Manufacturing Processes

(MSE – 881)

Dr. –Ing. Farhan Javaid

([email protected])
Office # 320 (SCME Building) +92-51-9085 5218
Course Contents
• Introduction, Material Properties and product attributes, Solidification
Processes, Metal Casting
• Bulk Deformation Processes, Metal forming and Sheet metal.
• Shaping processes for Composites & Polymers, Shaping processes for
plastics, Rubber processing,
• Powder metallurgy, Particulate processing of metals and ceramics, Glass
working
• Metal Machining, Joining and Cutting, Grinding and other abrasive processes,
Non-traditional machining.
• Surface processing, Coating and deposition processes.
• Joining and assembly, Rapid Prototyping,
• Micro fabrication, Manufacturing systems, Numerical control and industrial
robotics.
• 3D printing technologies, Microwave processing of materials
Books
Textbook:
Fundamentals of Modern Manufacturing: Materials, Processes, and
Systems, 3nd Ed., by Mikell P. Groover, JOHN WILEY & SONS, INC.,
2007.

Reference books:
Manufacturing Processes for Engineering Materials, 4th ed., by Serope
Kalpakjian, and Steven R. Schmid, Prentice Hall, Pearson Educational
Int., 2003.
Materials and Processes in Manufacturing, by E. Paul DeGarmo, J.T.
Black, and Ronald A. Kohser, Prentice Hall of India, 2001.
INTRODUCTION AND OVERVIEW OF
MANUFACTURING
INTRODUCTION AND OVERVIEW OF MANUFACTURING

1. What is Manufacturing?

2. Materials in Manufacturing

3. Manufacturing Processes

4. Production Systems

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
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.

✓ Most modern manufacturing operations are accomplished by mechanized and

automated equipment that is supervised by human workers

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing is Important

1. Historically

2. Technologically

3. Economically

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing - Historically Important

✓ Throughout history, human cultures that were better at making things were more
successful

✓ Making better tools meant better crafts & weapons

➢ Better crafts allowed people to live better

➢ Better weapons allowed them to conquer other cultures in times of
conflict

✓ To a significant degree, the history of civilization is the history of humans' ability to

make things.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing - Technologically Important

Technology - the application of science to provide society and its members with those
things that are needed or desired

✓ Technology provides the products that help our society, and its members live better

❑ What do these products have in common?

✓ They all are manufactured

✓ Manufacturing is the essential factor that makes technology possible

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing - Technologically Important

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing - Economically Important

✓ Manufacturing is one way by which nations create material wealth

✓ GNP (Gross National Product):

Takes into account net income receipts from
abroad.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing - Technologically

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

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing - Economically

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

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing - Industries

Industry consists of enterprises and organizations that produce or supply goods and
services.

✓ Primary industries - those that exploit natural resources, e.g., farming, mining

✓ Secondary industries - take the outputs of primary industries and convert them into
consumer and capital goods - manufacturing is the principal activity

➢ Secondary industries include manufacturing, construction, and electric power

generation
➢ Manufacturing includes several industries whose products are not covered in this
book; e.g., apparel, beverages, chemicals, and food processing

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing - Industries

➢ For our purposes, manufacturing means production of hardware

o Nuts and bolts, forgings, cars, airplanes, digital computers, plastic parts, and
ceramic products

✓ Tertiary industries - service sector of the economy

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing - Industries

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing - Capability
A manufacturing plant consists of processes and systems (and people, of course)
designed to transform a certain limited range of materials into products of increased
value.

✓ The three building blocks - materials, processes, and systems - are the subject of
modern manufacturing

❑ Manufacturing capability includes:

1. Technological processing capability

2. Physical product limitations
3. Production capacity

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
1. Technological processing capability
The available set of manufacturing processes in the plant (or company).
✓ Certain manufacturing processes are suited to certain materials

o By specializing in certain processes, the plant is also specializing in certain

materials

✓ Examples:

o A machine shop cannot roll steel

o A steel mill cannot build cars

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
2. Physical Product Limitations
Given a plant with a certain set of processes, there are size and weight limitations on
the parts or products that can be made in the plant

✓ Product size and weight affect:

o Production equipment
o Material handling equipment

✓ Production, material handling equipment, and plant size must be planned for
products that lie within a certain size and weight range

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
3. Production Capacity
Defined as the maximum quantity that a plant can produce in a given time period (e.g.,
month or year) under assumed operating conditions

✓ Operating conditions refer to number of shifts per week, hours per shift, direct labor
manning levels in the plant, and so on

✓ Usually measured in terms of output units, such as tons of steel or number of cars
produced by the plant

✓ Also called plant capacity

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Materials in Manufacturing
Most engineering materials can be classified into one of three basic categories:

1. Metals
2. Ceramics
3. Polymers

✓ Their chemistries are different

✓ Their mechanical and physical properties are dissimilar

✓ These differences affect the manufacturing processes that can be used to produce
products from them

