MAE 304 [SVT 304] General Information

Manufacturing Technology
B.Sc. in Marine Engineering • Lecturer’s Background
• Syllabus
• Course Schedule
Introduction to • Teaching Style
Manufacturing Technology • Responsibility of Learning
Lecture No. 01 • Ground Rules (Attendance / punctuality / preparedness /
feedback / homework)
Prepared By :
Pubudu Ranaweera, BSc (Hons) MSc AMIESL
• Preparation of a portfolio on Manufacturing Technology
• Soft copies of notes/slides and videos will be available
(for non-profit educational use only)
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Method of Assessment What is Design?

• Examination • Conversion of ideas into reality to fulfill consumer needs.

One question paper, 3 hours • Pugh 1990 – “Total activity necessary to provide a
• Practicals product or process to meet a market need”.

5 laboratory and/or workshop sessions, 3 hours each • Mechanical design – design of products, processes and
systems of a mechanical nature.

Everything should be made as simple as possible, but not simpler.

Albert Einstein

The nation which does not do novel things (inventions) will be bogged
in the same place for ever.
Kumaratunga Munidasa
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 Scope of Engineering Design Scope of Engineering Design
• Products • Processes
Machines Domestic
Structures Vehicles & Tools Products Manufacturing Plants Power Plants

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Inputs and Outputs of

Scope of Engineering Design
Design Process
• Systems
Individual customers Drawings
Robotic Systems Flexible Manufacturing Systems

Computer
Needs Design representations
Companies

Documentation
Production process

Source:
Manufacturing Engineering and Technology
Fifth Edition
RKPS Serope Kalpakjian 2014 7 RKPS 2014 8
Steven R. Schmid
 What are the Qualities required What are the Factors to be
of a Design Engineer? considered in a Design problem?
• Imaginative power – visualisation • Intended purpose
• Logical thinking • Cost
• Inventive talents • What material to be used
• Sense of responsibility and self-confidence • External loads (Type and nature)
• Size / shape / weight limitations
• Team working skills
• Manufacturing limitations
• Communication skills • Reliability requirements
• Environment consciousness • Safety requirement
• Aesthetic sense • Service life
• Ergonomics • Maintenance requirement
• Reporting skills – technical reporting • User population
• Optimisation skills • Environmental conditions
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Subject areas of particular interest

Example of a Design Problem
to a Design Engineer
• Problem / Need
Applied Mechanics

Manufacturing Techniques Strength of Materials

Thermodynamics Design Mathematics

Properties of Materials
Theory of Machines

Engineering Drawing

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 Example of a Design Problem Example of a Design Problem
• Clarification of the Task / Idea Generation • Feasible Alternative Conceptual Designs

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Example of a Design Problem Example of a Design Problem

• Embodiment Design (moulding in to a system that can actually be produced ) • Products available in the Market

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 Product Life Cycle What is Manufacturing?
• Description of the presence or behavior of a product in the • Economic term for making goods and services available
market-place over time to satisfy human wants.
• Transformation of materials into useful goods by means
of one or more processing or assembly operation.

Digital Video Discs Compact Discs

• Adding value to the material by changing its shape or
properties using physical and chemical processes.

Blu-ray Discs
Floppy Discs
? Discs

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History of Manufacturing Design & Manufacture

Market
• Dates back to 5000-4000 B.C
• First materials used were gold, copper, iron, followed by Specification
silver, lead, tin , bronze and brass.
• Production of steel in 600-800 A.D Concept Design

• “Industrial Revolution” in the 1750s

Detail Design
• By 1940s major milestones have been reached in all
manufacturing aspects. Manufacture
• Advancement of manufacturing technology with the
advent of computer. Sell
Chart showing general Product Flow
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 Example of a
Design & Manufacture
Manufactured Product
Product flow in • Coat Hanger
concurrent
Various steps engineering,
involved in from market
design and analysis to
manufacturing selling the
a product. product.

Source:
Manufacturing Engineering
and Technology
Fifth Edition
Serope Kalpakjian
Steven R. Schmid

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Material Selection Material Selection

• Availability – in the desired shape, dimensions &
quantities, and reliability of supply
• Appearance – color, feel and surface texture
• Service Life – wear, fatigue, creep, dimensional stability
• Recycling – to conserve resources
• Cost

Section of an automotive engine - the Duratec V-6

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 Types of Materials Properties of Materials
• Ferrous Metals – carbon, alloy, stainless steels and, tool & • Mechanical Properties – strength, toughness, ductility,
die steels hardness, elasticity, fatigue, creep and strength to weight
ration & stiffness to weight ratio
• Nonferrous Metals – Al, Mg, Cu, Ni, Ti, Refractory metals,
low melting alloys, beryllium, zirconium, etc • Physical Properties – density, specific heat, thermal
expansion and conductivity, melting point and electrical and
• Plastics – thermoplastics, thermosets & elastomers magnetic conductivity
• Ceramics and Diamond • Chemical Properties – oxidation, corrosion, general
• Composite or Engineered Materials – reinforced plastics, degradation, toxicity, flammability
metal matrix or ceramic matrix composites • Manufacturing Properties – castability, formability,
machinability, weldability and ability to heat-treat

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Basic Manufacturing Processes Machining and Finishing Processes

Schematic
• Machining and Finishing Processes illustrations of
various machining
• Forming or Shaping Processes and finishing
processes.
• Casting or Moulding Processes
• Joining Processes
• Heat Treatment
Source:
• Assembly Manufacturing Engineering
and Technology
Fifth Edition
Serope Kalpakjian
Steven R. Schmid

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 Forming or Shaping Processes Forming or Shaping Processes
Schematic Schematic
illustration of various illustration of various
Extrusion bulk deformation sheet metal forming
processes. processes.

Source: Source:
Manufacturing Engineering Manufacturing Engineering
and Technology and Technology
Fifth Edition Fifth Edition
Serope Kalpakjian Serope Kalpakjian
Steven R. Schmid Steven R. Schmid

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Forming or Shaping Processes Casting or Moulding Processes

Schematic Schematic
illustration of various illustration of various
polymer processing casting processes.
methods.

Source: Source:
Manufacturing Engineering Manufacturing Engineering
and Technology and Technology
Fifth Edition Fifth Edition
Serope Kalpakjian Serope Kalpakjian
Steven R. Schmid Steven R. Schmid

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 Example of a
Joining Processes
Manufactured Product
Schematic
illustration of various • Paper Clip
joining processes.
Questions for consideration:
1. What material properties are
required?
2. What manufacturing attributes
are required?
Source: 3. Would the material and
Manufacturing Engineering processing strategy change if
and Technology
Fifth Edition the desired quantity was
Serope Kalpakjian 10,000 vs. 1 million per day?
Steven R. Schmid

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Example of a
Manufactured Product
• Bolt

There is more than which meets the eye…

- The movie ‘Transformers’

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 References

• MANUFACTURING ENGINEERING & TECHNOLOGY

Serope Kalpakjian, Steven R Schmid
Addison Wesley Longman (Singapore) Pte. Ltd.
Fourth Edition.

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