Basic Manufacturing Process

1. Basic Machine
Processes
Competency D403.00
Identify the basic concepts of
the manufacturing processes.

2. Basic Machine Processes
Objective D403.01
Explain the concepts of
the manufacturing
process.

3. Manufacturing
 Arrived from the Latin word
“manu factus”, meaning “made
by hand”.
 Manufacturing is the process of
converting raw materials into
products.

4. WHY STUDY
MANUFACTURING PROCESSES?
The designer and the drafter
must have a working knowledge
of the various processes that
could produce a part in order to:
lower cost and reduce
production time.

5. Three Phases Of The
Manufacturing Process
1. Product design.
2. Selection of materials.
3. Selection of production
methods and techniques.

6. The information needed to produce a
part, most often comes in the form of a:
Working Drawing

7. Three Main Stages Of The
Production Of A Machined Part
Rough Forming
Casting, Forging, Welding
Finishing
Drilling, machining, surfacing
Assembling
The assembly of parts

8. The Casting Process
 First a pattern is made.
 Then a cavity is made by placing a pattern in
wet sand.
 Next molten metal is poured into the cavity of
damp sand.

9. The Casting Process
 The rough casting is now ready for the machine shop.
 Holes are then bored and reamed.
 Top and bottom surfaces are machined
 Smaller holes will be drilled and counterbored.
 All corners on cast parts are fillets and rounds.
Rough
Casting
Machined
Finish

10. Forging Process
 Forging is produced by using heavy mechanical
presses or hammering heated bars of metal
between dies.
 Advantages of forging over sand casting are that
forged parts are much stronger and less brittle.

11. Welding
Welding is the fusion or joining of
two pieces of metal by means of
heat, with or without the application
of pressure.
Cast
Welded

12. Manufacturing Materials
Fall into three general categories:
1. Metal
2. Plastic
3. Inorganic materials

13. Metals are classified as:
 Ferrous - contain iron and steel.
 Nonferrous - do not have iron content
(such as copper and aluminum).
 Alloys - mixture of two or more metals.

14. Inorganic Materials Include:
• Carbon and graphite - have low
tensile strength (ability to be
stretched).
• Ceramics are clay and glass
materials. (resistant to heat,
chemicals, & corrosion).

15. Heat-Treating:
 Annealing – is the process generally used
to soften metal by heating followed by slow
cooling.
 Hardening – requires heating and then
rapid cooling in oil or water.

16. Plastics Processing
The plastics industry represents one of the
major manufacturing segments.
 Thermoplastic – becoming or remaining
soft and moldable when subjected to heat.
 Thermosetting – becoming permanently
hard and unmoldable when once subjected
to heat.

17. Typical Plastic Processing Operations Include:
 Extrusion
 Blow Molding
 Injection Molding
 Thermoforming

18. Extruding
The process of producing
shapes by forcing hot metal
through a die that has and
opening of the desired shape.

19. Blow Molding
Used in the production of
bottles, automotive ductwork,
hollow toy components, and
door panels.

20. Injection Molding
Used to manufacture products such
as housings for electronic
implements, automotive components,
food storage containers, and
components for medical applications.
.

21. Thermoforming
 Used in the manufacturing of thin-walled
packages for the food industry.
 Manufactured primarily by injection molding.

22. CAD in Manufacturing
 The process of developing a design drawing on a
CAD system and producing it on a computerized
machine is called CAD/CAM.
 The process of converting the CAD drawing into a
preprogrammed, coded instructions is called
Computer Numerical Control (CNC).
 The advantages of the (CNC) is, better production and
control, increased productivity, decreased labor and
lower production costs.

23. The Machinist Steel Ruler
 Commonly used measuring tool for getting
rough measurements on a part.
 The smallest division on the fractional
scale is 1/64” (.016).

24. Vernier Caliper
 Precise measuring.
 Decimal, fractional, or
metric.
 Often used by drafters
to record dimensions
from a machined
prototype or part.

25. 6” Dial Caliper
Inside Inside
Outside
Depth
Step
4-way
Measurement

26. 6” Dial Caliper – Three Scales
METRIC
(mm)
DECIMAL
(.XX)
FRACTIONAL
(1/64”)