ME 240

Manufacturing
Course Overview
Lecture 01
Importance of Manufacturing

Welcome to ME 240 - Manufacturing

Welcome to ME 240 - Manufacturing

Lectures: M & W 10:10 - 11:00 a.m.

Labs: M, T, W & R 1:10 - 4:00 p.m.

Textbook: Fundamentals of Modern Manufacturing: Materials,

Processes and Systems (5th Edition) M. Groover
Course Structure

Welcome to ME 240 - Manufacturing

Course Components
28 Lecture Periods
Hands-on Lab Activities (9 weeks)
Pneumatic Engine
Design & Manufacturing Project (4 lab sessions)
 For all course info
Course Site Website
(https://coursesite.lehigh.edu/)

ME-240-00-SP16

Lecture PPT Notes

Available for download 1 day prior to Lecture
Download, Print,
and use to take Notes
Course Overview
Grading

Mid Term Exam 25%

Final Exam 25%
Labs 25%
Design Project 25%
100%
Personnel

Faculty & Staff

Professor Graduate T.A. Graduate T.A. MechE Shop

Dave Angstadt Jerard Gordon Matt Dragovich Dick Towne

Dravo Student Shop Dravo Student Shop

Eli Towne Bill Maroun

Personnel

Undergraduate Teaching Assistants

Colin Bader Teresita Liebel Brian Oliver David Rodriguez

[TUES] [TU/TH] [TU/TH] [WED]

Deanna Shepherd Jonathan Whitcraft Becky White Zach Wilson

[THURS] [MON] [WED] [MON]
Importance of Manufacturing

MANUFACTURING...

is the process of converting raw materials into products

encompasses both design and production.
is a key value-added process.

IMPORTANCE...

Almost everything we consume is the output of some sort

of manufacturing process

Level of manufacturing is directly related to the economic

health of a society.

Level of Manufacturing Standard of Living

Importance of Manufacturing

From (U.S. ) National Association of Manufacturers Website (Jan. 2016):

Manufacturers contributed $2.09 trillion to the economy.

The Manufacturing sector accounts for 12.0 percent of GDP.1
For every $1.00 spent in manufacturing, another $1.37 is
added to the economy, the highest multiplier effect of any
economic sector.2

http://www.nam.org/Newsroom/Facts-About-Manufacturing/
Importance of Manufacturing

GDP of:
California - $1.959 Trillion (2012)
Texas - $1.414 Trillion (2013)

http://www.bloomberg.com/bw/ar
ticles/2014-04-28/why-factory-
jobs-are-shrinking-everywhere
Importance of Manufacturing

** Cost to manufacturer Wages paid

China $1.07 (2007)

USA $34.74

All European Countries

Importance of Manufacturing

From (U.S.) National Association of Manufacturers Website (Jan. 2016):

Manufacturers contributed $2.09 trillion to the economy.

The Manufacturing sector accounts for 12.0 percent of GDP.1
For every $1.00 spent in manufacturing, another $1.37 is
added to the economy, the highest multiplier effect of any
economic sector.2
Manufacturing supports an estimated 17.6 million jobs in the
United Statesabout one in six private-sector jobs. More than
12 million Americans (or 9 percent of the workforce) are
employed directly in manufacturing.3
In 2013, the average manufacturing worker in the United
States earned $77,506 annually, including pay and benefits.
The average worker in all industries earned $62,546.4
Manufacturers in the United States are the most productive in
the world, far surpassing the worker productivity of any other
major manufacturing economy, leading to higher wages and
living standards.5
Manufacturers in the United States perform more than three-
quarters of all private-sector R&D in the nation, driving more
http://www.nam.org/Newsroom/Facts-About-Manufacturing/
innovation than any other sector.6
 Scope of Manufacturing

Manufacturers make stuff to make money (it is an investment):

Typical Cost Breakdown for a Manufactured Product

Design & Manufacturing Project

Background Checks!!

Please initiate checks & get fingerprinted (Campus Square Mail Center) asap so
we can proceed with project kick-off meeting during Week 4 of the semester

1. We will be using their Lehigh email address to order the checks so

they will need to check that email for the instructions from CBY.

DO NOT CLICK ON LINK unless you intend to actually complete the required
information (Link is only valid for one use!!)

2. Students that have already had background checks completed for other
activities we will need to have the students bring the documentation from all three
checks (PATCH, Child Abuse and FBI) to the Provost Office as soon as possible so
we know that we do not need to order checks for them.
Importance of Manufacturing

Trends & Developments in Manufacturing

Global Economy
International competition
Market fluctuations
Make it faster
Product variety
Make it better
Product life cycle
Make it cheaper
Labor costs

Increased Engineering Systems Complexity

Decreased Hands-on Experience of Incoming

Student Population
Importance of Manufacturing

Trends & Developments in Manufacturing

Microelectronics (new sector)

Computerization in manufacturing processes
Flexible manufacturing (BMW)
Microfabrication and Nanotechnology
Lean production and Six Sigma
Globalization and outsourcing
Environmentally conscious manufacturing (Sustainability, Plant emissions)
Importance of Manufacturing

Machining Processes Deformation Processes Metal Casting & Polymer Processes Composites Processes
Single Point Machining Open-Die Forging Powder Processes Extrusion Pultrusion
Turning, Boring Impression-Die Forming Ingot Casting Fiber Spinning Filament Winding
Facing, Forming Closed-Die Forging Continuous Casting Calendaring Pull Forming
Shaping, Planing Precision Forging Sand Casting Film Blowing Braiding
Coining Shell Molding Coating Autoclave Molding
Multipoint Machining Heading, Piercing, HubbingSlurry Molding Melt, Solution,Plasma Compression Molding
Drilling, Milling Cogging, Fullering, Edging Investment Casting Electrostatic, Plastisol, UV Cure Resin Transfer Molding (RTM)
Sawing, Filing Roll Forging, Skew Rolling Evaporative Casting Blow Molding Autocomp Molding
Broaching, Thread Cutting Die Casting Injection molding Hand Lay-up
Rolling Centrifugal Casting Reaction Injection Molding (RIM)Spray-up
Grinding Flat, Ring, Thread Squeeze Casting Compression Molding Automatic Tape Lay-up
Surface Grinding Gear, Piercing, Extrusion Rheocasting Transfer Molding Stamping
Cylindrical Grinding Casting Diaphragm Forming
Centerless Grinding Extrusion Crystal Pulling Thermoforming Injection Molding
Internal Grinding Direct, Indirect, Hydrostatic
Zone Melting Rotational Molding Reinforced RIM

172 Different Processes!!

Form Grinding Impact, Backward Solid State Forming
Powder Metallurgy Machining Metal Matrix Composites
Abrasive Wire Cutting Drawing Pressing Etching, Solvent Processing Hot Pressure Bonding
Honing, Lapping Rod/Wire, Flat Strip Isostaic Pressing Foaming Hot Isostatic Pressing
Ultrasonic Machining Tube, Swaging Sintering Bonding Liquid Metal Infiltration
Buffing, Polishing Electroforming Impregnating Electrodeposition
Burnishing, Tumbling Shearing Plasma Spraying Painting Plasma Spray Deposition
Grit Blasting Bending
Press, Brake Forming Joining Processes Ceramics Processes Microelectronics Processes
Chemical Machining Roll Forming, Tube FormingMechanical Joining Powder Processes Czochralski Crystal Growth
Engraving Bolts, Screws, Rivets Consolidation Flat Zone Crystal Growth
Chemical Milling Beading, Flanging, Hemming Solid State Welding Sintering Wafer Processing
Chemical Blanking Stretch Forming, Seaming Diffusion, Forging Melt Processes Slicing, Etching, Polishing
Bulging Friction, Deformation Crystalline Materials Chemical Vapor Deposition
Electrochemical Machining Deep Drawing Liquid State Welding Glasses Epitaxial Film Growth
Electrical Discharge Machining
Press Forming Resistance Welding Drawing, Casting, Blowing Poly Crystalline Film Growth
Laser Machining Rubber Forming Arc Welding Tempering, Coating Ion Implantation
Electron Beam Machining Spinning Thermal Welding Sol-Gel Ceramics Physical Vapor Deposition
Plasma Arc Cutting Explosive Forming High Energy Beam Weld Sputtering
Flame Cutting Electrohydraulic Forming Brazing, Soldering Lithography
Water Jet Cutting Magnetic Pulse Forming Adhesive Bonding Chemical Etching
Superplastic Forming
Scope of Manufacturing

Classification According to U.S. Census Bureau

http://www.census.gov/econ/isp/

NAICS North American Industry

Classification System

System of Classifying businesses used by

Federal Government

Replaced SIC Standard Industrial

Classification codes in 1997
Click here to see the List!

Some Examples:

3321 Forging and Stamping

3336 Engine, Turbine, and Power Transmission

Equipment Manufacturing

3352 Household Appliance Manufacturing

3361 Motor Vehicle Manufacturing

3364 Aerospace Product and Parts Manufacturing

 Scope of Manufacturing

Classifications According to U.S. Census Bureau

http://www.census.gov/econ/isp/
Scope of Manufacturing

Classification According to Groover:

PRIMARY Industries:
Cultivate/Exploit Natural Resources
Mining, Agriculture, Forestry, Petroleum

SECONDARY Industries:
Convert natural resources into consumer/capital
goods
Most manufacturing resides here
Textiles, Chemicals, Basic Metals, Machinery, etc.
TERTIARY Industries:
Provide Services to consumers & other industries
Education, Banking, Real Estate, Financial Services,
Government
Scope of Manufacturing

