Metal Forming (ME252)

ME 252: Metal Forming

Dr. Saeed Mousa
Email: [email protected]
LECTURES
All sections, Sunday (07:00 – 08:50 pm)
LABS
All sections meet in workshops and move to respective shop areas. Don’t
be late!
Tuesday 08:00 – 11:50 am
OFFICE HOURS:
Available before and after the lectures and labs
(You can set up a time through the email)
 Metal Forming (ME252)

TEXTBOOK:
Groover, M.P., 4th, 2010, “Fundamentals of Modern
Manufacturing, Materials, Processes, and Systems”,
John Wiley & Sons, Inc. (You have to have the PDF
book)

Other Reference Materials and Books:

Kalpakjian, S.and Schmidt, S. R., 5th, 2008,
“Manufacturing Processes for Engineering
Materials”, Prentice Hall, Upper Saddle River, NJ.
 Metal Forming (ME252)

COURSE TOPICS:
• Mechanical Behavior of Materials: mechanical properties of metallic materials
using tensile, hardness, surface roughness and dimensional measurements.

• Metal forming: bulk and sheet metal deformation processes, work hardening and
its effect on mechanical properties, analysis of bulk deformation processes, and
principles of sheet metal operation.
 Metal Forming (ME252)

GRADING:

Exams (~ 2-3 sets, each 10–15%) 30%

Term paper and presentation 15% (Outlines of the topic: 5%, final report and
presentation: 10%)
Lab and Case studies 15%
Attendance and discussion 5%
NOTE: All above grades will be weighted to 50%
Final exam 35% (will be weighted to 50%)

The class will be divided into groups containing no more than 5 students (preferably 4)
within your selected sections. Each group will work together on presentation project.
Listed below is the breakdown by category between the group and individual
assignments.
 INTRODUCTION AND
OVERVIEW OF MANUFACTURING

1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production Systems
5. Manufacturing Economics
6. Recent Developments in Manufacturing

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Manufacturing is Important

 Making things has been an essential human activity

since before recorded history
 Today, the term manufacturing is used for this
activity
 Manufacturing is important to the United States and
most other developed and developing nations
 Technologically
 Economically

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Technological Importance

 Technology - the application of science to provide

society and its members with those things that are
needed or desired
 Technology affects our daily lives, directly and
indirectly, in many ways
 Technology provides the products that help our
society and its members live better

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Technological Importance

 What do these products have in common?

 They are all manufactured
 They would not be available to our society if they
could not be manufactured
 Manufacturing is the essential factor that makes
technology possible

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Economic Importance

U.S. Economy
Sector: %GDP
Agriculture and natural resources 5
Construction and public utilities 5
Manufacturing 12
Service industries* 78
100
* includes retail, transportation, banking,
communication, education, and government

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 What is Manufacturing?

 The word manufacture is derived from two Latin

words manus (hand) and factus (make); the
combination means “made by hand”
 “Made by hand” described the fabrication methods
that were used when the English word
“manufacture” was first coined around 1567 A.D.
 Most modern manufacturing operations are
accomplished by mechanized and automated
equipment that is supervised by human workers

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Manufacturing - Technological

 Application of physical and chemical processes to

alter the geometry, properties, and/or appearance of
a starting material to make parts or products

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Manufacturing - Economic

 Transformation of materials into items of greater value

by one or more processing and/or assembly operations

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Manufacturing Example:
Artificial Heart Valve

Left: Heart valve Right: Starting titanium billet

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Manufacturing Industries

 Industry consists of enterprises and organizations that

produce or supply goods and services
 Industries can be classified as:
1. Primary industries - cultivate and exploit natural
resources, e.g., agriculture, mining
2. Secondary industries - take the outputs of primary
industries and convert them into consumer and
capital goods
3. Tertiary industries - service sector
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Specific Industries in Each
Category

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Production Quantity Q

 The quantity of products Q made by a factory has an

important influence on the way its people, facilities, and
procedures are organized
 Annual quantities can be classified into three ranges:
Production range Annual Quantity Q
Low production 1 to 100 units
Medium production 100 to 10,000 units
High production 10,000 to millions of units

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Product Variety P

 Product variety P refers to different product types or

models produced in the plant
 Different products have different features
 They are intended for different markets
 Some have more parts than others
 The number of different product types made each
year in a factory can be counted
 When the number of product types made in the
factory is high, this indicates high product variety

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 P vs Q in Factory Operations

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Materials in Manufacturing

 Most engineering materials can be classified into one of

three basic categories:
1. Metals
2. Ceramics
3. Polymers
 Their chemistries are different, and their mechanical and
physical properties are different
 In addition, there is a fourth category:
4. Composites
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Classification of
engineering
materials

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 1. Metals

 Usually alloys, which are composed of two or more

elements, at least one of which is metallic. Two basic
groups:
1. Ferrous metals - based on iron, comprises about
75% of metal tonnage in the world:
 Steel and cast iron
2. Nonferrous metals - all other metallic elements
and their alloys:
 Aluminum, copper, nickel, silver, tin, etc.

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 2. Ceramics

 Compounds containing metallic (or semi-metallic) and

nonmetallic elements.
 Typical nonmetallic elements are oxygen, nitrogen,
and carbon
 For processing, ceramics divide into:
1. Crystalline ceramics – includes traditional
ceramics, such as clay, and modern ceramics,
such as alumina (Al2O3)
2. Glasses – mostly based on silica (SiO2)

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 3. Polymers

 Compound formed of repeating structural units called

mers, whose atoms share electrons to form very large
molecules. Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without
altering molecular structure
2. Thermosetting polymers - molecules chemically
transform into a rigid structure – cannot reheat
3. Elastomers - shows significant elastic behavior

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 4. Composites

 Material consisting of two or more phases that are

processed separately and then bonded together to
achieve properties superior to its constituents
 Phase - homogeneous material, such as grains of
identical unit cell structure in a solid metal
 Usual structure consists of particles or fibers of
one phase mixed in a second phase
 Properties depend on components, physical
shapes of components, and the way they are
combined to form the final material
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Manufacturing Processes:
Two Basic Types

1. Processing operations - transform a work material

from one state of completion to a more advanced
state
 Operations that change the geometry, properties,
or appearance of the starting material
2. Assembly operations - join two or more components to
create a new entity

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Classification of
Manufacturing
Processes

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Solidification Processes

 Starting material is heated sufficiently to transform it

into a liquid or highly plastic state
 (1) Casting process and (2) casting product

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Particulate Processing

 (1) Starting materials are metal or ceramic powders,

which are (2) pressed and (3) sintered

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Deformation Processes

 Starting workpart is shaped by application of forces

that exceed the yield strength of the material
 Examples: (a) forging and (b) extrusion

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Material Removal Processes

 Excess material removed from the starting piece so what

remains is the desired geometry
 Examples: (a) turning, (b) drilling, and (c) milling

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Waste in Shaping Processes

 It is desirable to minimize waste in part shaping

 Material removal processes are wasteful in the unit
operations, but molding and particulate processing
operations waste little material
 Terminology for minimum waste processes:
 Net shape processes - little or no waste of the
starting material and no machining is required
 Near net shape processes - when minimum
machining is required

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Property-Enhancing Processes

 Processes that improve mechanical or physical

properties of work material
 Examples:
 Heat treatment of metals and glasses
 Sintering of powdered metals and ceramics
 Part shape is not altered, except unintentionally
 Example: unintentional warping of a heat treated
part

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Surface Processing Operations

 Cleaning - chemical and mechanical processes to

remove dirt, oil, and other surface contaminants
 Surface treatments - mechanical working such as
sand blasting, and physical processes like diffusion
 Coating and thin film deposition - coating exterior
surface of the workpart
 Examples:
 Electroplating
 Painting

