Manufacturing

Process Selection
Analysis
Manufacturing process decisions

• How do we choose the specific manufacturing processes?

• How do the selected materials influence the choice of manufacturing
processes?
• Would product function or performance issues influence our choice of
processes?
• What criteria should we use to select processes?
• Which criteria are more important?
• Who will make the final decisions?
Parts undergo sequence of processes
• Primary - alter the (“raw”) material’s basic shape or form.
Sand casting
Rolling
Forging
Sheet metalworking

• Secondary - add or remove geometric features from the basic forms

Machining of a brake drum casting (flat surfaces)
Drilling/punching of refrigerator housings (sheet metal)
Trimming of injection molded part flash

• Tertiary - surface treatments

Polishing
Painting
Heat-treating
Joining
Part / Mfg. Process Considerations

1. Production Volume
2. Part Size (overall)
3. Shape Capability (features)/ geometric complexity
boss/depression 1D
boss/depression >1D
holes
undercuts (int./ext.)
uniform walls
cross sections - uniform/regular
rotational symmetry
captured cavities
Manufacturing

“The Process of Converting Raw Materials

Into Products”
Manufacturing a Product: General Considerations

• Material Selection
• Processing Methods
• Final Shape and Appearance
• Dimensional and Surface Finish
• Economics of Tooling
• Design Requirements
• Safety and Environmental Concerns
Commercially available shapes of metals
Manufacturing Processes for Metals
➢Casting: expendable mold and permanent mold.
➢Forming and Shaping: rolling, forging, extrusion, drawing, sheet
forming, powder metallurgy, molding
➢Machining: turning, boring, drilling, milling, planing, shaping,
broaching, grinding, ultrasonic machining, chemical machining,
electrical discharge machining (EDM), electrochemical machining,
high-energy beam machining
➢Joining: welding, brazing, soldering, diffusion bonding, adhesive
bonding, mechanical joining
➢Finishing: honing, lapping, polishing, burnishing, deburring,
surface treating, coating, plating
Choosing Methods of Production
Casting Processes

Introduction of molten metal into a mold cavity; upon

solidification, metal conforms to the shape of the cavity.

Sand Casting
Die Casting
Casting Processes

The process in which molten metal is poured into a cast to solidify.

• Sand casting
• Die casting
• Investment casting
Sand casting (closed-mold)

Cope
Core Riser
Flask Sprue

Parting Runner
line
Drag Gate

• Uses sand mold. The mold is destroyed to remove the part.

• Mold size ranges from inches to feet. (e.g. as mold cast for industrial engine
blocks as large as 12 feet in cross section and 30 feet long)
• Economical production quantity: very small i.e. 1 to 10
• Material: all ferrous and nonferrous metals
• Parts produced have a granular surface finish.
Die casting

• Molten metal is injected under

high pressure into permanent die Stationary Moving
set usually made of steel. die die

• Die casting is faster than sand

casting but can more expensive. Molten
• Smoother surface finish than metal
sand-cast parts.
• Size: maximum part size 30 x 30
inches to parts less than an inch.Plunger Ejector
pins
• Economic production quantity:
over 10,000 Sprue
• Material: low-melting-point
metals (e.g. aluminum, zinc,
magnesium, brass)
Parting line
Investment casting (lost wax casting)

• Molten metal solidifies in a ceramic cast made by coating a wax pattern

with liquid slurry, then dried.
• Wax is melted out and ceramic mold is destroyed after part solidifies.
• Material: alloy of aluminum, zinc, magnesium, brass, steel, stainless steel.
• Economic production quantity: less than 10,000 pieces
Investment casting
Ceramic mold
4-part pattern tree (hardened slurry)

Wax pattern
is cast

Wax removed Molten metal Ceramic mold is

by melting solidifies in cast removed
Forming and Shaping Processes

Bulk deformation processes that induce shape changes by

plastic deformation under forces applied by tools and dies.

Forging
Extrusion
Machining Processes
Material removal from a work piece: cutting, grinding,
nontraditional machining processes

Milling Lathe Machine

Bulk Deformation

To change the shape or form of bulk material caused by compressive or

tensile yielding.
• Rolling
• Extrusion
• Drawing
• Forging
 Rolling
• Two or more cylindrical rollers
plastically compress material,
forming sheets, bars and rods.
• Hot rolling requires less work
but an oxidized surface finish
• Cold rolling requires more
work but increases the yield
strength of the material and
produces superior surface
finish.
Rolling

bloom
structural

ingot
coil
slab sheet

billet bar rod

 Extrusion

• Heated metal plastically yields as

it is pushed through a die, Extrusion
producing long pieces with a die
constant cross-section.
• Size: 40-foot in length
• Economical production
quantities: 1,000 to 100,000 Cross
pieces sections
Ram
• Materials: ductile metals (e.g.
aluminum, steel, zinc, copper,
magnesium)
Billet
Drawing