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Materials in Manufacturing

Nonhomogeneous mixtures of the other three

In Addition: Composites
basic types rather than a unique category

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
1. Metals:

Metals used in manufacturing are usually alloys, which are composed of two or more
elements, with at least one being a metallic element

▪ Two basic groups:

1. Ferrous metals - based on iron, comprises about 75% of metal tonnage in the
world:
▪ Steel = Fe-C alloy (0.02 to 2% C)
▪ Cast iron = Fe-C alloy (2% to 4% C)

2. Nonferrous metals - all other metallic elements and their alloys: aluminum,
copper, magnesium, nickel, silver, tin, titanium, etc.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
2. Ceramics:

Compounds containing metallic (or semi-metallic) and nonmetallic elements

✓ Typical nonmetallic elements are oxygen, nitrogen, and carbon

➢ For processing, ceramics divide into:

1. Crystalline ceramics – includes:

▪ Traditional ceramics, such as clay (hydrous aluminum silicates)

▪ Modern ceramics, such as alumina (Al2O3)

2. Glasses – mostly based on silica (SiO2)

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
3. Polymers

Compound formed of repeating structural units called polymers, whose atoms share
electrons to form very large molecules

➢ Three categories:

1. Thermoplastic polymers - can be subjected to multiple heating and cooling cycles

without altering molecular structure

2. Thermosetting polymers - molecules chemically transform (cure) into a rigid

structure – cannot be reheated

3. Elastomers - shows significant elastic behaviour, e.g. rubber.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
4. Composites

Material consisting of two or more phases that are processed separately and then
bonded together to achieve properties superior to its constituents

✓ Phase - homogeneous mass of material, such as grains of identical unit cell

structure in a solid metal

✓ Usual structure consists of particles or fibers of one phase mixed in a second

phase

✓ Properties depend on components, physical shapes of components, and the way

they are combined to form the final material

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Classification of Engg. Materials
Manufacturing Processes

A manufacturing process is a designed procedure that results in physical and/or

chemical changes to a starting work material with the intention of increasing the value
of that material.

✓ A manufacturing process is usually carried out as a unit operation ,which means that
the sequence of steps required to transform the starting material into a final product

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing Processes

Two basic types:

1. Processing operations - transform a work material from one state of

completion to a more advanced state

▪ Operations that change the geometry, properties, or appearance of the

starting material

2. Assembly operations - join two or more components to create a new entity

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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing
Manufacturing Processes

© John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Processing Operations

Alters a material’s shape, physical properties, or appearance in order to add value

➢ Three categories of processing operations:

1. Shaping operations - alter the geometry of the starting work material

2. Property-enhancing operations - improve physical properties without

changing shape

3. Surface processing operations - to clean, treat, coat, or deposit material on

exterior surface of the work

© John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Shaping Processes

1. Solidification processes Starting material is a heated liquid or semifluid

2. Particulate processing Starting material consists of powders

3. Deformation processes Starting material is a ductile solid

4. Material removal processes Starting material is a ductile or brittle solid

© John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Solidification processes

Starting material is heated sufficiently to transform it into a liquid or highly plastic state

▪ Examples: metal casting, plastic molding

© John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Particulate Processing

Starting materials are powders of metals or ceramics

✓ Usually involves pressing and sintering, in which powders are first compressed and
then heated to bond the individual particles together

© John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Deformation Processes

Starting workpart is shaped by application of forces that exceed the yield strength of
the material

✓ Examples: (a) forging, (b) extrusion

© John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Material Removal Processes

✓ Examples: machining such as turning, drilling, and milling; also grinding etc.

© John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Waste in Shaping Processes

Desirable to minimize waste in part shaping

✓ Most casting, molding, and particulate processing operations waste little material

✓ Terminology for minimum waste processes:

o Net shape processes - when most of the starting material is used and no subsequent
machining is required
o Near net shape processes - when minimum amount of machining is required

© John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Property-Enhancing Processes

Performed to improve mechanical or physical properties of work material

✓ Part shape is not altered, except unintentionally:

o Example: unintentional warping of a heat-treated part

✓ Examples:

o Heat treatment of metals and glasses

o Sintering of powdered metals and ceramics

© John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Surface Processing Operations

✓ Cleaning - chemical and mechanical processes to remove dirt, oil, and other
contaminants from the surface

✓ Surface treatments - mechanical working such as sand blasting, and physical

processes like diffusion

✓ Coating and thin film deposition - coating exterior surface of the workpart

© John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Assembly Operations

Two or more separate parts are joined to form a new entity

➢ Types of assembly operations:

1. Joining processes – create a permanent joint

▪ Welding, brazing, soldering, and adhesive
bonding

2. Mechanical assembly – fastening by mechanical

methods
▪ Threaded fasteners (screws, bolts and nuts);
press fitting, expansion fits

© John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing