Materials

Teaching Faculty
The Materials Processing Group
Dr. Hasan Bin Awais Dr. Fahad Ali Mr. Naeem-ul-Haq Tariq Mr. Hafiz Rubnawaz

Manufacturing
The Process of Converting Raw Materials Into Products

Manufacturing Processes - 1

Permanent mold Permanent Pattern Expendable mold and pattern

Centrifugal casting Investment Casting

Ceramic mould casting

Casting Cutting
Process

Forming

Fabrication

Properties of Materials
Mechanical Properties: strength, toughness,
ductility, hardness, elasticity, fatigue, creep.

Behavior Under Loading: tension, compression,

bending, torsion, shear.

Physical Properties: density, specific heat, thermal

expansion, thermal conductivity, melting point, electrical and magnetic properties.

Chemical Properties: oxidation, corrosion,

degradation, toxicity, flammability.

Types of Materials
Ferrous Metals: iron and steel.

Nonferrous Metals and Alloys: aluminum,

magnesium, copper, nickel, titanium, superalloys, beryllium, zirconium, low-melting alloys, precious metals.

Plastics: thermoplastics, thermosets, elastomers.

Ceramics: glass, graphite, diamond.

Composite materials: reinforced plastics, metalmatrix and ceramic-matrix composites, honeycomb structures.

Ferrous Metals: Applications

Structural: building structures, concrete reinforcement Automotive: chassis, engine parts, drive train, body parts Marine: ship hulls, structure, engines Defense: tanks, weapons Consumer Products: appliances, recreational vehicles, toys, utensils and tools

Nonferrous Metals: Applications

Architectural: aluminum windows and doors

Automotive: aluminum engine blocks, copper wiring, mag wheels Marine: brass/bronze fittings, bearings, propellers
Defense: brass shell casings Consumer Products: electrical wiring, utensils, jewelry, electronics

Plastics (Polymers)
Compared to metals, plastics have lower density, strength, elastic modulus, and thermal and electrical conductivity, and a higher coefficient of thermal expansion The design of plastic parts should include considerations of their low strength and stiffness, and high thermal expansion and low resistance to temperature.

Plastics: Applications
Architectural: electrical and thermal insulation, weather seals, carpets, wall coverings, paint Aerospace: electrical and thermal insulation, instrument panels,upholstery, seals Automotive: body panels, instrument panels, upholstery, electrical and thermal insulation, seals, hoses, tires

Consumer Products: toys, sporting goods, appliances, tools, utensils, clothing, shoes, packaging

Manufacturing
The Process of Converting Raw Materials Into Products

Manufacturing a Product: General Considerations

Material Selection
Processing Methods Final Shape and Appearance Dimensional and Surface Finish Economics of Tooling

Design Requirements
Safety and Environmental Concerns

Choosing Methods of Production

Use a Selection Chart

Manufacturing Processes for Metals

Casting: expendable mold and permanent mold. Forming and Shaping: rolling, forging, extrusion, drawing,
sheet forming, powder metallurgy, molding

Machining: turning, boring, drilling, milling, planing, shaping,

broaching, grinding, ultrasonic machining, chemical machining, electrical discharge machining (EDM), electrochemical machining, high-energy beam machining

Joining: welding, brazing, soldering, diffusion bonding,

adhesive bonding, mechanical joining

Finishing: honing, lapping, polishing, burnishing, deburring,

surface treating, coating, plating

Casting Processes
Introduction of molten metal into a mold cavity; upon solidification, metal conforms to the shape of the cavity.

Die Casting

Sand Casting

Forming and Shaping Processes

Bulk deformation processes that induce shape changes by plastic deformation under forces applied by tools and dies.

Forging Extrusion

Machining Processes
Material removal from a work piece: cutting, grinding, nontraditional machining processes.

Milling

Lathe Machine

NC Machine Tool and Controller

NC Punch Press Machine

Manufacturing Processes for Plastics

Plastics are shipped to manufacturing plants as pellets or powders and are melted just before the shaping process. Polymers melt at relatively low temperatures and are easy to handle. Plastics can be molded and formed, as well as machined and joined, into many shapes with relative ease.

Injection Molding of Plastics

Selective Laser Sintering System

Courtesy of the University of Texas

Shape Complexity
The shape complexity index is obtained by using a feature based classification system which enables the important design issues. Classification of different shape complexity:A Part envelop is largely a solid of revolution. B Part envelope is largely a prismatic solid. C Flat or thin wall section component.

Sub-Classifications of Categories A,B,C

Basic features Secondary features Multi axis Non-uniform Single axis Through features

1. Basic Features
Straight forward processing where the operation can be carried out without a change of setting or the need of complex tooling. Parts are usually uniform in cross section.

2.Secondary features
Same as basic features but where additional processing is necessary or more complex tooling is required.

3.Multi-axis Features
Parts require to be processed in more than a single axis/set-up.

4.Non-uniform Features
Parts require the development of more complex processing techniques.

5.Complex Forms
Parts need dedicated tooling and the development of specialized processing techniques.

6. Single Axis
This is usually the axis along the components largest dimension, however in the case of cylindrical or disc shaped components it is more convenient to consider the axis of revolution as the primary axis.

7. Through Features Features which run along across or through a component from one end or side to the other

8. Important
If the component falls into more than one category, always choose the one that gives highest value of complexity.

Basic Rotational features Regular Secondary features A1 A2

Category includes Rotationally symmetrical/groove holes along the primary axis

Internal/external threads around primary axis.

Secondary Axis
Interna A3 A4

Complex forms
A5

Internal or external features Irregular or complex forms

Holes/threads counterbores and other internal features not on primary axis

Projections, complex features.

Complex contoured surfaces

Single Axis
Basic features only

Secondary/Repetitive
Uniform thickness

C1

C2

Blanks, washers, simple bends etc

Plain cogs/gears

Regular forms
cup., cone and box-type parts

Complex forms
Non-uniform forms

C4

C5

Components may involve changes in section thickness

Complex or irregular features