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Assembly Operations

 Two or more separate parts are joined to form a new

entity
 Types of assembly operations:
1. Joining processes – create a permanent joint
 Welding, brazing, soldering, adhesive bonding
2. Mechanical assembly – fastening by mechanical
methods
 Threaded fasteners (screws, bolts and nuts);
press fitting, expansion fits

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Model of the Production System

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Fixed-Position Plant Layout

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Medium Production

 Two different types of facility, depending on product

variety:
 Batch production
 Suited to medium and hard product variety
 Setups required between batches
 Cellular manufacturing
 Suited to soft product variety
 Worker cells organized to process parts without
setups between different part styles
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Process Plant Layout

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Cellular Plant Layout

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 High Production

 Often referred to as mass production

 High demand for product
 Manufacturing system dedicated to the
production of that product
 Two categories of mass production:
1. Quantity production
2. Flow line production

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Product Plant Layout

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Manufacturing Support Systems

 A company must organize itself to design the

processes and equipment, plan and control
production, and satisfy product quality requirements
 Accomplished by manufacturing support systems
 The people and procedures by which a
company manages its production operations
 Typical departments:
 Manufacturing engineering, Production
planning and control, Quality control

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Typical Cost Breakdown for a
Manufactured Product

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Recent Developments
in Manufacturing

 Microelectronics manufacturing (Group1)

 Computerization in manufacturing (Group 3)
 Green manufacturing (Group 5)
 Microfabrication and Nanotechnology (group 7)
 Lean production and Six Sigma (Group 8)
 Applications of adhesive bonding in automotive
industry (Group 2)
 Applications of welding in automotive industry (Group
4)
 ©2012
Applications of welding in areospace industry (Group
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
6)
 Microelectronics

 Electronic devices that are fabricated on a

microscopic scale: Integrated circuits (ICs)
 Today’s fabrication technologies permit billions of
components to be included in a single IC
 A large proportion of the products manufactured
today are based on microelectronics technology
 About 2/3 of the products in Table 1.1 are either
electronics products or their function and
operation depend on electronics

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Computerization of
Manufacturing

 Direct Numerical Control (DNC) was one of the first

applications of computers in manufacturing (1960s)
 Mainframe computer remotely controlling multiple
machine tools
 Enabled by advances in microelectronics, the cost of
computers and data processing has been reduced,
leading to the widespread use of personal computers
 To control individual production machines
 To manage the entire enterprise

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Flexible Manufacturing

 Although mass production is widely used throughout

the world, computerization has enabled the
development of manufacturing systems that can
cope with product variety
 Examples:
 Cellular manufacturing
 Mixed-model assembly lines
 Flexible manufacturing systems

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Microfabrication and
Nanotechnology
 Microfabrication
 Processes that make parts and products whose
feature sizes are in the micron range (10-6 m)
 Examples: Ink-jet printing heads, compact disks,
microsensors used in automobiles
 Nanotechnology
 Materials and products whose feature sizes are in
the nanometer range (10-9 m)
 Examples: Coatings for catalytic converters, flat
screen TV monitors

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Lean Production and Six Sigma

 Lean production
 Doing more work with fewer resources, yet
achieving higher quality in the final product
 Underlying objective: elimination of waste in
manufacturing
 Six Sigma
 Quality-focused program that utilizes worker
teams to accomplish projects aimed at improving
an organization’s organizational performance

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Globalization

 The recognition that we have an international economy

in which barriers once established by national
boundaries have been reduced
 This has enabled the freer flow of goods and
services, capital, technology, and people among
regions and countries
 Once underdeveloped countries such as China,
India, and Mexico have now developed their
manufacturing infrastructures and technologies to
become important producers in the global economy

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Outsourcing

 Use of outside contractors to perform work that was

traditionally accomplished in-house
 Local outsourcing
 Jobs remain in the U.S.
 Outsourcing to foreign countries
 Offshore outsourcing - production in China and
other overseas locations
 Near-shore outsourcing - production in Canada,
Mexico, and Central America

