Topic 1 – Manufacturing processes

M2031 – Manufacturing Technologies

What is Manufacturing?
 The word manufacture is derived from the Latin manu
factus, meaning “made by hand”
 Manufacturing is concerned with making products
 A manufactured product may itself be used to make other
products, e.g. a drill for producing holes
 A manufactured item typically starts with raw materials,
which are then subjected to a sequence of processes to
make individual products that have certain value
Manufacturing system
 Is a method of organizing production
 Many types of manufacturing systems include assembly
lines, batch production, and computer-integrated
manufacturing
Manufacturing process classification
Casting processes

Expendable Expendable mold,

pattern and mold permanent Permanent mold
and other pattern

Investment Permanent mold

Sand casting
casting casting

Lost-foam casting Shell-mold casting Die casting

Melt-spinning Ceramic-mold Centrifugal

process casting casting

Squeeze casting
Manufacturing process classification
Sheet-metal-
forming
processes

Bending and
Shearing Forming
drawing

Blanking Bending Stretch forming

Slitting Hemming Hydroforming

Punching Roll forming Spinning

Magnetic-pulse
Piercing Deep drawing
forming
Manufacturing process classification
Polymer-
processing
processes

Themoplastics Thermosets Rapid prototyping

Compression
Extrusion Stereolithography
molding

Fused-deposition
Injection molding Pultrusion
modeling

Three-
Vacuum-bag
Blow molding dimensional
forming
printing

Laminated-object
Themoforming Transfer molding
manufacturing
Manufacturing process classification
Bulk-
deformation
processes

Extrusion and
Rolling Forging
drawing

Open-die
Flat rolling Direct extrusion
forging

Closed-die
Shape rolling Cold extrusion
forging

Ring rolling Heading Drawing

Tube drawing
Manufacturing process classification
Machining and
finishing
processes

Advanced
Machining Finishing
machining

Turning Wire EDM Surface grinding

Chemical Centerless
Drilling
machining grinding

Milling Laser machining Lapping

Water-jet Electrochemical
Broaching
machining polishing
Manufacturing process classification
Joining
processes

