Mulungushi University

(School of Engineering & Technology)

Manufacturing
Technology I
(MEE411)
Instructor: Mr. Muzeya
 Mulungushi University
(School of Engineering & Technology)

What is Manufacturing Technology?

Manufacturing Technology is the study of methods and equipment used to

convert raw materials into finished products.

It combines engineering principles, materials science, mechanics, and

automation to design, control, and improve production systems.

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Core Topic Covered in Manufacturing Technology

❑ Materials Science: metals, polymers, ceramics, composites.

❑ Manufacturing Processes: casting, forming, machining, welding, additive
manufacturing (3D printing).
❑ Computer-Aided Design & Manufacturing (CAD/CAM).
❑ CNC machining and automation.
❑ Industrial Metrology & Quality Control.
❑ Production Planning & Lean Manufacturing.
❑ Robotics and Industrial Automation.

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Knowledge and Skills You gain from studying

Manufacturing Technology

❑ Ability to select the right manufacturing process for a product.

❑ Hands-on operation of machine tools and modern equipment.

❑ Knowledge of production optimization and cost efficiency.

❑ Problem-solving in design-for-manufacture and process improvement.

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Applications and Career Paths for Graduate Engineers

Graduates can work in:

❑ Automotive and aerospace industries.
❑ Heavy machinery and equipment manufacturing.
❑ Electronics and consumer goods.
❑ Metalworking and fabrication industries.
❑ Quality control and production management.
❑ Emerging fields like advanced manufacturing and smart factories (Industry
4.0).

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Manufacturing Technology I - course outline

1. Introduction And Overview Of Manufacturing: What Is Manufacturing?,
Materials in Manufacturing, Manufacturing Processes, Production Systems,
Trends in Manufacturing
2. Material Properties and Product Attributes: Mechanical Properties Of
Materials, Physical Properties Of Materials
3. Engineering Materials: Metals
4. Solidification Processes: Metal Casting Processes, Shaping Processes For
Plastics
5. Particulate Processing of Metals: Powder Metallurgy
6. Metal Forming and Sheet Metalworking: Fundamentals Of Metal Forming,
Bulk Deformation Processes In Metalworking, Sheet Metalworking
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Manufacturing Technology I - course outline

8. Property Enhancing and Surface Processing Operations: Heat Treatment Of
Metals, Surface Processing Operations
9. Joining and Assembly Processes: Fundamentals Of Welding; Welding
Processes; Brazing, Soldering, And Adhesive Bonding; Mechanical Assembly
10. Material Removal Processes: Theory Of Metal Machining, Machining
Operations And Machine Tools Student assessment
Continuous assessment (CA): 40%
• Assignments/quizzes – 5%
• Tests – 20%
• Laboratory experiments – 20%
• Laboratory test – 5%
Final theory examination: 60%
Total: 100% 7
 Mulungushi University
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Recommended Books

Fundamentals of Modern Manufacturing; Materials, Processes and Systems,

by M. P. Groover, 4th Edition, John Wiley & Sons, Inc. ISBN: 978-0-470-
46700-8.).

Phillip D. Rufe, Fundamentals of Manufacturing, Society of Manufacturing

Engineering, 2nd ed.

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1. INTRODUCTION AND OVERVIEW OF MANUFACTURING

Making things (known today as manufacturing) has been an essential
activity of human civilizations since before recorded history, evolving from
ancient craftsmanship to modern industrial processes.

From the earliest days, humans crafted tools, pottery, and textiles to meet
their needs, using materials available to them in nature. Ancient Egyptians,
for instance, are known for their precision in creating intricate jewelry and
statues. The Greeks and Romans perfected metalworking, while medieval
blacksmiths shaped tools and weapons by hand.
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1. INTRODUCTION AND OVERVIEW OF MANUFACTURING (cont…)

In ancient times, craftsmanship involved skilled
artisans using manual techniques to produce
items such as pottery, weapons, furniture, and
clothing. This was labor-intensive work requiring
detailed knowledge of materials like wood, stone,
and metal. Manufacturing activities played a
crucial role in shaping human culture, economies,
and technological advancements, laying the
foundation for modern engineering and
industrialization.
ancient craftsmanship 10
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1. INTRODUCTION AND OVERVIEW OF MANUFACTURING (cont…)
Ancient metalworking craftsmanship. The
blacksmiths are shown working in a forge,
shaping metal tools and weapons. This image
highlights the process of forging, which has
been an essential part of manufacturing since
ancient times.

Metalworkers, such as blacksmiths, played a

critical role in early societies by producing
tools for agriculture, warfare, and
construction. 1
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1. INTRODUCTION AND OVERVIEW OF MANUFACTURING (cont…)
Importance of manufacturing to a nation

❑ For technological and economic reasons, manufacturing is important to the

welfare of both developed and developing nations.

❑ Technology can be defined as the application of science to provide society

and its members with those things that are needed or desired.

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1. INTRODUCTION AND OVERVIEW OF MANUFACTURING (cont…)
Importance of manufacturing to a nation: technologically
❑ For technological and economic reasons, manufacturing is important to the
welfare of both developed and developing nations.
❑ Technology can be defined as the
application of science to provide society
and its members with those things that are
needed or desired.