• Process of producing a wire, bar Drawing

or tube by pulling on a material die
until it increases in length
accompanied with a reduction in
its cross-sectional diameter. Cross
• Size: bar size range 1/8 to 6 sections
inches in cross-section, wire size
range 0.001 to 3/8 inches. Pulling
• Material: ductile metals (e.g. Billet force
aluminum, steel, copper)
Forging (closed-die)

Ram pressure

Blocked Flash
preform
Gutter

• A process in which material is plastically compressed between 2

halves of a die set by hydraulic pressure or the stroke of a
hammer.
• Size: maximum size limit roughly 36 inches
• Economic production quantity: 1,000 to 100,000 pieces
Polymer Processes
• Part shapes are created by solidification of thermoplastic polymers or
curing of thermosetting polymers.
• Results in little waste of raw material and require few, if any, finishing
operations
• Compression molding
• Transfer Molding
• Blow molding
• Injection molding
Compression molding

Heated
mold Ram Pressure

Charge
Part

• Charge of thermoset or elastomer is formed between heated mold halves under

pressure while the polymer cures.
• Compression molds are simpler than injection molds (no sprue, runners, risers)
• Size: minimum part size of the order of 1/8 to ¼ inch in cross-section
• Economic production volume: more than 10,000 pieces
Transfer molding

Ram pressure

Ram

Heated
mold
Sprue

Charge
Part
Blow molding
Air
Molten Mold blown
parison is halves into Part is
extruded close parison removed

Extruder
air injector

parison
Blow moulding

• A molten parison of
thermoplastic material
injected with air, then
expands to the shape of
the mold.
• Is used to produce hollow
parts within thin walls.
• Size: maximum size of
about 3 feet in diameter
Injection moulding

• Thermoplastic pellets are melted and injected under high pressure

into a metal mold.
• Size: maximum part size less than 24 x 24 inches, minimum part
size are of the order of 1/8 to ¼ inch in cross-section
• Economic production quantity: more than 10,000
Sheet Metalworking
• The permanent deformation of thin metal sheets by bending and
shearing forces produced by mechanical or hydraulic forces.
• Often called stamping forces.
• Produces parts of moderate complexity.
• Size: less than 24x24inches
• Economic production quantity: more than 10,000
• Material: alloys of steel and aluminum
• Bending
• Blanking
• Drawing
• Punching
• Shearing
• Spinning
Sheet Metalworking

• Shearing : cutting or separating sheet metal along a straight line.

• Blanking: shearing of a smaller, shaped piece, called a blank, from the
stock.
• Punching: produces slots, notches, extruded holes, and holes.
• Embossing: forming plastic indentations to form ribs, beads, or
lettering on the surface of metal.
Sheet metal drawing

Punch ram
Punch

Blank
holder Clamp
Die force
Blank
Drawn part

• Punch plastically deforms a blank sheet material into a die, forming

cupped-, box-, or hollow-shaped parts
• Products: soda cans, ammunition cartridge casings, and pots and
pans.
Machining

• The removing of material from the workpiece by a sharp cutting tool that
shears away chips of material to create a desired form or features.
• It is a subtractive process that produces manufactured waste and can,
therefore be expensive.
• Often used as a secondary process to true-up critical dimensions or
surfaces or to smooth the surface finish.
• Often used for low-volume production.
 Machining processes

Manufacturing
Processes

Sheet Polymer
Deformation Casting Metal Processes Machining Finishing Assembly

Extrusion Centrifugal Bending Blow molding Boring Anodizing Automated

Forging Die casting Blanking Casting Drilling Honing Bonding
Rolling Investment Drawing Compression molding Facing Painting Brazing
Bar drawing Permanent mold Punching Extrusion Grinding Plating Manual
Wire drawing Sand casting Shearing Injection Molding Milling Polishing Riveting
Spinning Thermoforming Planing Soldering
Transfer molding Turning Welding
Sawing
ECM, EDM
Machining – removal of material…

Sawing –using a toothed blade.