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Environmentally Conscious
Manufacturing
 Determining the most efficient use of materials and
natural resources in production, and minimizing the
negative consequences on the environment
 Associated terms: green manufacturing, cleaner
production, sustainable manufacturing
 Basic approaches:
1. Design products that minimize environmental
impact
2. Design processes that are environmentally
friendly

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
 Examples

1 (A) A company invests $750,000 in a piece of production equipment. The cost

to install the equipment in the plant = $25,000. The anticipated life of the
machine = 12 years. The machine will be used eight hours per shift, five shifts
per week, 50 weeks per year. Applicable overhead rate = 18%. Assume
availability = 100%. Determine the equipment cost rate if (a) the plant
operates one shift per day and (b) the plant operates three shifts per day.
 Solution: (a) For a one-shift operation, hours of operation per year H =
50(1)(5)(8) = 2000 hr/yr. Using Eq. (1.8), Ceq = (750,000 + 25,000)(1.18)/(60
x 12 x 2000) = $0.635/min = $38.10/hr
 (b) For a three-shift operation, hours of operation per year H = 50(3)(5)(8) =
6000 hr/yr.
 Ceq = (750,000 + 25,000)(1.18)/(60 x 12 x 6000) = $0.212/min = $12.70/hr
 Note the significant advantage the company has if it runs three shifts per day
rather than one shift.
 Example 2

1 A stamping press produces sheet-metal stampings in batches. The press is operated by a worker
whose labor rate = $15.00/hr and applicable labor overhead rate = 42%. Cost rate of the press =
$22.50/hr and applicable equipment overhead rate = 20%. In one job of interest, batch size = 400
stampings, and the time to set up the die in the press takes 75 min. The die cost $40,000 and is
expected to last for 200,000 stampings. Each cycle in the operation, the starting blanks of sheet metal
are manually loaded into the press, which takes 42 sec. The actual press stroke takes only 8 sec. Cost
of the starting blanks = $0.43/pc. The press operates 250 days per year, 7.5 hours per day, but the
operator is paid for 8 hours per day. Assume availability = 100% and scrap rate = 0. Determine (a)
cycle time, (b) average production rate with and without setup time included, and (c) cost per
stamping produced.
 Solution: (a) Cycle time Tc = 42 + 8 = 50 sec = 0.833 min
 (b) Including setup time, Tp = 75/400 + 0.833 = 1.021 min
 Rp = 60/1.021 = 58.78 pc/hr
 Excluding setup time, Rc = 60/0.833 = 72.03 pc/hr
 (c) Equipment cost rate Ceq = 22.50(1.20)/60 = $0.45/min.
 Die cost per piece Ct = 40,000/200,000 = $0.20/pc
 Labor cost rate CL = 15.00(1.42)/60 = $0.355/min
 This labor cost should be adjusted for the fact that although the press operates 7.5 hr/day, the
operator is paid for 8 hr. CL = 0.355(8/7.5) = $0.379
 Finally, cost per stamping Cpc = 0.43 + (0.379 + 0.45)(1.021) + 0.20 = $1.48/pc
 Example 3

1 (A) During a particular 40-hour week of an automated production

operation, 336 acceptable (non-defective) parts and 22 defective parts
were produced. The operation cycle consists of a processing time of 5.73
min, and a part handling time of 0.38 min. Every 60 parts, a tool change is
performed, and this takes 7.2 min. The machine experienced several
breakdowns during the week. Determine (a) hourly production rate of
acceptable parts, (b) scrap rate, and (c) availability (proportion uptime) of
the machine during this week.
 Solution: (a) Production rate of acceptable parts Rp = 335/40 = 8.40 pc/hr
 (b) Total parts processed during the week Qo = 336 + 22 = 358 pc
 Scrap rate q = 22/358 = 0.0615 = 6.15%
 (c) Cycle time of the unit operation Tc = 5.73 + 0.38 + 7.2/60 = 6.23 min
 Total uptime during the week = 358(6.23) = 2230.34 min = 37.17 hr
 Proportion uptime A = 37.17/40 = 0.929 = 92.9%