This document provides an introduction to manufacturing processes. It defines manufacturing as a sequence of operations that converts raw materials into finished products. Manufacturing processes are classified into primary shaping, deforming, machining, surface finishing, joining, and material property modification. Examples of processes in each category are described along with schematic illustrations. The document also discusses the technological and economic considerations of manufacturing from the perspectives of applying physical/chemical processes and adding value through processing.
4. Books/References
Fundamental of Modern Manufacturing: Materials,
Processes and Systems: M. P. Groover(John Wiley).
Manufacturing Engineering and Technologyby S.
Kalpakjian and S. R. Schmid(Prentice Hall).
Fundamental of Manufacturing Processes: G. K. Laland
S. K. Choudhuary(Narosa).
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7. What is Manufacturing?
The word manufacture is derived from two Latin words
manus (hand) and factus (make); the combination means
“made by hand”
“Made by hand” accurately described the fabrication
methods that were used when the English word
“manufacture” was first coined around 1567 A.D.
Now a day, most modern manufacturing operations are
accomplished by mechanized and automated
equipment that is supervised by human workers
9. Classification of Manufacturing
Processes
Various processes applied in manufacturing to convert raw materials into
finished goods can be classified in the following broad categories:
Primary Shaping (Forming Processes)
Deforming Processes
Machining/ Material Removal Processes
Surface Machining Processes
Joining Processes
Material Properties Modification Processes
10. Primary Shaping (Forming Processes)
Its an additive manufacturing in which the products are made by addition.
Cohesion is normally observed among particles
Casting
Powder Metallurgy
3D Printers
Plastic Technology
12. Deforming Processes
These processes make suitable use of stresses like compression, tensile and
shearing or combined to cause plastic deformation of materials to convert
them into the desired shapes:
Forging
Rolling
Extrusion
Drawing
Embossing
Sheet Metal Working
15. Machining/ Material Removal
Processes
In these processes desired surface is produced by providing suitable relative
motion between the tool and workpiece. In this case the material is removed
by shearing so the workpiece is subjected to comparatively lower stresses
than Deformation processes:
Turning
Drilling
Milling
Shaping
Grinding
Broaching
Slotting
Hobbing
Boring
Threading
Knurling
Parting
17. Surface Finishing Operations
These operations are used to provide good surface finish on the metal surfaces. Small or
negligible amount of material is added or removed:
Honing
Lapping
Buffing
Tumbling
Galvanizing
Pickling
Sand blasting
Electroplating
Plastic and metal coating
18. Joining Processes
In these processes two or more metal pieces are united together to make a final
product permanently or temporarily:
Welding
Riveting
Soldering
Brazing
Sintering
Couplings
Nuts & Bolts
Keys and Cotters
20. Material Properties Modification
Processes
In this process properties of the material are changed to suit the desirable
characteristics without changing the shape
Heat Treatment
Shot Peening
Surface Chemical Treatment
21. Technological and Economic
Considerations
manufacturing can be defined in the two ways; one is the technological way and
another is economical way
Manufacturing
Technological
Considerations
Physical and chemical processes used for changing shape size
and properties of raw materials to convert in the usable product
Economical
Considerations
Manufacturing processes add value to the product and
ultimately results in the value creation
22. Manufacturing Technological Considerations
Defined by Mikell P Groover :
“Technologically, manufacturing is the
application of physical and chemical
processes to alter the geometry,
properties, and/or appearance of a
starting material to make parts or
products
Manufacturing also includes
assembly
Almost always carried out as a
sequence of operations”
23. Manufacturing - Technologically
Important
Technology - the application of science to provide society the Newer
methods/processes and materials for improved products and services
Manufacturing is the application of technology to produce products of
increased value
Manufacturing provides the products that help our society and its
members to live better
What do these products have in common?
They are all manufactured
24. Manufacturing Economical Consideration
Defined by: Mikell P Groover
“Economically, manufacturing is
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”
25. Need of Manufacturing
Role of manufacturing is to satisfy the needs of human beings through offering the improved
products and services for the facility of mankind.
To produce goods to support the living and improve the standard of living
To take advantage of the economies of scale and produce large quantities in low cost
As resources are limited, we need to optimize the use of resources to increase the
productivity
“More goods are produced using less resources” or “Reduce Wastages”
Six Sigma, TQM, TPM, Kaizen, Quality Circles, lean and Agile Manufacturing
Editor's Notes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
