1.01.Historical Developments

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HISTORICAL

DEVELOPMENTS INMANUFACTURING

(001)


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Introduction to Manufacturing

What is manufacturing?

Does manufacturing benefit

human kind?

Is manufacturing important

for the economy?

Manufacturing creates goods for

our existence. The products of

manufacturing are all around us.

Every thing we wear, we live in,

we travel on, even most of what

we eat, has gone through some

manufacturing process.

Manufacturing ------latin------

manus(hand) ;factus(made)

Manufacturing is the making of

goods and articles by hand or

especially by machinery, often on

large scale and with division of

labour.


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The history of manufacturing is marked by gradual developments ;the

cumulative effects have been of such substancial social consequences thatthey may be rightly regarded as revolutionary.

The First Industrial Revolution

At the end of 18th century, the development of steam engine made

power available in large quantities and many locations. This spurred

advances in manufacturing processes providing an abundance of goods ;The industrial revolution was characterized by the mechanical power

supplementing the physical power of the worker.

Toward the middle of 19th century, some functions of the worker were

taken over by machines in which mechanical components such as cams

and levers were ingeniously arranged to perform simple and repetitivetasks. Such hardautomation eliminated some jobs.

Around the turn of20th century, development was further aided by the

introduction of electric power.


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The Second Industrial Revolution

Beginning with the second half of the 20th century; Computers offerredthe undreamed of computational power

In the early 1970s the availability of microchip, with thousands of

electronic components crammed onto a tiny silicon wafer, made it

possible to perform computational, control, planning and management

tasks at high speeds Many dangerous, physically challenging and boring jobs(mind skills) are

performed by machines/robots controlled by computers.

The capability for gathering and processing information has dramatically

increased and it is commonly accepted that we have entered the

information age.

The belief is: we are in the process of developing into a post industrial

society, in which manufacturing will wither and the service sector based

on information processing will generate wealth.


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Do we really need manufacturing at all in the

information age?

The Economic Role of Manufacturing Engineering:

The factory was the alternative willingly chosen the

masses seeking to escape a rural existence burdened byfamine and disease.

Manufacturing as a Technical Activity:

Products coming out from high-tech industry face new

demands on safety and quality. Its manufacture too

demands the most advanced techniques.


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The Economic Role of Manufacturing Engineering

The GNP (sum of the value of all goods and services produced in a nationaleconomy) can be taken as a measure of material well being, though itexcludes the work performed in home, voluntary organisations, etc.

By analyzing the components of the GNP, it is evident that material wealthcomes from two substantial sources: material resource & knowledge andenergy that people apply in utilizing these resources.

Manufacturing claimed the largest single share until 1950s.

Since then much of the developments are in the service sector.

Increasing wealth is based on increasingly sophisticated manufacturingsector; this inturn creates the need for many increasingly sophisticatedsupporting activities ( research, design, finance, maintenence, distributon,field service, hospitality, travel industry, etc.)

For statistical purposes all these supporting activities are termed as

services

Yet, unless a nation is exceptionally well endowed with natural resources,strong service sector can exist only if there is a similarly strongmanufacturing sector.


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The Economic Role of Manufacturing Engineering

In the information age, knowledge is the most valuablecommodity.

Wealth is generated abundantly by producing tradable articlesin which knowledge is embodied (knowledge itself can bebought cheaply).

No nation exists in isolation any more, and international tradehas grown to a point where economies of all nations areinetrconnected. The flow of goods and services areincreasingly liberated from the earlier restrictions.

Manufacturing thus occupies a central position in theeconomies of all nations.

Many economic activities provide essential inputs tomanufacturing. Manufacturing creates all products needed forthe conversion of energy and raw materials: construction,transportation, communication, health care, entertainmentand leisure.


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Manufacturing as a Technical Activity

Example 1

The jet engine is the machine designed with most advanced

knowledge of thermal and fluid engineering principles, using

all available computer models for design and performance

evaluation. Its manufacture too demands the most advanced

techniques, as components are subjected to extremeconditions in operation.


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Manufacturing as a Technical Activity Example 1

First Stage : Compression

Second Stage : Combustion Third Stage : A large fan at the front of the engine increases thrust by

increasing the mass of the air displaced: in a high-bypass turbo fan engine, thebypass ratio is 6:1 or higher, which means that 6 times as much air passesaround the engine as passes through it.

Compression raises the temperature of the incoming air, and in recent

engines, the final-stage compressor blades are required to run red hot; weshall see throughout the text that new materials and technologies had to bedeveloped for making the compressor blades.

Developments in super alloys allowed a gradual increase in the operatingtemperature but a jump in performance came from cooling the blades bypassing the uncombusted compressor air through small holes in the airfoil.

Thus in addition to developing new processes for difficult ot manufacturealloys , techniques had to be found for very fine deep holes in very hardmaterials. Everybody recognizes jet engine is high-tech product.


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Schematic diagram illustrating the operation of a

low-bypass turbofan engine
http://upload.wikimedia.org/wikipedia/commons/7/77/Turbofan_operation_lbp.svghttp://upload.wikimedia.org/wikipedia/commons/7/77/Turbofan_operation_lbp.svg


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A Pratt & Whitney F100 turbofan engine for the F-15 Eagle beingtested in the hush house at Florida Air National Guard base. Thetunnel behind the engine muffles noise and allows exhaust to escape

(www.en.wikipedia.org)
http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Turbofanhttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/Hush_househttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://www.en.wikipedia./http://upload.wikimedia.org/wikipedia/commons/6/69/F100_F-15_engine.JPGhttp://www.en.wikipedia./http://www.en.wikipedia./http://www.en.wikipedia./http://www.en.wikipedia./http://www.en.wikipedia./http://www.en.wikipedia./http://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Florida_Air_National_Guardhttp://en.wikipedia.org/wiki/Hush_househttp://en.wikipedia.org/wiki/Hush_househttp://en.wikipedia.org/wiki/Hush_househttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/F-15_Eaglehttp://en.wikipedia.org/wiki/Turbofanhttp://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100http://en.wikipedia.org/wiki/Pratt_&_Whitney_F100


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Manufacturing as a Technical Activity- Example 2

Many changes had to be made by the automobile

industry in the existing design of the automobiles, tosatisfy new demands regarding safety, pollution level,

gasoline consumption, durability, and quality of

product. These changes have affected the choice of

materials and manufacturing techniques.

Early automobile bodies had a steel frame to

which wooden panels were attached. Soon

wood was replaced with all steel body thatwas secured to a heavier chasis.


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First bits get assembled onto chassis 1200cc Herald on

Burlingtons new ladder chassis.

Frame at the back is where the petrol tank will go.
http://upload.wikimedia.org/wikipedia/commons/e/e5/Origin19.jpghttp://upload.wikimedia.org/wikipedia/commons/e/e5/Origin19.jpg


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A bare chassis of the new Proton Exora MPV exhibited

at the Proton Technology Week.

The desire for weight reduction has led to uni-body construction
http://upload.wikimedia.org/wikipedia/commons/e/e5/Origin19.jpghttp://upload.wikimedia.org/wikipedia/commons/e/e5/Origin19.jpghttp://paultan.org/topics/proton-mpv-2009/http://upload.wikimedia.org/wikipedia/commons/5/5a/Proton-MPV-Chassis.jpghttp://paultan.org/topics/proton-mpv-2009/


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Polski Fiat on its side

The all-welded frameless steel bodies were made of low

carbon steel which has desirable forming properties.
http://upload.wikimedia.org/wikipedia/commons/2/23/126p_Polski_Fiat_on_its_side.JPG


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Aluminium chassis

Further interest in weight reduction and corrosion resistance led to the

introduction of galvanized steel , HSLA steel and Al alloys specially for

automotive applications. Much had to be learnt about the formingcapabilities of these materials so as to predict their formability to comlex

shapes.
http://upload.wikimedia.org/wikipedia/commons/7/7c/LotusEvorachassis.jpghttp://upload.wikimedia.org/wikipedia/commons/7/7c/LotusEvorachassis.jpg


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Polymers have also been used first as fiber glass

reinforced epoxies and more recently as mass

produced body parts attached to a precision

machined drivable steel space frame. The car, in its entirety, has become a

sophisticated product, with several onboard

computers performing critical control functions.Auto production now has all the characteristics of

a high-tech industry.


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Bioengineering offers examples where manufacturing benefits humans

directly. One of the most frequently performed orthopaedic surgeries is the

replacement of arthritic hip joints with surgical implants.Materials had to

be found that could be implanted in to the body without adverse reactions

that could withstand the adverse dynamic loading (of millions of cycles per

year) by ever youger and active patients.

The shape of the spherical head is critical and techniques had to be

developed for high-precision machining.

Better ways of fastening the replacement in the bones also had to be

found since adhesive joints frequently fail after some years of service.


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Hip joint replacements are advanced

manufacturing products The Ti alloy stem is inserted into

the femur (thighbone) and thecup into the acetabulum (socketof the hip bone), with a wireresistant polymer lining providingthe sliding surface( Zimmer Inc,Warsaw, Indiana)

Pure Ti wire of 0.25mm diameteris sintered into a porous mass toprovide room for the ingrowth offresh tissue which fixes theimplant of the bone of anexperimental animal( Dr.W.Rostoker).


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Micro-electronics which is the heart of the second

industrial revolution could be exploited only byadapting old and creating new manufacturing

technologies, for new materials.

Advanced manufacturing processes have made it

possible to create millions of components on a single

silicon chip.


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Synthetic detail of an integrated circuit through four

layers of planarized copper interconnect, down to the

polysilicon (pink), wells (greyish), and substrate (green)
http://upload.wikimedia.org/wikipedia/commons/c/c6/Siliconchip_by_shapeshifter.png


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Microchips (EPROM memory) with a transparent window,

showing the integrated circuit inside. Note the fine silver-colored

wires that connect the integrated circuit to the pins of the

package. The window allows the memory contents of the chip to

be erased, by exposure to strong ultraviolet light in an eraser

device
http://en.wikipedia.org/wiki/EPROMhttp://en.wikipedia.org/wiki/Ultraviolet_lighthttp://upload.wikimedia.org/wikipedia/commons/5/5c/Microchips.jpghttp://upload.wikimedia.org/wikipedia/commons/5/5c/Microchips.jpghttp://en.wikipedia.org/wiki/Ultraviolet_lighthttp://en.wikipedia.org/wiki/Ultraviolet_lighthttp://en.wikipedia.org/wiki/Ultraviolet_lighthttp://en.wikipedia.org/wiki/EPROM


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References

Introduction to Manufacturing, John.A.Schey,

3rd Edition, Mc Graw Hill International

Editions, 2000.

(www.en.wikipedia.org)

1.01.Historical Developments

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