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Unit 1 - Manufacturing Concept

Manufacturing is the process of converting raw materials into products through various processes, equipment, and operations according to a detailed plan. It involves designing the product, selecting raw materials, and determining the sequence of processes. Common manufacturing processes include casting, machining, forming, powder metallurgy, and joining. Selection of the manufacturing process depends on the material, part size and shape, tolerances, complexity, finish, and costs. The type of production ranges from job shops and small batch to batch and mass production.

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92 views15 pages

Unit 1 - Manufacturing Concept

Manufacturing is the process of converting raw materials into products through various processes, equipment, and operations according to a detailed plan. It involves designing the product, selecting raw materials, and determining the sequence of processes. Common manufacturing processes include casting, machining, forming, powder metallurgy, and joining. Selection of the manufacturing process depends on the material, part size and shape, tolerances, complexity, finish, and costs. The type of production ranges from job shops and small batch to batch and mass production.

Uploaded by

Iamzura Abdullah
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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12/28/2017

Manufacturing Process
DME 3701

Manufacturing Concept
What is “MANUFACTURING”

“the process of converting raw material into products”

“the conversion of stuff into things” – DeGarmon, 1998

“processing or making a product from raw materials, especially


as a large scale operation using machinery” – Collin English
Dictionary, 1998

“economic term for making goods and services available to


satisfy customer” – T. Black, 1991

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Modern context
“the making of products from raw materials using various
processes, equipments, operations and manpower according to
a detailed plan”

• During processing, the raw material undergoes changes to


allow it to become a part of a product(s).

• Once processed, it should have worth in the market or a value

• Therefore, it encompasses:
- the design of the product
- the selection of raw materials
- the sequence of processes through which the product will be
manufactured

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Materials in an Automotive Engine

Section of an automotive engine - the Duratec V-6 - showing various components


and the materials used in making them. Source: Courtesy of Ford Motor
Company. Illustration by David Kimball.

Manufacture of Light Bulbs

Components of a common incandescent Manufacturing steps in making an


light bulb. Source: Courtesy of General incandescent light bulb. Source:
Electric Company. Courtesy of General Electric
Company.

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Manufacturing Process
• Casting
• Machining
• Forming
• Powder metallurgy
• Joining

Casting
• An object made by pouring molten metal or other material
into a mould.

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Machining
• 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.

Forming
• Forming manufacturing processes which make use of suitable
stresses (like compression, tension, shear or combined
stresses) which cause plastic deformation of the materials to
produce required shapes.

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Powder Metallurgy
• Powder metallurgy is a term covering a wide range of ways in
which materials or components are made from metal
powders.
• It can avoid, or greatly reduce, the need to use metal removal
processes, thereby drastically reducing yield losses in
manufacture and often resulting in lower costs.

Steps in making powder metallurgy parts

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Joining
• Product assembly requirement. Can be divided into
mechanical fastener & permanent joining.
• Bolting is a standard fastening method, for instance, but
welding may cut down the weight of assemblies.

Allied Activities
Heat treating
- Used to alter the physical, and sometimes chemical, properties
of a material. The most common application is metallurgical.
- Heat treatment techniques include annealing, case
hardening, precipitation strengthening, tempering, normalizing
and quenching.

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Allied Activities
Assembly line
- An assembly line is a manufacturing process (most of the time
called a progressive assembly) in which parts are added as the
semi-finished assembly moves from workstation to
workstation where the parts are added in sequence until the
final assembly is produced.
- Assembly lines are common methods of assembling complex
items such as automobiles and other transportation
equipment, household appliances and electronic goods.

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Selection of Manufacturing Process


Before selecting a manufacturing process, we need to
know the following attributes:
•Material to be used
• number of parts required (batch size)
•Size and shape to be produced
•Dimensional tolerances required
•Geometrical complexity
•Surface finish
•Cost of tooling, capital, scrap rate, etc…
•Environment and safety

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Shape classification

Prismatic shape : Wire drawing, extrusion, rolling, shape rolling


Sheet shape : Stamping, spinning, folding, deep drawing
3-D shape : Casting, molding, power method

Process cost

Cost of part/component is depending on:


• Material of which is made
• Cost of manufacture

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There are two rules in reducing cost:


1. Keep things standard and simple
• Parts that can be made from standard stock (sheet, rod, tube) usually
cheaper than those requiring shape or special casting.
• Try to use standard materials, and as few as possible (it reduces inventory
cost and the range of tooling the manufacturer needs)

2. Do not specify more than is necessary


• Performance must be paid for. High strength metals usually contain large
amount of alloying elements which are expensive and hard to fabricate
• High performance polymers are chemically complex
• High performance ceramics require greater quality control in their
manufacture

Schematic illustration of various casting processes

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Schematic illustrations of various machining


and finishing processes.

Schematic illustration of various polymer


processing methods

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Schematic illustration of various bulk deformation processes

Schematic illustration of various sheet metal forming processes

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Schematic illustration of various joining processes

Type of Production
Job shops
- Small lot size (100<)
- Using general purpose machines – lathes, milling machines,
drill, etc.

Small-batch production
- Quantity from 10-100
- Using general purpose machines – lathes, milling machines,
drill, etc.

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Type of Production
Batch production
- Lot size 100 to 5000
- Using advance machinery with computer control

Mass production
- Lot size over 100,000
- Using special purpose machinery, various automated
equipment for transferring parts in progress

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