Milling – from a flat surface by a rotating cutter tool.
Planing – using a translating cutter as workpiece feeds.
Shaping - from a translating workpiece using a stationary cutter.
Boring - increasing diameter of existing hole by rotating the workpiece.
Drilling- using a rotating bit forming a cylindrical hole.
Reaming – to refine the diameter of an existing hole.
Turning - from a rotating workpiece.
Facing - from turning workpiece using a radially fed tool.
Grinding - from a surface using an abrasive spinning wheel.
Electric discharge machining (EDM) - by means of a spark.
Machining process considerations

solid material machining material removed

-->sawing, shaping, turning, boring, milling, drilling, grinding,

• hardness, strength of material

• shear forces = strong jigs & fixtures
• tool/bit wear, replacement
• size of workpiece, fit machine?
• Material volume to be removed
• rate of removal, hp needed
• Tolerances
• operator skill, CNC
• costs (materials, tooling, processing)
Finishing

• Preparing the final surface for aesthetics and protection from the
environment.
• Cleaning: wire brushing is used to remove grit and scale, and
chemical solutions, including acid baths, are used to remove oily
films
• Protection: polymers and ceramics requires little protection from
the environment. Metals, however, require some surface
treatment with oil-and-water based painting providing the least
expensive coating. Steels are often plated with chrome, cadmium,
or zinc). Aluminum alloys are usually anodized (a chemical surface
treatment).
Finishing processes
Manufacturing
Processes

Sheet Polymer
Deformation Casting Metal Processes Machining Finishing Assembly

Extrusion Centrifugal Bending Blow molding Boring Anodizing Automated

Forging Die casting Blanking Casting Drilling Honing Bonding
Rolling Investment Drawing Compression molding Facing Painting Brazing
Bar drawing Permanent mold Punching Extrusion Grinding Plating Manual
Wire drawing Sand casting Shearing Injection Molding Milling Polishing Riveting
Spinning Thermoforming Planing Soldering
Transfer molding Turning Welding
Sawing
ECM, EDM
Surface roughness
Assembly

• The process of putting together all the components of a product

before shipping.
• Operation include handling, insertion, and/or attachment of parts.
• Handling: grasping, moving, orienting, and placing parts, before
insertion or attachment.
• Attachment: either
- Permanent: welding, brazing, soldering, adhesive bonding, rivets,
eyelets, staples, shrink fits, press fits, or
- Temporary: threaded fasteners such as screws, nuts and bolts,
snap fits.
Assembly processes
– fastening / joining of 2 or more components

Manufacturing
Processes

Sheet Polymer
Deformation Casting Metal Processes Machining Finishing Assembly

Extrusion Centrifugal Bending Blow molding Boring Anodizing Automated

Forging Die casting Blanking Casting Drilling Honing Bonding
Rolling Investment Drawing Compression molding Facing Painting Brazing
Bar drawing Permanent mold Punching Extrusion Grinding Plating Manual
Wire drawing Sand casting Shearing Injection Molding Milling Polishing Riveting
Spinning Thermoforming Planing Soldering
Transfer molding Turning Welding
Sawing
ECM, EDM
 Process / Material Screening

Process-First Approach Material First Approach

Part Information Application Information

1. Production Volume 1. Applied Loads
2. Part Size (overall) magnitude
3. Shape Capability (features) cyclic nature (fatigue)
boss/depression 1D rate (slow, impact)
boss/depression >1D duration (creep)
holes 2. Ambient Conditions
undercuts (int./ext.) temperature
uniform walls moisture
cross sections – sunlight (ultra-violet)
(uniform /regular)
rotational symmetry chemical liquids/vapors
captured cavities 3. Safety/Legal (FDA, UL)
4. Cost
Product function is interdependent

Material
Properties

Product
Function

Manufacturing Product
Processes Geometry
Are materials compatible with mfg. process?

Material
Properties

Manufacturing compatible
Processes materials & processes
Specification of Machine Tools.

A machine tool may have a large number of various features and

characteristics.
But only some specific salient features are used for specifying a machine tool.

The methods of specification of some basic machine tools are as follows:

o Centre lathe
• Maximum diameter and length of the jobs that can be accommodated
• Power of the main drive (motor)
• Range of spindle speeds
• Range of feeds
• Space occupied by the machine.

What is ABC of a lathe? -Admit Between Centers

Specification of Machine Tools.

Shaping machine
• Length, breadth and depth of the bed
• Maximum axial travel of the bed and vertical travel of the bed / tool
• Maximum length of the stroke (of the ram / tool)
• Range of number of strokes per minute
• Range of table feed
• Power of the main drive
• Space occupied by the machine
Specification of Machine Tools.

Milling machine (knee type and with arbour)

• Type; ordinary or swiveling bed type
• Size of the work table
• Range of travels of the table in X-Y-Z directions
• Arbour size (diameter)
• Power of the main drive
• Range of spindle speed
• Range of table feeds in X-Y-Z directions
• Floor space occupied.
Specification of Machine Tools.
Drilling machine (column type)
• Maximum drill size (diameter) that can be used
• Size and taper of the hole in the spindle
• Range of spindle speeds
• Range of feeds
• Power of the main drive
• Range of the axial travel of the spindle / bed
• Floor space occupied by the machine
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YOU