This slide was made for a first-semester course named Professional Development Seminar (IPE 152). It mainly focuses on a few production processes.

1. DIFFERENTTYPES OF
PRODUCTION PROCESSES
AND SCOPE OF
APPLICATIONS
By Group F
 Taufiq Rahman Reg no: 2013334039
 Saif Istiaqe Reg no: 2013334040

2. PRESENTED TO
Engr Dr Mohammad Iqbal Mr Md Rezaul Hasan Shumon
Professor Assistant Professor
Department of Industrial and Department of Industrial and
Production Engineering Production Engineering
Shahjalal University of Science Shahjalal University of Science
andTechnology andTechnology

3. WHAT ARE PRODUCTION PROCESSES?
• Production Processes were accomplished primitively in ancient times. Weapons
were sharpened by stones having grinding properties; first cutting- tools were held
in the working position by hand, later they were secured to a handle by withes or
animal sinews. An achievement of that time was the application of a rotating stone
the prototype of the modern tool grinder. Later, rotary motion was employed to
make ceramic ware, and still later for producing round articles of wood, bone and,
finally, of metals. Along with devices for transmitting motion to the cutting tool,
mechanisms were used for driving the material being worked.The prototype of the
primitive lathe was the bow which rotated the work by means of the bow string,
the flint tool being held by hand.The simplest type of turning lathe thus got
developed gradually.

4. Primary
Processes
• MetalWorking
• Metal Casting
Secondary
Processes
• Chiseling, Filing, Scraping
• Traditional machining processes such as
turning, shaping, drilling, milling etc.
• Nontraditional machining processes such as
ultrasonic, electrical discharge, electro-
chemical, laser etc.
• Surface finishing processes such as abrasive
belt grinding, barrel tumbling, polishing,
anodizing etc.
• Metal joining processes such as welding,
brazing, soldering, riveting, screw fastening,
adhesive joining etc.

5. SHAPING PROCESSES : CASTING (FOR
METALS) AND MOLDING (FOR PLASTICS)
Casting and molding processes start with a work material
heated to a fluid or semifluid state.The process consists of:
(1) pouring the fluid into a mold cavity and (2)allowing the fluid
to solidify, after which the solid part is removed from the mold.

6. PARTICULATE PROCESSING
In particulate processing, the starting materials are powders of metals or ceramics.
Although these two materials are quite different, the processes to shape them in
particulate processing are quite similar.The common technique involves pressing and
sintering, illustrated in the figure below, in which the powders are first squeezed into
a die cavity under high pressure and then heated to bond the individual particles
together.
Particulate processing: 1) the starting material is powder; the usual process consists
of (2) pressing and (3) sintering.

7. DEFORMATION PROCESSES (FORGING &
EXTRUSION)
Some common deformation processes: (a) forging, in which two halves of a die squeeze the
work part, causing it to assume the shape of the die cavity; and (b) extrusion, in which a
billet is forced to flow through a die orifice, thus taking the cross-sectional shape of the
orifice.

8. MACHINING
(Material Removal Process)
Milling
Turning
Drilling
Boring
Reaming
Shaping
Planning
Finishing
Machining is any of various
processes in which a piece of raw
material is cut into a desired final
shape and size by a controlled
material-removal process

9. MILLING
• A machining operation in which workpiece is fed against a rotating tool with
multiple cutting edges
Milling Operation
Face Milling Peripheral Milling
The cutting action occurs
primarily at the end
corners of the milling
cutter.
In peripheral milling, the
cutting action occurs
primarily along the
circumference of the
cutter

10. Face Milling Peripheral Milling

11. Turning is a machining process in which a
cutting tool, typically a non-rotary tool
bit, describes a helical toolpath by
moving more or less linearly while the
workpiece rotates.
TURNING OPERATION
Turning
Operations
TaperedTurning
Hard turning
Facing
Parting
Grooving
Boring
Knurling
Reaming
Threading

12. TAPER/ CONTOURTURNING
A taper is defined as a uniform increase or
decrease in diameter of a cylindrical workpiece
measured along its length.
Taper turning is a process of producing a conical
surface by gradual reduction in diameter from a
cylindrical workpiece.
A taper is generally turned by feeding the tool at
an angle to the axis of rotation of the workpiece.
The angle formed by the path of the tool with the
axis of the workpiece should correspond to the
half taper angle.

13. FACING
Facing in the context of turning work involves moving
the cutting tool at right angles to the axis of rotation
of the rotating workpiece.This can be performed by
the operation of the cross-slide, if one is fitted, as
distinct from the longitudinal feed (turning). It is
frequently the first operation performed in the
production of the workpiece, and often the last—
hence the phrase "ending up".

14. GROOVING
Grooving is like parting, except that grooves are cut to a specific depth instead of severing a completed/part-
complete component from the stock. Grooving can be performed on internal and external surfaces, as well as on
the face of the part (face grooving or trepanning).
External grooving Face grooving

15. • It is an operation of making a round
hole in a workpiece usually by
means of a rotating tool (drill bit)
that has two or more cutting edges.
DRILLING OPERATION
A Bench Drilling Machine is most commonly
used for drilling operations

16. BORING OPERATION
It is an operation of enlarging of a
hole already made in a work piece.
How the process works:
-A boring tool or a bit (single point cutting
tool) mounted on a rigid bar is held in the
tool post and fed into the work by hand or
power in the similar way as for turning.