Fastening and
Fusion welding Other welding
bonding

Shielded metal- Friction-stir Adhesive

arc welding welding bonding

Gas-metal arc Resistance Bolted

welding welding connection

Flux-cored arc Explosion

Wave soldering
welding welding

Gas-tungsten
Cold welding Brazing
arc welding
Manufacturing process selection
 The selection of a particular manufacturing process, or
sequence of processes, depends on the following factors:
 Geometric features of the parts to be produced, including the
dimensional tolerances and surface texture required
 Particular workpiece material and its manufacturing properties
Manufacturing process selection
 Two cases should be considered when selecting a
manufacturing process:
 Brittle and hard materials cannot be shaped or formed without
the risk of fracture, unless they are performed at elevated
temperatures, whereas these materials can easily be cast,
machined, or ground
 Metals that have been preshaped at room temperature become
less formable during subsequent processing. They become
stronger, harder, and less ductile than they were prior to
processing them further
Manufacturing process selection
 In process selection, several factors can have a major role,
such as the part size, shape complexity, and dimensional
accuracy and surface finish required. For example:
 Flat parts and thin cross sections can be difficult to cast
 Complex parts generally cannot be shaped easily and
economically by metalworking techniques (e.g. forging)
 Dimensional tolerances and surface finish in hot-working
operations are not as fine as those obtained in operations
performed at room temperature (cold working), because of
the dimensional changes, distortion, warping, and surface
oxidation that occur at the elevated temperatures involved
Net-shape and near-net-shape
manufacturing
 Net-shape and near-net-shape manufacturing together
constitute an important methodology by which a part is
made in only one operation at or close to the final
desired dimensions, tolerances, and surface finish
 The difference between net shape and near net shape is a
matter of degree of how close the product is to its final
dimensional characteristics.
Net-shape and near-net-shape
manufacturing
 The necessity for, and benefits of, net-shape manufacturing
can be appreciated from the fact that, in the majority of
cases, more than one additional operation is often
necessary to produce the part.
 Examples of net-shape manufacturing include precisión
casting, forging, forging sheet metal, powder metallurgy
and injection molding of metal powders
Types of production
 The number of parts to be produced and the rate are
important economic considerations in determining the
appropriate processes and the types of machinery
required.
 There are different types of production depending of the
annual quantities produced:
 Job shops: small lot sizes, typically less than 100, using general-
purpose machines such as lathes, milling machines, drill presses,
and grinders
Types of production
 Small-batch production: quantities from about 10 to 100, using
machines similar to those in job shops
 Batch production: lot sizes typically between 100 and 5000,
using more advanced machinery with computer control
 Mass production: lot sizes generally over 100,000, using special-
purpose machinery, known as dedicated machines, and various
automated equipment for transferring materials and parts in
progress
Computer-Integrated Manufacturing
 Computer-Integrated Manufacturing (CIM) integrates the
software and hardware needed for computer graphics,
computer-aided modeling, and computer-aided design and
manufacturing activities, from initial product concept
through its production and distribution in the
marketplace
Computer-Integrated Manufacturing
 This comprehensive and integrated approach began in the
1970s and has been particularly effective because of its
capability of making possible the following tasks:
 Responsiveness to rapid changes in product design
modifications and to varying market demands
 Better use of materials, machinery, and personnel
 Reduction in inventory
 Better control of production and management of the total
manufacturing operation
Computer-Integrated Manufacturing
 The elements of a Computer-Integrated Manufacturing
(CIM) system are the following:
 Computer numerical control (CNC)
 Adaptive control (AC)
 Industrial robots
 Automated materials handling
 Automated assembly systems
 Computed-aided process planning (CAPP)
 Group technology (GT)
 Just-in-time production (JIT)
 Cellular manufacturing (CM)
Computer-Integrated Manufacturing
 The elements of a Computer-Integrated Manufacturing
(CIM) system are the following:
 Cellular manufacturing (CM)
 Flexible manufacturing systems (FMS)
 Expert systems (ES)
 Artificial intelligence (AI)
 Artificial neural networks (ANN)
Quality assurance and Total Quality
Management
 Product quality is one of the most critical aspects of
manufacturing, because it directly influences customer
satisfaction, thus playing a crucial role in determining a
product’s success
 Continuous control of processes (known as online
monitoring) is a critical factor in maintaining product
quality, and the objective must be to control processes,
not products
 Quality assurance and total quality management (TQM)
are widely recongnized as being the responsibility of
everyone involved in the design and manufacture of
products and their components
Lean Production and Agile Manufacturing
 Lean production (also known as Lean Manufacturing) is a
methodology that involves a thorough assessment of each
activity of a company
 The basic purpose is minimizing waste at all levels and calling
for the elimination of unnecessary operations that do not
provide any added value to the product being made
 This approach identifies all of a manufacturer’s activities
from the viewpoint of the customer and optimizes the
processes used in order to maximize added value
 Agile manufacturing ensures agility and hence flexibility in
the manufacturing enterprise, so that it can respond
rapidly and effectively to changes in product demand and
the needs of the customer
Manufacturing Costs and Global Competition
 Always critically important, the economics of
manufacturing has become even more so with
 Ever-increasing global competition
 Demand for high-quality products at low prices
 Typically, the manufacturing cost of a product represents
about 40% of its selling price
Manufacturing Costs and Global Competition
 The total cost of manufacturing a product generally
consists of the following components:
 Materials: raw-material costs depend on the material itself, as
well as on supply and demand
 Tooling: tooling costs include those for cutting tools, die, molds,
work-holding devices, and fixtures
 Fixed: costs for energy, rent for facilities, insurance, and real-
estate taxes
 Capital: production machinery, equipment, buildings, and land
 Labor: direct and indirect costs. Direct labor concerns the
labor that is directly involved in manufacturing products.
Indirect labor pertains to servicing of the total manufacturing
operation
General trends in manufacturing
 Following are some general trends that have been
observed regarding varios aspects of manufacturing today:
 Global manufacturing trends
1. Product variety and complexity continue to increase
2. Product life cycles are becoming shorter
3. Markets have become multinational and global competition has been
increasing rapidly
4. Market conditions fluctuate widely
5. Customers are consistently demanding high-quality, low-cost
products and on-time delivery
General trends in manufacturing
 Following are some general trends that have been
observed regarding varios aspects of manufacturing today:
 Materials
1. Material composition, purity, and defects (impurities, inclusions, and
flaws) are coming under more control in order to further enhance
overall properties, manufacturing characteristics, reliability, and
service life
2. Developments have occurred in the selection of materials for
improved recyclability
3. Developments continue in nanomaterials, nanopowders, composites,
superconductors, semicondictors, amorphous alloys, shape-memory
alloys (smart materials), tool and die materials, and coatings
General trends in manufacturing
 Following are some general trends that have been
observed regarding varios aspects of manufacturing today:
 Manufacturing operations
1. Improvements are being made in predictive models of the effects of
material-processing parameters on product integrity, applied during
a product’s design stage
2. Developments continue in ultraprecision manufacturing,
micromanufacturing, and nanomanufacturing, approaching the level
of atomic dimensions
3. Computer simulation, modeling, and control strategies are being
applied to all areas of manufacturing
4. Optimization of manufacturing processes and production systems
are making them more agile