Industrial & Management Engineering Department

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Objectives
1. To understand the meaning of manufacturing process 2. To identify the types of manufacturing processes 3. To be aware of the principles of each production process 4. To identify the products produced by each process 5. To recognize the types and properties of engineering materials and select it for a certain product.
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Objectives (cont.)
6. 7. To know how iron and steel are produced and used. To be aware of the different methods and techniques used in metal joining, principles and characteristics of each method. To understand the principles of dimensional measurement, tools used in industrial measurements and how to determine the dimensions of a product. To identify the elements of industrial cost and to know how to determine the production cost, volume and profit.
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Contents
Engineering Materials Iron and Steel Casting Forming Machining Welding Dimensional measurements Industrial cost analysis
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Reading Resources
1. 2. Lecture Notes E.P. De Garmo, Materials and processes in manufacturing, 8th Ed. , Prentice Hall, 1997, ISBN 002-328621-0 S. Kalpakjian, Manufacturing Processes for Engineering Materials, 4th Ed., Prentice Hall, 2003, ISBN 0-13-045373-0. W.A.J. Chapman, Workshop Technology, part1, 5th Ed. E. Arnold limited, 1981, ISBN 0 7131 3287 6. W.A.J. Chapman, Workshop Technology, part2,5th Ed. E. Arnold limited, 1979, ISBN 0 7131 3291 4.

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Marking Scheme
1st Exam. 7th week 12th week 2nd Exam. Final Exam. 16th week Cont. Assessment 30 marks 20 marks 40 marks 10 marks total 100 marks

Attendance is mandatory Workshop is attended with white coat. Workbook should be at hand at workshop.

IM112 Lec 1

IM112 Lec 1

CONTENTS
1. Definition of manufacturing 2. Engineering Materials 3. Nature of materials Atomic Structure and the Elements Atom the basic unit of matter Nucleus and electrons Bonding between Atoms and Molecules Crystalline Structures Non-crystalline (Amorphous) Structures
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How to select materials for a specific product?

Car

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Classification of Materials Properties

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Comparison of Engineering Materials Properties

Density Metals High Mechanical Strength Medium Ductility High High Temp. stability Good

Plastics

Low

Low

Very High
(thermoplastic)

Not good

Low
(thermoset)

Ceramics
Composites

Medium Low

High High

Low Medium

Very good Not good

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Crystal Structure of materials

Crystals Atoms arrange themselves into various ordered configuration, called crystals. Crystalline structure. The arrangement of the atoms in the crystal is called crystalline structure. Unit cell The smallest group of atoms showing the characteristic lattice structure of a particular metal is known as a unit cell.
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Crystal Structure of Metals

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Metallic materials
Ferrous
Steel Alloy steel Cast iron Wrought Iron
Pure iron is called wrought iron Melting temperature = 1539 oC Ductile Crystalline unit BBC FCC BCC iron iron iron

Non- Ferrous
Aluminum Copper Gold Silver Lead , etc

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Steel (Plain Carbon steel)

0.25 0.6 0.9 2.0

It is an iron-carbon alloy Has high ability for plastic deformation. Has less than 2 % carbon of its weight Called Plain Carbon Steel if it has some alloying elements. Types: 1. Low carbon steel: < 0.25% C structural steel. 2. Medium Carbon Steel: 0.25% to 0.6% C machine parts for its good mechanical properties. 3. High Carbon Steel: 0.6% to 0.9% C high hardness and wear resistance. 4. Tool Steel: >0.9% C - cutting tools (drills, tapes, milling tools, etc., .)
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Alloy steel
Undesired impurities in carbon steel: Sulphur phosphorous oxygen nitrogen. Some elements are added to carbon steel to improve its mechanical properties such as chrome , tungsten, nickel, manganese. Types: 1. High strength structure steel: 0.1% (titanium, vanadium and boron ) 2. Chrome steel : high wear resistance and refractory steel 3. Nickel-chrome steel: Stainless steel 4. Manganese steel: High wear resistance. 5. Tungsten steel: Tool steel (High speed steel HSS).

