ME 3503

Material an
s

Manufacturi
ng

Tanzila
Younas

Email: tanzila@sz
abist.edu.pk

Process
es

ME 3503
Materials and
Manufacturing
Processes
Materials
Processing

Manufacturing
Technology

Microstructures of metals

Casting process

Defects in metals,
dislocations

Conventional Machining
process

Plastic flow, grain

boundaries

Non-conventional
machining process

Forming of Metals

Joining process

Week
1
2
3
4
5
6
7
8
9
10
11

12
13
14
15
16

Session
Topics
i.
Introduction to course, Properties
of
materials in general ii.
Casting (Disposable :
Sand and
investment :casting)
Casting
( Permanent
Slush, Pressure, Die, Centrifugal,
Continuous)
i.
A brief on microstructure, defects, dislocations, grain
boundaries &
recrystallization
ii.
Forming
processes
i.
Metal
Alloys,
Phase (cold, warm and hot working)
diagrams ii.
Heat
treatment
i.
Quiz 1
ii.
Powder Metallurgy
i.
Ceramics & Polymers (micro structure and their processing)
Mid term exam
Composites (ceramic matrix, metal matrix)
Fundamentals of joining, Intro to welding, Fusion & Solid-state
Welding
i.
Quiz 2
ii.
Brazing soldering, Mechanical Fastening

Assessment

Traditional Machining
i.
Fundamentals of
Machining ii.
Producing
i.
Quiz 3round shapes
ii.
Machining (Milling, Planing, Shaping, Broaching and
Sawing
Abrasive machining and finishing processes
Non-traditional Machining
Chemical, Electromechanical (ECM) , Mechanical (WJC,
AWC, AJM, AFM) , Thermal (EDM, LBM, PAC)
Revision Lecture
Final Exam

N/A

N/A
N/A
N/A
N/A
Quiz 1
N/A
N/A
N/A
Quiz 2

Quiz 3
N/A
N/A
N/A

Assessement

Three tests - 5 marks each

Two assignments 5 marks
each
Term Paper 10 marks
Mid term exam - 25 marks
Final exam - 40 marks

Books
Materials and Processes in Manufacturing by E.P Degarmo,
Prentice Hall,

of Modern Manufacturing, Mikel P.

Fundamentals
Latest Edition.
Groover, 4th Edition, Weily,2014.
Engineering Materials 2 : An Introduction to Microstructures,
Processing

Elements of material science and engineering , Van Vlack,

and Design, Michael F. Ashby and David R. H. Jones
5th Edition, Addison Wesley,2012.

Materials Science for Engineers, James F. Shackelford, 8th

Edition, Pearson ,2012.

Engineering with Polymers, P. C. Powell, Chapman and Hall,

Stanley Thornes, 5th Edition, ,2012

Materials selection
Material requirements based on the

operating
Mechanical conditions:
characteristics strength, fracture and impact
resistance,
fatigu

Physical characteristics density,

appearance
Service

- Operating temperature, corrosive

environment

environment

Materials

selection is

an integral part of the design

process

Wha ismanufacturin
t

g?

Raw
Materials

End
Products
Manufacturing

Manufacturing is the process of converting raw materials into

encompasses the design and manufacturing of goods using various
products; it
production
methods and techniques.

STRUCTU
Classifcation of solids on the basis of the arrangement of atoms or
molecules.
CRYSTALLINE

RE

Highly ordered three dimensional arrangement of

SOLIDS:

particles.
Sharp melting points.
Examples of crystalline engineering materials :
AMORPHOUS
metals, alloys, crystalline silicon dioxide),
Particles
diamondare randomly arranged in three dimension.
SOLIDS:

Melt over a wide range of temperature.

Examples of amorphous materials : glasses

and polymers.

ceramics
(alumina,

Mechanical properties of
materials

Tensile strength

Mechanical properties of
materials

Elastic limit (Yield strength)

The maximum stress that can be applied to a material

without causing
permanent deformation.

Offset yield strength /Proof stress

The stress that will cause a specifed small, permanent
extension of a
tensile test piece. Normally 0.1% or 0.2% strain.

It is used to defne the yield strength of the

materials which don`t have a well defned yield
point.

Ultimate Yield strength (UTS)

Mechanical properties of
materials
Modulus of Elasticity
It is a measure of the stiffness of an elastic
material and is
defned as the ratio of the linear stress to the linear
strain.

Compressive strength
The maximum compressive stress that can be applied
to a material without fracturing it.

Hardness
Ability to withstand surface indentation.

Mechanical properties of
materials

Toughness

Toughness is the work per unit volume required

to fracture a material. It is the ability of a
material to absorb energy and plastically
deform without fracturing.

Mechanical properties of
materials
Fracture Toughness
Fracture toughness is a property which is the
measure of the
material`s resistance to brittle fracture.
Structural
failure
whichelastic
results from
either the
cyclic
In the
linear
fracture
mechanics,

fracture toughness a material is determined

from the stress intensity factor at which the
of
a particular
cycle or entirely random
crack
begins loading
to propagate.
Fatigue
variations in
repetition

stress.

of

Mechanic properti of materia

al

es

ls

Fatigue Limit/ Endurance Limit

The stress below which the not fail

material will the number of regardless of
load cycles.

Mechanical properties of
materials

Creep

Even if the applied stress is much lower than the yield

component
elongates
with timeuntil
rupture,
Failure
caused
by
long
term
exposure
of
the
material
strength, the
exposed
to to elevated
temperatures
under
load
temperatures.if
continuously
elevated
.

Creep curve for a single specimen at a fxed