Classification According to Groover:

Scope of Manufacturing

Classification According to Groover:

Manufacturing Processes MATERIALS

Pneumatic Engine
Course Overview

LAB Weeks 1 & 2

CAD/Metrology/Teardown

Solid Works CAM software

Disassembly/Analysis of
Air Inflator

Manual Measurement of Air

Engine Components

Modeling, Assembly &

Engineering Drawings
LAB Weeks 3 - NC Milling

NX CAM Milling & Turning

Computer-aided process planning

Software process verification

NC machining Demos
Course Overview

LAB Weeks 4 & 5 - CASTING PROCESSES

Creation of Sand Mold from pattern

Analysis of Fill & Venting needs

Casting of Aluminum Part

Secondary processing (de-gate &

machine)
Course Overview

LAB Weeks 4 & 5 Injection Molding

Use of injection molding simulation

software (MOLDFLOW)

Injection molding Demo

Evaluation of Process simulation

Course Overview

LAB Weeks 9 & 10 - METAL DEFORMATION

Hole Punching

Sheet Metal Bending

Coining
Course Overview

LAB Weeks 12 & 13 - JOINING PROCESSES

Overview of joining methods

Applicability for each method

Important parameters to control

Hands-on experience stick & spot

welding, brazing and burning
Course Overview

LAB Weeks 12 & 13 - Thermofoming

Part thermoforming Large Scale Deformation measurement

Male vs Female Mold Geometry Experimental Determination of Strain &

Thickness distribution
Course Overview

LAB Week 14 STATISTICAL PROCESS CONTROL

Overview of SPC

Analysis of Simple Process by SPC

Creation of X-Bar and R-Bar Charts

Course Overview

DESIGN PROJECT

Matchbox Style Car

4 weeks of Lab time

Open-ended, loosely structured

assignment

Deliverables
- finished product, written report &
competition

Team with Broughal Students

Design & Manufacturing Project

Project involves individual & group...

Product conceptualization

Product Design

Prototyping of design

Mold/Tooling design

NC Machining

Polymer processing

Matchbox Style Vehicle Product quality/cost optimization

Product delivery under strict time

schedule
Design & Manufacturing Project

Work with Broughal Middle School

students

They are your customers.

Design & Manufacturing Project

Concept
Design & Manufacturing Project

Computer Model
Concept
of Car
Design & Manufacturing Project

Computer Model Computer Model

Concept
of Car of Mold
Design & Manufacturing Project

Computer Model Computer Model

Concept
of Car of Mold

Create Prototype
Design & Manufacturing Project

Computer Model Computer Model

Concept
of Car of Mold

Create Prototype

Generate Toolpaths
for Mold
Design & Manufacturing Project

Computer Model Computer Model

Concept
of Car of Mold

Create Prototype

Generate Toolpaths
for Mold

Machine Mold
from Wax
Design & Manufacturing Project

Computer Model Computer Model

Concept
of Car of Mold

Create Prototype

Generate Toolpaths
for Mold

Machine Mold Machine Mold

from Aluminum from Wax
Design & Manufacturing Project

Computer Model Computer Model

Concept
of Car of Mold

Create Prototype

Generate Toolpaths
for Mold

Injection Mold Machine Mold Machine Mold

Car Body from Aluminum from Wax
Design & Manufacturing Project

Computer Model Computer Model

Concept
of Car of Mold

Create Prototype

Generate Toolpaths
for Mold

Injection Mold Machine Mold Machine Mold

Car Body from Aluminum from Wax
Design & Manufacturing Project

Computer Model Computer Model

Concept
of Car of Mold

Create Prototype

Generate Toolpaths
for Mold

Injection Mold Machine Mold Machine Mold

Car Body from Aluminum from Wax
Design & Manufacturing Project

Computer Model Computer Model

Concept
of Car of Mold

Create Prototype
Paint Car &
Attach Wheels
Generate Toolpaths
for Mold

Injection Mold Machine Mold

Verify Toolpaths
Car Body from Aluminum
Design & Manufacturing Project

Background Checks!!

Please initiate checks & get fingerprinted (Campus Square Mail Center) asap so
we can proceed with project kick-off meeting during Week 4 of the semester

1. We will be using their Lehigh email address to order the checks so

they will need to check that email for the instructions from CBY.

DO NOT CLICK ON LINK unless you intend to actually complete the required
information (Link is only valid for one use!!)

2. Students that have already had background checks completed for other
activities we will need to have the students bring the documentation from all three
checks (PATCH, Child Abuse and FBI) to the Provost Office as soon as possible so
we know that we do not need to order checks for them.
Design & Manufacturing Project

Race Day: Friday May 5