r n in g
co m p o sit es, sem iso lid b io d egr a d a b le f o r m in g , c o m p u t e r cen t er s, flex ib le-
m et a lw o r k in g, p la st ics, elect r ica lly sim u la t io n m a n u fa ct u r in g syst em s,
a m o r p h o u s m et a ls, co n d u ct in g p o lym er s sen so r t ech n o lo gy,
sh a p e-m em o r y a llo ys a u t o m a t ed in sp ect io n,
(sm a r t m a t er ia ls), ex p er t syst em s, a r t ificia l
co m p u t er sim u la t io n in t elligen ce, co m p u t er
sim u la t io n a n d
o p t im iza t io n
1 9 9 0 –2 0 0 0 s R h eo ca st in g, N a n o p h a se m a t er ia ls, R a p id p r o t o t yp in g, Fr ict io n st ir M icr o - a n d n a n o -
Information Age

co m p u t er-a id ed d esign m et a l fo a m s, r a p id t o o lin g, w eld in g, lea d -fr ee fa b r ica t io n , LIG A

o f m o ld s a n d d ies, a d va n ced co a t in gs, en vir o n m en t a lly so ld er s, la ser b u t t - (a G er m a n a cr o n ym
r a p id t o o lin g h igh -t em p er a t u r e fr ien d ly m et a lw o r k in g w eld ed (t a ilo r ed ) fo r a p r o cess in vo lvin g
su p er co n d u ct o r s. flu id s sh eet -m et a l b la n k s, lit h o gr a p h y, elect r o p la t in g,
m a ch in a b le cer a m ics, elect r ica lly a n d m o ld in g), d r y
d ia m o n d lik e ca r b o n co n d u ct in g et ch in g, lin ea r m o t o r
a d h esives d r ives, a r t ificia l n eu r a l
n et w o r k s, six sigm a

So u r ce: J.A. Sch ey, C .S. Sm it h , R .F. Tyleco t e, T.K. D er r y, T.I. W illia m s, S.R . Sch m id , a n d S. Ka lp a k jia n .

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 Manufacturing Importance
40
USA
GDP per capita, 1000 US$

30 Australia
Japan
Kuwait France
20
Germany
Canada
10 Mexico Thailand
Bangladesh
Ethiopia China
0
0 5 10 15 20 25 30 35 40 45
Contribution of manufacturing to GDP, %

FIGURE 1.2 Importance of manufacturing to national economies. The trends shown

are from 1982 until 2006. Source: After J.A. Schey with data from the World
Development Report, World Bank, various years.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 Definition of product need;
marketing information

Development Process
Conceptual design and evaluation;
feasibility study

Design analysis; codes/standards

review; physical and analytical models

Computer-aided
Prototype production; testing design (CAD)
and evaluation

Production drawings; Market

instruction manuals

Computer-aided
Material specification; process and manufacturing and
Specification
equipment selection; safety review process planning
(CAM and CAPP)
Iterations
Pilot production
Concept design

design
Main

Flow
Production
Computer-integrated
manufacturing (CIM) FIGURE 1.3 (a) Chart showing various steps
Detail design
involved in designing and manufacturing a product.
Inspection and quality assurance
Depending on the complexity of the product and the
type of materials used, the time span between the
Packaging; marketing and Manufacture original concept and the marketing of a product may
sales literature
range from a few months to many years. (b) Chart
showing general product flow, from market analysis
Product Sell to selling the product, and depicting concurrent
(a) (b)
engineering. Source: After S. Pugh.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
Shape or feature Production methoda
Flat surfaces Rolling, planing, broaching, milling, shaping, grinding
Parts with cavities End milling, electrical-discharge machining, electrochemical
machining, ultrasonic machining, blanking, casting, forging,
extrusion, injection molding, metal injection molding
Shapes &
Parts with sharp features

Thin hollow shapes

Permanent-mold casting, machining, grinding, fabricating b ,
powder metallurgy, coining
Slush casting, electroforming, fabricating, lament winding,
Manufacturing
Tubular shapes
blow molding, sheet forming, spinning
Extrusion, drawing, lament winding, roll forming, spinning,
centrifugal casting
Process
Tubular parts Rubber forming, tube hydroforming, explosive forming, spin-
ning, blow molding, sand casting, lament winding
Curvature on thin sheets Stretch forming, peen forming, fabricating, thermoforming
Openings in thin sheets Blanking, chemical blanking, photochemical blanking, laser
machining
Cross-sections Drawing, extrusion, shaving, turning, centerless grinding,
swaging, roll forming
Square edges Fine blanking, machining, shaving, belt grinding
Small holes Laser or electron-beam machining, electrical-discharge ma-
chining, electrochemical machining, chemical blanking
Surface textures Knurling, wire brushing, grinding, belt grinding, shot blast-
ing, etching, laser texturing, injection molding, compression
molding
Detailed surface features Coining, investment casting, permanent-mold casting, ma-
chining, injection molding, compression molding
Threaded parts Thread cutting, thread rolling, thread grinding, injection
molding
Very large parts Casting, forging, fabricating, assembly
Very small parts Investment casting, etching, powder metallurgy, nanofabrica- TABLE 1.2 Shapes and some common methods
tion, LIGA, micromachining of production.
Notes:
a Rapid prototyping operations can produce all of these features to some degree.
b `Fabricating' refers to assembly from separately manufactured components.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 Design for Assembly
Poor Good
Poor Good
Poor Good

