Materials in An Automotive Engine - Steven

Chapter 0
General Introduction
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Materials in an Automotive Engine
Figure I.1 Section of an automotive engine - the Duratec V-6 - showing various
components and the materials used in making them.
(Source: Courtesy of Ford Motor Company. Illustration by David Kimball.)
Components in
Products
Single component Multi-component

(ball point pens,
(nail, bolt, fork, coat automobiles, washing
hanger, etc.) machines, etc.)
All components are

manufactured.
Manufacturing means,
literally, Made by
Hand.
Components in Products
Some products are a single
components (nail, bolt, fork,
coat hanger, etc.)
Some products are assemblies
of many components (ball point
pens, automobiles, washing
machines, etc.)
All components are
manufactured.
Manufacturing means, literally,
Made by Hand.
Historical Development of Material and Manufacturing Process
History of Manufacturing (1700-1960)
History of Manufacturing (1960-2000s)
Materials Selection for Paper Clips
Questions for consideration:

What material properties are
required?
What manufacturing attributes are
required?
Would the material and processing
strategy change if the desired
quantity was 10,000 vs. 1 million per
day?
Figure I.2 Examples of the wide variety of materials and geometries for paper clips.
Manufacture of Light Bulbs
Figure I.3b Manufacturing steps in

Figure I.3a Components of a common making an incandescent light bulb.
incandescent light bulb. Source: Courtesy of General Electric
Source: Courtesy of General Electric Company. Company.
Product Design Process
Figure I.4
Depending on the
complexity of the
product and the type
of materials used, the
time span between
the original concept
and the marketing of
the product may
range from a few
months to many
years.
(b) Product flow in concurrent

engineering, from market analysis to
selling the product. Source: After S.
(a) Various steps involved in design and Pugh, Total Design. Addison-Wesley,
manufacturing a product. 1991.
Redesign of Parts
Figure I.5 Redesign of parts to facilitate assembly.

Source: Reprinted from G. Boothroyd and P. Dewhurst, Product Design
for Assembly, 1989. Courtesy of Marcel Dekker, Inc.
Manufacturing Characteristics of Alloys
Baseball Bat Cross-sections
Figure I.6 Cross-sections of baseball

bats made of aluminum (top portion)
and composite material (bottom
portion).
Manufacturing Processes: Casting
Figure I.7a Schematic illustration of various casting processes

Manufacturing Processes: Forming and Shaping
Figure I.7b Schematic illustration of various bulk deformation processes

Figure I.7c Schematic illustration of various sheet metal forming processes

Figure I.7d Schematic illustration of

various polymer processing methods
Manufacturing Processes: Joining
Figure I.7f Schematic illustration of various joining processes

Manufacturing Processes: Machining
Figure 1.7e Schematic illustrations of various

machining and finishing processes.
Laser Cutting
Figure I.8 Cutting sheet metal with

a laser beam. Source: Courtesy of
Rofin-Sinar, Inc. and Manufacturing
Engineering Magazine, Society of
Manufacturing Engineers
Hip Replacement
Figure 1.9 Components of a

total hip replacement.
Source: Courtesy of Zimmer, Inc.
Manufacturing of Hip Replacement
Figure 1.10 (b) Manufacturing steps in the production of a

(a) Manufacturing steps in the production of a forged stem. Hip stems can also be produced
roll-formed and machined total hip replacement by investment casting, metal injection molding,
stem; insert injection molding, and assorted other
processes. Source: Courtesy of Zimmer, Inc.
Microscopic Components
Figure I.11
(a) Microscopic gears with dust mite. (b) A movable micro-mirror component of
Source: Courtesy Sandia National Laboratory; a light sensor.
Source: Courtesy of Richard Mueller,
University of California at Berkeley.
Salt and Pepper Shakers
Figure I.12 A salt and pepper mill set. The two

metal pieces (at the bottom) for the pepper mill
are made by powder-metallurgy techniques.
Source: Reproduced with permission from
Success Stories on P/M Parts, Metal Powder
Industries Federation, Princeton, NJ, 1998.
Automated welding of automobiles
Figure I.13 Automated spot

welding of automobile bodies
in a mass production line.
Source: Courtesy of Ford
Motor Company.
Application of CAD/CAM to make sunglasses mold
Figure I.14 Machining a mold

cavity for making sunglasses.
(a) Computer model of the sunglass

as designed and viewed on the
monitor.
(b) Machine the die cavity using a

computer numerical-control milling
machine
(c) Final product. Source: Courtesy of

Mastercam/CNC Software, Inc.
Hourly Compensation for Production Workers

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Chapter 0

Single component Multi-component

All components are

Questions for consideration:

Figure I.3b Manufacturing steps in

(b) Product flow in concurrent

Figure I.5 Redesign of parts to facilitate assembly.

Figure I.6 Cross-sections of baseball

Figure I.7a Schematic illustration of various casting processes

Figure I.7b Schematic illustration of various bulk deformation processes

Figure I.7c Schematic illustration of various sheet metal forming processes

Figure I.7d Schematic illustration of

Figure I.7f Schematic illustration of various joining processes

Figure 1.7e Schematic illustrations of various

Figure I.8 Cutting sheet metal with

Figure 1.9 Components of a

Figure 1.10 (b) Manufacturing steps in the production of a

Figure I.12 A salt and pepper mill set. The two

Figure I.13 Automated spot

Figure I.14 Machining a mold

(a) Computer model of the sunglass

(b) Machine the die cavity using a

(c) Final product. Source: Courtesy of

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