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

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.)
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

Components in Products Single component (nail, bolt, fork, coat hanger, etc.) All components are manufactured. Manufacturing means, literally, Made by Hand.
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

Multi-component (ball point pens, automobiles, washing machines, etc.)

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.
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

Historical Development of Material and Manufacturing Process

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

History of Manufacturing (1700-1960)

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

History of Manufacturing (1960-2000s)

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

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.

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

Manufacture of Light Bulbs

Figure I.3a Components of a common incandescent light bulb. Source: Courtesy of General Electric Company.

Figure I.3b Manufacturing steps in making an incandescent light bulb. Source: Courtesy of General Electric Company.

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

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.

(a) Various steps involved in design and manufacturing a product.

(b) Product flow in concurrent engineering, from market analysis to selling the product. Source: After S. Pugh, Total Design. Addison-Wesley, 1991.

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

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, 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

Manufacturing Characteristics of Alloys

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

Baseball Bat Cross-sections

Figure I.6 Cross-sections of baseball bats made of aluminum (top portion) and composite material (bottom portion).

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

Manufacturing Processes: Casting

Figure I.7a Schematic illustration of various casting processes

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

Manufacturing Processes: Forming and Shaping

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

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

Manufacturing Processes: Forming and Shaping

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

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

Manufacturing Processes: Forming and Shaping

Figure I.7d Schematic illustration of various polymer processing methods

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

Manufacturing Processes: Joining

Figure I.7f Schematic illustration of various joining processes

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

Manufacturing Processes: Machining

Figure 1.7e Schematic illustrations of various machining and finishing processes.

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

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

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

Hip Replacement

Figure 1.9 Components of a total hip replacement. Source: Courtesy of Zimmer, Inc.

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

Manufacturing of Hip Replacement

Figure 1.10 (a) Manufacturing steps in the production of a roll-formed and machined total hip replacement stem;

(b) Manufacturing steps in the production of a forged stem. Hip stems can also be produced by investment casting, metal injection molding, insert injection molding, and assorted other processes. Source: Courtesy of Zimmer, Inc.

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

Microscopic Components

Figure I.11 (a) Microscopic gears with dust mite. Source: Courtesy Sandia National Laboratory; (b) A movable micro-mirror component of a light sensor. Source: Courtesy of Richard Mueller, University of California at Berkeley.

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

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.

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

Automated welding of automobiles

Figure I.13 Automated spot welding of automobile bodies in a mass production line. Source: Courtesy of Ford Motor Company.

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

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.

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

Hourly Compensation for Production Workers

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