Parts can Chamfer allows part Part must be released Part is located Can easily Will tangle only
hang up to fall into place before it is located before release tangle under pressure
(a) (b) (c)

Poor Good

Poor Good

Difficult to feed—parts overlap Easy to feed Insertion Air-relief hole Air-relief Air-relief
difficult in workpiece hole in pin flat on pin
(d) (e)

FIGURE 1.4 Redesign of parts to facilitate automated assembly. Source: Reprinted from G. Boothroyd and P. Dewhurst,
Product Design for Assembly, 1989, by courtesy of Marcel Dekker, Inc.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 All-Aluminum Automobile
Robotically applied, advanced arc-welding processes
provide consistent, high-quality assembly of castings,
extrusions, and sheet components
Die-cast nodes are thin-walled
to maximize weight reduction
yet provide high performance

Advanced extrusion bending processes Strong, thin-walled extrusions

support complex shapes and tight radii exhibit high ductility, energy
absorption, and toughness
(a) (b)

FIGURE 1.5 (a) The Audi A8 automobile, an example of advanced materials construction; (b) The aluminum body
structure, showing various components made by extrusion, sheet forming, and casting processes. Source: Courtesy of
ALCOA, Inc.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 Methods of Manufacture

Before After

Joined

(a) (b) (c) (d) (e)

FIGURE 1.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c)
extrusion, (d) machining, (e) joining two pieces.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 Classification Examples
in nature
Manufacturing
process examples
Applications

Aircraft
Scales in
10 m

1m
Human
height
Casting
Automobile Manufacturing
Macromanufacturing

Forging
Machinery
0.1 m gears
Mouse
Machining
0.01 m
Integrated
5 1 cm Ant circuit
package
Grain
manufacturing

1 mm of sand
Chemical
blanking
Meso-

0.1 mm Human
5 100 mm Gear for
cell
MEMS
Size

Micromanufacturing

LIGA
10 mm Virus
Features in
integrated
Lithography circuit
1 mm
Dust
particle
0.1 m
5 100 nm
Nanomanufacturing

10 nm
Atoms FIGURE 1.7 Illustration of the range of
1 nm common sizes of parts and the capabilities of
5 10 Å
manufacturing processes in producing these
parts.
1Å

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 Machining a Mold Cavity

(a)

(b)

(c)

FIGURE 1.8 Machining a mold cavity for making sunglasses. (a) Computer model of the sunglasses as designed and
viewed on the monitor. (b) Machining the die cavity using a computer numerical control milling machine. (c) Final
product produced from the mold. Source: Courtesy Mastercam / CNC Software, Inc.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 Flexible Manufacturing

FIGURE 1.9 General view of a flexible manufacturing system, showing several machines (machining centers) and an
automated guided vehicle (AGV) moving along the aisle. Source: Courtesy of Cincinnati Milacron, Inc.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7
 Global Labor Rates
TABLE 1.3
Approximate Relative Hourly Compensation for Production Workers,
for 2003. United States = 100. Compensation Costs Vary Depending
on Benefits and Allowance.
Denmark 147 Ireland, Italy 85
Norway 144 Spain 67
Germany 136 Israel 53
Belgium, Switzerland 127 New Zealand, Korea 48
Finland, Netherlands 123 Singapore 33
Austria, Sweden 116 Portugal, Taiwan 27
United States 100 Czech Republic 20
France 96 Brazil, Mexico 11
United Kingdom 93 China, India 10
Australia, Canada, Japan 90
European countries 111
Asian countries 33
Source: Courtesy of U.S. Department of Labor, November 2004.

FIGURE 1.5 (a) The Audi A8 automobile, an example of advanced materials construction; (b) The aluminum body
structure, showing various components made by extrusion, sheet forming, and casting processes. Source: Courtesy of
ALCOA, Inc.

Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian • Schmid
© 2008, Pearson Education
ISBN No. 0-13-227271-7