❑ Manufacturing is the critical factor that

makes technology possible.
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1. INTRODUCTION AND OVERVIEW OF MANUFACTURING (cont…)
Importance of manufacturing to a nation: economically
Economically, manufacturing is an important means by which a nation creates
material wealth.
❑ In the USA, the manufacturing industries
account for about 15% of GDP.

❑ In China, it accounts for about 26%

❑ In Zambia, it accounts for 8%

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1.1. What is manufacturing?
Originally, manufacturing means “made by hand”

As a field of study in the modern context, manufacturing can be defined two

ways: technologic and economic.

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.
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1.1. What is manufacturing? (cont…)
Two ways of defining manufacturing

As a technical process As an economic process

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1.1. What is manufacturing? (cont…)
Economically, manufacturing is the transformation of materials into items of
greater value by means of one or more processing and/or assembly
operations.

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, e.g, iron ore is converted into
steel, value is added.

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1.1.2. Manufacturing industries and products
Industries can be classified as primary, secondary, or tertiary.

❑ Primary industries cultivate and exploit natural resources, such as

agriculture and mining.
❑ Secondary industries take the outputs of the primary industries and
convert them into consumer and capital goods. Manufacturing is the
principal activity in this category, but construction and power utilities are
also included.
❑ Tertiary industries constitute the service sector of the economy.

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1.1.2. Manufacturing industries and products (cont…)

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1.1.3. Manufacturing capabilities
A manufacturing plant consists of a set of processes and systems (and
people) designed to transform a certain limited range of materials into
products of increased value. These three building blocks—materials,
processes, and systems—constitute the subject of modern manufacturing.
❑ A company engaged in manufacturing cannot do everything. It must do only certain
things, and it must do those things well.

Manufacturing capability refers to the technical and physical limitations of a

manufacturing firm and each of its plants. Several dimensions of this
capability can be identified: (1) technological processing capability, (2)
physical size and weight of product, and (3) production capacity
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1.1.3. Manufacturing capabilities (cont…)
1. The Technological Processing Capability The technological processing
capability of a plant (or company) is its available set of manufacturing
processes.
2. Physical Product Limitations: a second aspect of manufacturing capability
is imposed by the physical product. A plant with a given set of processes is
limited in terms of the size any weight of the products that can be
accommodated.
3. Production Capacity: a third limitation on a plant’s manufacturing
capability is the production quantity that can be produced in a given time
period (e.g., month or year).
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1.2. Materials in manufacturing
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.

In addition, there are (4) composites—non homogeneous mixtures of the

other three basic types.

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Classification of the four engineering materials

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1.2.1. Metals
Metals used in manufacturing are
usually alloys, which are composed
of two or more elements, with at
least one being a metallic element.

Metals and alloys can be divided into

two basic groups: (1) ferrous and (2)
nonferrous.

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1.2.1. Metals (cont…)
Ferrous metals: based on iron; the group includes steel and cast iron. Pure
iron has limited commercial use, but when alloyed with carbon, iron has more
uses and greater commercial value than any other metal.

Steel can be defined as an iron–carbon alloy containing 0.02% to 2.11%

carbon. It is the most important category within the ferrous metal group. Its
composition often includes other alloying elements, such as manganese,
chromium, nickel, and molybdenum - to enhance the properties of the metal.

Cast iron is an alloy of iron and carbon (2% to 4%) used in casting (primarily
sandcasting). Silicon is also present in the alloy (in amounts from 0.5% to 3%).
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1.2.1. Metals (cont…)
Nonferrous Metals include
the other metallic
elements and their alloys.
In almost all cases, the
alloys are more important
commercially than the
pure metals.

The nonferrous metals include the pure metals and alloys of aluminum,
copper, gold, magnesium, nickel, silver, tin, titanium, zinc, and other metals.
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1.2.2. Ceramics
A ceramic is defined as a compound containing metallic (or semimetallic) and
nonmetallic elements. Typical nonmetallic elements are oxygen, nitrogen, and
carbon. Ceramics include a variety of traditional and modern materials:
❑ Traditional materials: clay, silica, alumina, and silicon carbide.
❑ Modern materials: carbides and nitrides

For processing purposes, ceramics can be divided

into crystalline ceramics and glasses.

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1.2.3. Polymers
A polymer is a compound formed of repeating structural units called mers,
whose atoms share electrons to form very large molecules. Polymers usually
consist of carbon plus one or more other elements, such as hydrogen,
nitrogen, oxygen, and chlorine.
Polymers are divided into:
❑ thermoplastic polymers (e.g.,
nylon, polystyrene)
❑ thermosetting polymers (e.g.,
epoxies, amino resins)
❑ Elastomers (e.g., rubber, silicon)
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1.2.4. Composites
Composites are mixtures of the other three types. A composite is a material
consisting of two or more phases that are processed separately and then
bonded together to achieve properties superior to those of its constituents.

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End of lecture 1

Lecture 1 - 11/9/2024