Manufacturing processes definition, Classification of manufacturing processes, Typical examples of applications, Manufacturing capability, Selection of materials, Selection of manufacturing process
2. Need
1. To create goods for human being to support
living and improve standard of life.
2. Producing more goods using less resource is
the target to cater needs of public in general
3. So productivity is of prime importance and is
achieved by reducing wastage in the form of
scrap and defective products
4. The first incandescent lamp was made by TA.
Edison (1847-1931) in New Jersey and was first
lit in 1879. A typical bulb then had a life of only
about 13.5 hours.
main purpose
increasing their life and reducing production
costs.
materials and production methods
Incandescent Light Bulbs
“glowing with heat”
5. The light-emitting component is the filament,
which, by the passage of current and due to its
electrical resistance, is heated to incandescence
to a temperature of 2200°-3000°C.
Edison’s first successful lamp had a carbon
filament, although he and others also had
experimented with carbonized paper and metals
such as osmium, itidium, and tantalum.
Incandescent Light Bulbs
“glowing with heat”
6. However, none of these materials has the
strength, resistance to high temperature, and long
life as has tungsten, which is now the most
commonly used filament material.
Incandescent Light Bulbs
“glowing with heat”
7. The first step is making the glass
stem that supports the
lead-in wires and
the filament
connects them to the base of the
bulb.
Step in Manufacturing a Light Bulb
8. All these components are
positioned,
assembled, and
sealed
while the glass is heated by gas
flames.
Step in Manufacturing a Light Bulb
9. The filament is then attached to
the lead-in wires.
Step in Manufacturing a Light Bulb
10. The filament is made by powder
metallurgy techniques.
which involves first pressing
tungsten powder into ingots and
sintering it.
Step in Manufacturing a Light Bulb
11. Next, the ingot is shaped into
round rods by rotary swaging and
then drawing it through a set of
dies into thin wire.
The wire diameter for a 60-W,
120-V bulb is 0.045 mm.
Step in Manufacturing a Light Bulb
12. The diameter must be controlled
precisely, because if it is only 1%
less than the diameter specified,
the life of the bulb would be
reduced by as much as 25%.
R = p (L / A)
Step in Manufacturing a Light Bulb
13. The diameter must be controlled
precisely, because if it is only 1%
less than the diameter specified,
the life of the bulb would be
reduced by as much as 25%.
R = p (L / A)
Step in Manufacturing a Light Bulb
14. filament wire is coiled
this is done in order to increase
the light producing capacity of the
filament.
Step in Manufacturing a Light Bulb
15. The completed stem assembly
(called the mount) is transferred to
a machine that lowers a glass bulb
over the mount.
Gas flames are used to seal the
rim of the mount to the neck of
the bulb.
Step in Manufacturing a Light Bulb
16. The air in the bulb is then
exhausted and filled with inert
gas.
The filling gas must be pure.
Step in Manufacturing a Light Bulb
17. The next step involves attaching
the metal base to the glass bulb
with a special cement. The
machine that performs this
operation also solders or welds the
lead-in wires to the base, to
provide the electrical connection.
Step in Manufacturing a Light Bulb
18. The lead-in wires are usually
made of nickel, copper, or
molybdenum, and the support
wires are made of molybdenum
Step in Manufacturing a Light Bulb
19. The bulb base is generally made
from aluminum, replacing the
more expensive brass base.
Bulb Industry
Step in Manufacturing a Light Bulb
20.
21. Resources for manufacturing
In manufacturing for producing goods used are
the resources in the form of
– Natural resources (air, water, animal, wheat,
minerals etc.)
– Machine tool: plants, machines, tool, robots,
automation
Creation of goods for human being:
(Natural Resources) × (Man power)machine tool
22. Manufacturing
Today, production methods have advanced to such an
extent that
(a) aluminum beverage cans are made at rates of more
than 500 per minute, with each can costing about Rs
1.2 to make,
(b) holes in sheet metal are punched at rates of 800 holes
per minute, and
(c) incandescent light bulbs are made at rates of more
than 2000 bulbs per minute.
23. Manufacturing
The word manufacture first appeared in English in 1567
and is derived from the Latin manu factus, meaning
“made by hand”.
The word manufacturing first appeared in 1683, and the
word production, which is often used interchangeably
with the word manufacturing, first appeared sometime
during the 15th century.
24. Manufacturing
– Technologically: Physical and chemical processes to
alter size, shape and properties of material suitable for
service use.
– Economically: (value addition) A step to convert raw
material into useful product of high value.
25. Manufacturing- Technologically
Application of physical and chemical processes used
for changing shape, size, properties, and appearance of
raw material for required function.
▪ Always carried out as a sequence of operations.
