Materials Processing in Automotive Engineering - Chapter 1.pdf

Materials Processing in Automotive Engineering - Chapter 1

1. MATERIALS PROCESSING IN
AUTOMOTIVE ENGINEERING
DEPARTMENT OF METAL FORMING
SCHOOL OF MECHANICAL ENGINEERING
Lecturer: Assoc.Prof.Dr. Nguyen Dac Trung
E-mail: [email protected]

2. GENERAL INFORMATION
◼Course name: Materials Processing in Automotive Engineering
◼Volume: 3(3-1-0-6)
◼COURSE DESCRIPTION: Materials Processing in Automotive
Engineering is a specialized subject. This course provides the
basic and in-depth knowledge about engineering materials
such as metal and composite material, manufacturing
processes and technologies to fabricate the parts or details
applied in automotive industry.
◼OBJECTIVES AND EXPECTED LEARNING OUTCOMES : Analyze
and calculate technology parameters for processing materials,
choose appropriate processing equipment. Apply technology
and Assess environmental impact.

3. GENERAL INFORMATION
Learning
outcomes
Description Objectives /Expected learning outcomes of the course
M1 Understanding of basic engineering materials such as metals, polymers and composite materials.
M1.1Understand the materials to produce the parts of car.
M1.2Understand the mechanical properties of materials.
M1.3Understand the requirements for durability and working conditions of automotive parts.
M2 Understanding of manufacturing processes and technologies for making of parts used in the
automotive industry.
M2.1Understand of technology, equipment and process to produce the parts made by metals.
M2.2Understand of technology, equipment and process to produce the parts made by polymers and composite
materials.
M3 Capability to determine the appropriate technology to fabricate the parts made by metal, polymers
and composite materials.
M3.1Designthetechnologicalschemaforcasting,cutting,forming,welding,joining,pressing,injection
molding...
M3.2Determinetechnologicalparametersforfabricationofparts
M4 Capabilitytoanalyzeandcalculatetechnologicalparametersforprocessingmaterials,chooseappropriate
equipments.
M4.1Analyzeandcalculatemaintechnologicalparametersforprocessing
M4.2Selectappropriateequipments
M4.3Designthemanufacturinglinewithsupportsystems

4. CONTENT OF COURSE
Chapter 1. Introduction and Overview of Materials Processing in Automotive Engineering
1.1 Introduction into Materials Processing
1.2 Overview of Parts in the car
1.3 Development of manufacturing technology
Chapter 2. Materials used in automotive engineering
2.1 Concept of materials
2.2 Metal and Alloy
2.3 Polymers and composite materials
2.4 Material Properties
2.5 Influence factors on material properties
Chapter 3. Materials Processing
3.1 Casting Process
3.2 Metal Forming
3.3 Machining
3.4 Welding and Joining
3.5 Pressing
3.6 Injection molding
Chapter 4. Equipments for Material Processing
4.1 Equipments for metal processing
4.2 Equipments for polymers and composite materials
4.3 Selection equipments and auxiliary devices
Chapter 5. Manufacturing and Support Systems
5.1 Automation Technologies for Manufacturing Systems
5.2 Integrated Manufacturing Systems
5.3 Process Planning and Production Control

5. Chapter 1. Introduction and Overview of Materials
Processing in Automotive Engineering
1.1 Introduction into Materials Processing
The automotive industry is one of the world's most innovative industries. It has always been an
important driving force of the economy. With a view to ensuring quality, reliability and economic
efficiency, the manufacture of vehicles and automotive components such as engines and
gearboxes is only possible in automated manufacturing facilities.
Pressing Plant

6. 1.1 Introduction into Materials Processing
Body-in-white

7. 1.1 Introduction into Materials Processing
Painting

8. 1.1 Introduction into Materials Processing
Powertrain

9. 1.1 Introduction into Materials Processing
Assembly

10. 1.1 Introduction into Materials Processing
Two ways to define manufacturing: (a) as a technical process, and (b) as an economic process
Technologically, manufacturing is the application of physical and chemical processes to alter
the geometry, properties, and/or appearance of a given starting material to make parts or
products; manufacturing also includes assembly of multiple parts to make products. The
processes to accomplish manufacturing involve a combination of machinery, tools, power,
and labor. Manufacturing is almost always carried out as a sequence of operations. Each
operation brings the material closer to the desired final state.
Economically, manufacturing is the transformation of materials into items of greater value by
means of one or more processing and/or assembly operations. The key point is that
manufacturing adds value to the material by changing its shape or properties, or by
combining it with other materials that have been similarly altered. The material has been
made more valuable through the manufacturing operations performed on it. When iron ore is
converted into steel, value is added. When sand is transformed into glass, value is added.
When petroleum is refined into plastic, value is added. And when plastic is molded into the
complex geometry of a patio chair, it is made even more valuable.

11. Materials in Manufacturing
1.1 Introduction into Materials Processing
Most engineering materials can be
classified into one of three basic
categories:
(1) metals, (2) ceramics, and (3) polymers.
Their chemistries are different, their
mechanical and physical properties are
different, and these differences affect the
manufacturing processes that can be used
to produce products from them.
(4) Composites - non homogeneous
mixtures of the three basic types.

12. Manufacturing Processes
1.1 Introduction into Materials Processing

13. Manufacturing Processes
1.1 Introduction into Materials Processing

14. Manufacturing Processes
1.1 Introduction into Materials Processing

15. Manufacturing Processes
1.1 Introduction into Materials Processing

16. Chapter 1. Introduction and Overview of Materials
Processing in Automotive Engineering
1.2 Overview of Parts in the car
Car body, frame, engine, electric
motor, internal combustion engine,
transmission, gearbox….
Crankshaft
Joint

17. 1.2 Overview of Parts in the car

18. 1.2 Overview of Parts in the car

19. Overview of Materials used in automotive industry
Materials used for the manufacture of car bodies

20. Overview of Materials used in automotive industry
Materials used for the manufacture of car bodies

21. Overview of Materials used in automotive industry
Materials used for the manufacture of car frame

22. Overview of Materials used in automotive industry
Materials used for the manufacture of car frame

23. Overview of Materials used in automotive industry
Materials used for the manufacture of car frame

24. Overview of Materials used in automotive industry
Parts of various types of
materials used for the
manufacture of car parts
Types of sheet steel for car bodies

25. Primary processing routes of AMCs
Types of AMCs Particulate Reinforced Aluminum Matrix Composites (PAMCs) are
one of the key research and development areas of metal matrix composites. The
development prospect is very broad and will lead the revolution of advanced
materials through large-scale production and application. These composites
generally contain equated ceramic reinforcements with an aspect ratio less than
about 5. Ceramic reinforcements are generally oxides or carbides
Overview of Materials used in automotive industry

26. Primary processes for manufacturing of AMCs
Overview of Materials used in automotive industry

27. Chapter 1. Introduction and Overview of Materials
Processing in Automotive Engineering
1.3 Development of manufacturing technology
(1) microelectronics,
(2) computerization of manufacturing,
(3) flexible manufacturing,
(4) micro-fabrication and nanotechnology,
(5) lean production and Six Sigma,
(6) globalization,
(7) environmentally conscious manufacturing.
Six Sigma can be defined as “a quality-focused program that utilizes worker
teams to accomplish projects aimed at improving an organization’s
operational performance.”