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Introduction To The Course

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Introduction To The Course

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sseema
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© © All Rights Reserved
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ME572: Analysis of Manufacturing Processes

Introduction
Dr. S. Sohail Akhtar
Mechanical Engineering Department
King Fahd University of Petroleum & Minerals
Dhahran 31261, Saudi Arabia

ME 572 Prepared by Dr. Sohail Akhtar 1


Course Objectives and Learning Outcomes
Objectives
o The principles of machine tools and metal machining
o The principles of metalworking processes
o Recent advances in machining and forming
CLOs
o To understand the principles of machine tools and metal
machining
o To understand the principles of metal forming processes
o To understand the metallurgical and economic considerations in
machining and metal forming processes
o To have knowledge about recent advances in machining and
forming
o To have knowledge about non-traditional machining processes
ME 572 Prepared by Dr. Sohail Akhtar 2
Text and Reference Books
Textbook:
• G. Boothroyd and W.A. Knight “Fundamentals of metal machining and machine tools”, 3rd Ed,
CRC Press, 2006
• W. Hosford, R. Caddell, “Metal Forming, Mechanics and Metallurgy,” 4th edition, Cambridge
University Press, 2011
References:
• Milton C. Shaw “Metal Cutting Principles”, 2nd Edition, Oxford, 2005.
• M.P. Groover, “Automation, Production Systems and Computer-Aided Manufacturing”,
Prentice Hall, Inc., 1980.
• E. Trent, P. Wright, “Metal Cutting,” Butterworth–Heinemann, 2000
• G.W. Rowe, “Principles of industrial metalworking processes”, Edward Arnod, 1977

Link to the Textbooks


https://drive.google.com/drive/folders/1KMYpjQ-
6oGpTC0rQs107H6YvEmAMgxLv?usp=sharing

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Course Grade Distribution

Course Grade Distribution

Midterm Exam 25%


Homework 10%
In-class and take-home quizzes 15%
Term project 20%
Final Exam 30%
Total 100%

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Status of Manufacturing
✓ With the advent of globalization, manufacturing enterprises today are
facing many challenges, ranging from product design to manufacturing.
✓ In response to increasing customer demand and dynamic competition,
companies are under high pressure to shorten time-to-market by
providing tailored products to customers for the economy of scope and
to reduce time-to-volume via mass production for the economy of
scale.
✓ These requirements are driving the technology needs of
manufacturing enterprises to:
• speed up product design and development, and
• to enhance manufacturing capability and capacity
✓ Innovations in advanced product design and manufacturing have
continued to expand and attract attention to address these challenges

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Status of Manufacturing

Product Lifecycle

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What is Manufacturing

Manufacturing - Technological Manufacturing - Economic

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Manufacturing Processes

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Manufacturing Processes

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A recap of manufacturing processes/systems

https://www.dre.vanderbilt.edu/~schmidt/PDF/SITaxonomies-finalwithBio.pdf
Tentative Outline of Topics

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Tentative Outline of Topics

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A few glimpses of research projects related
to various manufacturing processes

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Metal forming tools/processes
Surface Treatment and Coating Processes

Schematic of typical thermal spray deposition


process on flat substrate Nitrding Cycle

Collaborators:
• Rezayat Protective Coating Co. Ltd.
Dammam (for coating)
• University of Toronto ((for coating)
• ALUPCO, Dammam (for nitriding)
Evolution of Residual Stress in Thermal Spray
Coatings using Hybrid Computational Approach

1 Point cloud model


2 3

Coupling interface Finite element model

− Droplet impact and deformation→0-2 μs


Powder Metallurgy: Spark Plasma Sintering
Mapping porosity on
SPS process Modeling the process densified powder

Densification
Mechanisms considered

• Creep
• Electro-migration
• Diffusion Under load
• Surface tension Experimental Simulation

Process parameters
Cutting Tools: Design, Development and
Performance

Design using
Predictive tools

Development

Performance
Metal Casting

Collaborator:
MASABIK, Dammam
Metal Casting

MAGMALINK

Interface between
MAGMASOFT and ABAQUS
Modeling and Simulation of Multi-Physics
Problems
o Metal forming/tools
o Laser manufacturing and surface treatment
o Coatings performance
o Phase-Field modeling

Full three-cell model showing


meshed domains of solar cells

Laser surface melting

Laser Machining
Some on-going projects..
1. Manufacturing of functionally-graded SiAlON-Based cutting inserts and performance
optimization using machining modeling
2. Development of Physics-based Computational Framework for Optimization of Metal
Additive Manufacturing
3. Advancing Metal Additive Manufacturing through Hybrid Constitutive Modeling for
Biomedical Component Optimization.
4. Simulation-based Optimization of Mold Design for High-Quality Castings
5. Hybrid Additive Manufacturing Technology for Metal Parts Used in the Nuclear
Industry
6. Advancing Hybrid Polymer Coating Technology for Mitigating Fouling and Mechanical
Degradation in Metallic Surfaces for Desalination and Related Applications
7. Design and Development of Sustainable Polymer-Composite Heat Transfer
components in Thermal Desalination System

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What is next..
Review of Machining
Operations
Chapter 1

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