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Cast Iron
Iron-carbon alloy has >2% carbon. Has low relatively melting temperature. Preferred in casting operations. Types: 1. White cast iron: carbon is united with iron in form of iron carbide - high brittleness no industrial applications. 1. Grey cast iron: carbon is found in form of flacks low hardness used in manufacturing of machine structure. 1. Malleable cast iron: high impact resistance made of white Cast iron that is heat treated. 1. Spheroid cast iron: ductile, strong - heat treated cast iron with magnesium
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Non ferrous materials

Aluminum:
Aluminum
melting temperature = 658 oC. Crystalline cell: FCC Has good rust resistance light in weight. Used in manufacturing of electric cables. Wrought alloys Casting alloys. Used in manufacturing of ships, air crafts

Aluminum alloys:

Copper
Copper :
melting Temp.= 1083 oC - FCC used in making electric cables.

Copper alloys:
1. Brass: copper + tin 2. Bronze : copper + zinc 3. Aluminum bronze : copper + aluminum

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The process of manufacturing iron from iron ore is called iron making. Iron is produced in a blast furnace Materials used in manufacturing Pig iron: 1. Iron ore (magnetite, hematite, contains up to 70% iron) iron oxides with earth impurities; 2. Coke reducing agent and fuel, providing heat for melting the metal and slag. 3. Limestone Calcium silicate fluxes, forming a fluid slag
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The top of the furnace is equipped with the bell-like or other system, providing correct charging and distribution of the raw materials (ore, coke, limestone). Air heated to 2200F (1200C) is blown through the tuners at the bottom. Oxygen contained in air reacts with the coke, producing carbon monoxide: 2C + O2= 2CO Hot gases pass up through the descending materials, causing reduction of the iron oxides to iron according to the following reactions: 3Fe2O3 + CO = 2Fe3O4 + CO2 Fe3O4 + CO = 3FeO + CO2 FeO + CO = Fe + CO2

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The ore and coke are mixed by fluxes, forming slag which is capable to absorb the impurities. The furnace is periodically tapped and the melt (pig iron) is poured into ladles, which are transferred to cast iron and steel making furnaces. Pig iron usually contains 4 - 6.7% of carbon, 2-4% of silicon, 1-2% of manganese and 1-1.2% of phosphorous.
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INCOMING Iron ore (0.5 1.5 ) Pellets (lower iron content ore) Sinter (fine ore, small coke, fine limestone) Coke Limestone (flux) Hot blast (hot air) Oxygen
OUT-COMING

Pig Iron (molten) Slag Blast Furnace Gas

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Cast iron is an alloy of iron, containing up to 4% of carbon. It is usually produced by cupola furnace. Cupola is similar to the blast furnace. The liquid cast iron is periodically (or continuously) removed through a spout. Pig Iron (solid), coke and limestone flux are charged by means of an opening located in the upper half of the steel shell.
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Steel isanalloyofiron,containingupto2%ofcarbon (usuallyupto1%). Steelisproducedfrompigiron(liquid)by processes,involvingreducingtheamountsof carbon,siliconandphosphorous. Themainsteelmakingmethodsare: 1. Basicoxygenfurnace(basicoxygen converter) 2. Electricarcfurnace.
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The converter is capable to rotate about its horizontal axis, for charge loading and pouring the steel out of the converter. The converter is equipped with the water cooled oxygen lance for blowing oxygen into the melt. The oxygen converter uses no additional fuel. The pig iron impurities (carbon, silicon, manganese and phosphorous) serve as fuel. The oxygen converter has a capacity up to 400 ton and production cycle of about 1 hour.
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The electric-arc furnace employs 3 vertical carbon rods as electrodes for producing arcs. The heat, produced by the arcs, causes oxidizing phosphorous, silicon & manganese. The oxides are absorbed into the slag. By the end of the stage the slag is removed. The function of this slag is refining of the steel from sulfur and absorption of oxides, formed as a result of deoxidation.
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Unlimited scrap quantity may be melt Easy temperature control Deep sulfur refinement Precise alloying

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