17. It is a process of sizing and finishing a hole
already made by a drill.
• A multi-point cutting tool with straight
cutting edges used to size or smooth
holes.
• A reamer follows the original hole and
cannot shift its center.
REAMING OPERATION

18. • It is a process of producing small straight, flat
surfaces: horizontal, vertical, or inclined.
• Workpiece is rigidly held in a vice or clamped
directly on the table.
• A single point cutting tool is held in the tool
holder, which is mounted on the ram.
• The ram reciprocates and thus cutting tool held in
tool holder moves forward and backward over the
workpiece.
• Tool performs the cutting operation during its
forward stroke.
• The backward stroke remains idle and no cutting
takes place during this stroke.
• Both the forward and backward strokes form one
working cycle of the shaper.
• The feed is given to the workpiece after one
working cycle, and
• he depth of cut is adjusted by moving the tool
downward towards the workpiece.
• The time taken during the idle stroke is less as
compared to forward cutting stroke.
• This is obtained by quick return mechanism.
SHAPING OPERATION
How the process works

19. PLANNING OPERATION
-A shock initiated machining process,
-Low cutting speed due to start-and-stop motion, and
-Used to produce straight, flat surfaces on the workpiece
-Parts are too large and heavy to be accommodated on the shaping machine table.
Planning is similar to shaping. It is a

20. THREADING
An operation of cutting threads or helical grooves of
specific shape (V or square) on the external cylindrical
surface of the job.
How the process works:
The job is held in between centers or in a chuck and the
single point cutting tool (thread cutting tool) is held on
tool post.
To make or cut threads:
The cutting tool is brought to the start of job and a small
depth of cut is given to cutting tool using cross slide.
The cutting tool must travel a distance equal to the pitch
of the thread to be cut (in mm) as the work piece
completes a revolution.

21. KNURLING
Knurling is the cutting of a serrated pattern onto the surface of a
part to use as a hand grip using a special purpose knurling tool.

22. FINISHING PROCESS
• Surface finishing processes
can be categorized by how
they affect the workpiece:
• Removing or reshaping
finishing
• Adding or altering finishing
Surface Finishing
Methods
Wet Process
Methods
Electrical Methods
Non Electrical
Methods
Dry Process
Methods
Mechanical
Methods
InVaccum Coating
Methods
Diffusion Coating
Methods
Others

23. JOINING PROCESSES: WELDING
Welding is a fabrication or sculptural
process that joins materials, usually
metals or thermoplastics, by causing
coalescence. This is often done by
melting the workpieces and adding a
filler material to form a pool of molten
material (the weld pool) that cools to
become a strong joint, with pressure
sometimes used in conjunction with
heat, or by itself, to produce the weld.
Photo: Working on welding projects

24. Some of the best known welding methods include:
Shielded Metal Arc Welding (SMAW) - also known as "stick welding", uses an electrode that has flux, the protectant for the puddle,
around it. The electrode holder holds the electrode as it slowly melts away. Slag protects the weld puddle from the outside world.
Gas Tungsten Arc Welding (GTAW) – also known as TIG (tungsten, inert gas), uses a non-consumable tungsten electrode to produce the
weld. The weld area is protected from atmospheric contamination by an inert shielding gas such as Argon or Helium.
Gas Metal Arc Welding (GMAW) – commonly termed MIG (metal, inert gas), uses a wire feeding gun that feedswire at an adjustable
speed and sprays an argon-based shielding gas or a mix of argon and carbon dioxide (CO2) over the weld puddle to protect it from the
outside world.
Flux-Cored Arc Welding (FCAW) – almost identical to MIG welding except it uses a special tubular wire filled with flux; it can be used with
or without shielding gas, depending on the filler.
Submerged Arc Welding (SAW) - uses an automatically fed consumable electrode and a blanket of granular fusible flux. The molten weld
and the arc zone are protected from atmospheric contamination by being "submerged" under the flux blanket.
Electroslag Welding (ESW) - a highly productive, single pass welding process for thick (greater than 1 in/25 mm up to about 12 in/300
mm) materials in a vertical or close to vertical position.

25. JOINING PROCESSES: SOLDERING
Soldering is a process in which two or more
metal items are joined together by melting and
flowing a filler metal (solder) into the joint, the
filler metal having a lower melting point than
the adjoining metal. Soldering differs from
welding in that soldering does not involve
melting the work pieces. In brazing, the filler
metal melts at a higher temperature, but the
work piece metal does not melt. In the past,
nearly all solders contained lead, but
environmental concerns have increasingly
dictated use of lead-free alloys for electronics
and plumbing purposes.
Desoldering a contact from a wire

26. JOINING PROCESSES: BRAZING
Brazing is a metal-joining process whereby a filler
metal is heated above melting point and distributed
between two or more close-fitting parts by capillary
action. The filler metal is brought slightly above its
melting (liquidus) temperature while protected by a
suitable atmosphere, usually a flux. It then flows
over the base metal (known as wetting) and is then
cooled to join the workpieces together. It is similar
to soldering, except the temperatures used to melt
the filler metal are higher for brazing.
Working on projects which need brazing

27. References
• Fundamentals of Modern Manufacturing: Materials, Processes, and Systems by Mikell P. Groover
• Lecture: Manufacturing Process -1 by Dr Mohammad Muhshin Aziz Khan
• ProductionTechnology by O P Khanna
• http://en.wikipedia.org/wiki/List_of_manufacturing_processes
• Manufacturing Engineering &Technology by S.Kalpakjian and S.A.Schmidt
• Introduction to Basic Manufacturing Process andWorkshopTechnology by Rajender Singh
• Images taken from www.custompartnet.com and google image search