26. Manufacturing – Economically
( value Addition)
Transformation of materials into items of greater value
by means of one or more processing and/or assembly
operations
▪ Raw material processed by manufacturing processes
usable goods are obtained (high value)
43. Materials in Manufacturing
Most engineering materials can be classified
into one of three basic categories:
1. Metals
2. Ceramics
3. Polymers
▪ Their chemistries are different.
▪ Their mechanical and physical properties are
dissimilar.
▪ These differences affect the manufacturing
processes that can be used to produce products
from them.
44. Metals
Two basic groups:
1. Ferrous metals - based on iron:
▪ Steel = Fe - C alloy (0.08 to 2.1%C)
▪ Cast iron = Fe - C alloy (2.1% to 6.76%C)
2. Non-ferrous metals - all other metallic elements
and their alloys: aluminum, copper, magnesium,
nickel, silver, tin, zinc, brass, gold, titanium, etc.
45. Ceramics
Ceramic materials are inorganic, non-metallic materials
made from compounds of a metal and a non metal.
▪ Typical non-metallic elements are oxygen,
nitrogen, and carbon
▪ For processing, ceramics divide into:
1. Crystalline ceramics – includes:
▪ Traditional ceramics, such as clay (hydrous
aluminum silicates)
▪ Modern ceramics, such as alumina (Al2O3),
silicon carbide (SiC), etc.
2. Glasses – mostly based on silica (SiO2)
46. Ceramics>Characteristics of Ceramics
▪ Low density compared to metals
▪ High melting point or decomposition temperature
▪ High hardness and very brittle
▪ High elastic modulus and moderate strength
▪ Low toughness
▪ High electrical resistivity
▪ Low thermal conductivity
▪ High temperature wear resistance
▪ Thermal Shock resistance
▪ High corrosion resistance
Main drawback is brittleness and low toughness
47. Ceramics>Silicon nitride bearings(Si3N4)
have good shock resistance
compared to other ceramics.
SNB bearings are harder than
metal,
results in
✓80% less friction,
✓3 to 10 times longer
lifetime, 80% higher speed,
✓60% less weight,
✓higher corrosion resistance
and
✓higher operation temp., as
compared to traditional
metal bearings.
Silicon nitride bearings are
especially useful in applications
where corrosion, electric or
magnetic fields prohibit the use of
metals.
Si3N4 was used as abrasive and cutting tools.
48. Polymers
(Greek poly-, "many" + mer, "part")
The word POLYMER means many ‘mers’
▪ A ‘mer’ is a unit
▪ Polyethylene means many ‘ethylenes’
▪ The molecular weight of a polymer (length of the chain –
number of ‘mers’) will effect the properties.
• 10-20 ethylenes – greases or oils
• 200-300 waxes
• 20,000 + polyethylene
49. Polymers
(Greek poly-, "many" + mer, "part")
Compound formed of repeating structural units
called monomers, who share atoms with
neighboring monomers to form a long chain.
Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without
altering molecular structure.
2. Thermosetting polymers - molecules
chemically transform (cure) into a rigid
structure – cannot be reheated.
3. Elastomers - shows significant elastic behavior
50. Polymers
(Greek poly-, "many" + mer, "part")
Compound formed of repeating structural units
called monomers, who share atoms with
neighboring monomers to form a long chain.
Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without
altering molecular structure.
2. Thermosetting polymers - molecules
chemically transform (cure) into a rigid
structure – cannot be reheated.
3. Elastomers - shows significant elastic behavior
A monomer (one part) is a
molecule that can undergo
polymerization.
Large numbers
of monomers combine to form
polymers in a process
called polymerization.
51. Polymers
(Greek poly-, "many" + mer, "part")
Compound formed of repeating structural units
called monomers, who share atoms with
neighboring monomers to form a long chain.
Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without
altering molecular structure.
2. Thermosetting polymers - molecules
chemically transform (cure) into a rigid
structure – cannot be reheated.
3. Elastomers - shows significant elastic behavior
A monomer (one part) is a
molecule that can undergo
polymerization.
Large numbers
of monomers combine to form
polymers in a process
called polymerization.
polymerization is a process of
reacting monomer molecules
together in a chemical reaction
to form polymer chains.
52. Polymers
(Greek poly-, "many" + mer, "part")
Compound formed of repeating structural units
called monomers, who share atoms with
neighboring monomers to form a long chain.
Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without
altering molecular structure.
2. Thermosetting polymers - molecules
chemically transform (cure) into a rigid
structure – cannot be reheated.
3. Elastomers - shows significant elastic behavior
A monomer (one part) is a
molecule that can undergo
polymerization.
Large numbers
of monomers combine to form
polymers in a process
called polymerization.
polymerization is a process of
reacting monomer molecules
together in a chemical reaction
to form polymer chains.
