The document provides an overview of manufacturing, tracing its evolution from ancient practices to modern technologies such as CNC machines. It outlines various manufacturing processes including primary shaping, secondary machining, metal forming, joining, and surface finishing, each with specific applications and characteristics. Additionally, it discusses the importance of a good manufacturing system, emphasizing design requirements, cost-effectiveness, quality, flexibility, and productivity.

1. Workshop Practice (Theory) :ESC-104
Lecture-1
Presented By:
Jagdip Chauhan
Assistant Professor
Mechanical Engineering Department
Guru Jambheswar University of Science & Technology, Hisar

2. What is Manufacturing?

3. Manufacturing:
Manu Factus : Latin for ‘made by hand’
Definition:
A Well organized method of converting raw material to end
product
End Product: Value and utility added to output.

4. History of Manufacturing
• Manufacturing started during 5000 – 4000 BC Wood work,
ceramics, stone and metal work
• Steel Production 600-800 AD
• Industrial Revolution 1750 AD: Machine tools run by invention of
steam engine
• Mass Production and Interchangeable Parts
• Computer Controlled Machines 1965
• CNC,FMS systems

5. Requirements of a good manufacturing system
• Product should meet design requirement
• Economical Process
• Quality should be built into the system
• Should be flexible and responsive to new technology
• High productivity: Best utilization of man, material, machine, capital and
available resources.

6. Types of manufacturing process:
• Primary Manufacturing/Shaping Process
• Secondary Manufacturing / Machining Process
• Metal Forming process
• Joining Processes
• Surface Finishing
• Processes that involve the changes in the material
properties

7. Primary Manufacturing/Shaping Process:
The primary shaping process is used to give the
amorphous/raw material a well-defined shape. The
primary shaping process involves the casting process,
plastic forming technology, powder metallurgy,
bending of the metals, forging and gas cutting, and
many more.

8. Secondary Manufacturing Process:
Secondary processes further improve the properties, surface quality,
dimensional accuracy, tolerance, etc. Advanced processes usually (but not
necessarily) manufacture desired products in one step. The process to
remove unwanted materials from the jobs using cutting tools is known as
machining. The purpose is to give perfect dimensions and desired shape.
Machines used for these operations include lathe, milling, drilling, shaper,
planner, etc. At the time of machining different multi-point cutting tools, jigs
and fixtures, and measuring devices are used. Machining produces a lot of
waste metals in the form of chips. These days CNC machining is used for
better accuracy and quick machining. Turning, knurling, parting, facing,
boring, reaming, slotting, punching, threading, milling, gear cutting are some
of the metal removing processes.

9. Metal Forming process:
Metal forming is another manufacturing technique used to give the metal
desired shape through the application of pressure/stress, forces like
compression or tension or shear, or a combination of both. By applying these
forces permanent deformation of the metal is achieved. These processes are
also known as mechanical working processes. These mechanical working
processes are classified into two categories,– hot working processes and cold
working processes. The metal forming process does not incorporate metal
removal. The metal is deformed and sometimes displaced by the application
of forces. Metal forming always includes plastic deformation. In this
technique, directly usable articles can be made. Wires, rods, cold drinks
bottles, tubes are made by the metal forming process. The hot working
process includes forging, hot spinning, rolling, extrusion, hot drawing,
etc. Cold Working processes include cold forging, cold rolling, sheet metal
working, punching, piercing, squeezing, notching, etc.

10. Joining Processes:
Joining is a process we are using in our everyday life frequently. Different
sub-assemblies are joined together to get a completely assembled product. In
the fabrication process joining is used frequently. In manufacturing or
fabrication, two or more metal parts are put together and joined by means of
fusion, riveting, screwing, applying pressure, and rubbing. These joining
processes are needed to make air-tight joints and semi-permanent or
permanent fasteners. These joining techniques are very important in making
bigger assemblies. For example, an airplane is assembled by putting together
more than a thousand subassemblies. The joining process includes different
types of welding, soldering, brazing, riveting and screwing, pressing, nut and
bolt joints, etc.

11. Surface Finishing:
Surface finishing is a process that is applied to get the desired leveling of the
surface and also to obtain the desired smoothness. This process removes a
very negligible amount of the materials from the surface and does not
involve any effective change in the dimensions. It is not an effective metal
removal process It should not be confused with the machining process.
Putting some kind of coating over the metal is also a surface finishing
process. Various surface finishing processes include honing, lapping,
superfinishing, sanding, deburring, electroplating, buffing, painting,
anodizing, galvanizing, etc. Sherardizing, Parkerizing, plastic coating, or
metal spraying is also known as one kind of surface-finishing process.
Surface finishing provides excellent finishing of the metal surface and at the
same time gives good protection from environmental contaminants.

12. Processes that involve the changes in the material properties:
Different properties of the same metal are desired for different applications. So
metal property is needed to be changed in those cases. Material property change
may include improved hardness, greater ductility, durability, etc. For some
particular uses or operations, suitable properties are needed to be incorporated.
Some operations need softer materials, some need harder ones. The properties
of the materials change when the total grain size of the materials is regrouped
or reorganized. Different grain conditions provide different properties. The
grain sizes are changed by the application of different heat treatments. Through
heat treatments, the internal structure of the material is changed. And they
achieve different improved properties. Common heat treatment methods
include –annealing, hardening, case hardening, normalizing, grain refining,
tempering and age hardening, etc.