Polymers referred to as
"homopolymers," repeated long
chains or structures of the same
monomer unit, whereas polymers that
consist of more than one monomer unit
are referred to as “copolymers”
53. Polymers
(Greek poly-, "many" + mer, "part")
Compound formed of repeating structural units
called monomers, who share atoms with
neighboring monomers to form a long chain.
Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without
altering molecular structure.
2. Thermosetting polymers - molecules
chemically transform (cure) into a rigid
structure – cannot be reheated.
3. Elastomers - shows significant elastic behavior
A monomer (one part) is a
molecule that can undergo
polymerization.
Large numbers
of monomers combine to form
polymers in a process
called polymerization.
polymerization is a process of
reacting monomer molecules
together in a chemical reaction
to form polymer chains.
Polymers referred to as
"homopolymers," repeated long
chains or structures of the same
monomer unit, whereas polymers that
consist of more than one monomer unit
are referred to as “copolymers”
54. Polymers
(Greek poly-, "many" + mer, "part")
Compound formed of repeating structural units
called monomers, who share atoms with
neighboring monomers to form a long chain.
Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without
altering molecular structure.
2. Thermosetting polymers - molecules
chemically transform (cure) into a rigid
structure – cannot be reheated.
3. Elastomers - shows significant elastic behavior
56. Composites
Material consisting of two or more phases that are
processed separately and then bonded together to
achieve properties superior to its constituents:
▪ Matrix - homogeneous mass of material, such as
grains of identical unit cell structure in a solid
metal or polymer.
▪ Reinforcements – particles, fibers, whiskers of
as a foreign element.
▪ Properties of composites depend on physical
shapes of components, method of processing,
content of foreign element as well as their shapes.
57. Post-Manufacturing Processes
Alters a material’s shape, physical properties,
or appearance in order to add value.
Four categories of processing operations:
1. Shaping operations – to alter the geometry
of the starting work material
2. Property enhancer operations – to improve
physical properties without changing shape
3. Surface processing operations - to clean,
coat, or deposit material on exterior surface
of the work
4. Assembly
58. Solidification Processes
Starting material is heated sufficiently to transform
it into a liquid or highly plastic state.
▪ Examples: metal casting, plastic molding, etc.
59. Particulate Processing
Starting materials are powders of metals or ceramics
or even thermoset plastics.
▪ Usually involves pressing and sintering, in which
powders are first compressed and then heated to
bond the individual particles.
60. Deformation Processes
1. Starting material is shaped by application of
forces that exceed the yield strength of the material.
2. Starting material can be heated to reduce the
amount of input force.
Examples: (a) forging, (b) rolling and (b) extrusion.
62. Waste Problem While Manufacturing
Desirable to minimize waste in part shaping.
▪ Material removal processes are wasteful in unit operations,
simply by the way they work.
▪ Most casting, molding and particulate processing operations
waste little material.
▪ Almost zero waste in metal forming processes.
Terminology for minimum waste processes:
▪ Net-shape processes - when most of the starting material
is used and no subsequent machining is required (3D
printing and powder metallurgy.
▪ Near-net shape processes - when minimum amount of
machining is required (forging, rolling, sheet metal
operations).
63. Surface Processing Operations
▪ Cleaning - chemical and mechanical processes to remove
dirt, oil, and other contaminants from the surface
▪ Surface roughness treatments - mechanical working such
as sand blasting, barrel finishing and simply rubbing with
files or emery papers.
64. Assembly Operations
Two or more separate parts are joined to form a new entity
▪ Types of assembly operations:
▪ Permanent joints.
Examples: welding, soldering, brazing and use of
adhesives.
▪ Temporary joints.
Examples: screws, bolts, nuts, press fitting, and
expansion fits.
▪ Semi-permanent joints.
Examples: rivets, and clamps
66. Low/Job Production
Job shop is the term used for this type of production
facility.
▪ A job shop makes low quantities of specialized and
customized products.
▪ Products are typically complex, e.g., space capsules,
prototype aircraft and special machinery .
▪ Equipment in a job shop are flexible.
▪ Designed for maximum flexibility.
67. Medium Production
1. Depends upon demand and can vary time to time:
2. Also called Batch production
3. Further extensions: Cellular manufacturing
68. High Production
▪ Often referred to as mass production.
▪ High demand for product.
▪ Manufacturing system dedicated to the production of
that product.
70. How to select a particular type of
suitable process?
✓ On basis of experience.
✓ Facility available.
✓ Material characters.
✓ Processing time and processing cost.
✓ Capital cost of the facility
✓ Overhead and operational cost
✓ Features of manufacturing process
✓ Geometrical features of the products