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35 views24 pages

Lec 1

Uploaded by

Mark Tamer
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Introduction To

Manufacturing Processes

By

Dr. Ahmed Safwat Mobasher


About Me

PhD, lecturer of Mechanical Design and Production Engineering


And Quality control director in Faculty of Industry and Energy Technology,
Misr International Technological University, Cairo.
• personal education
• 2006 : Bachelor degree in (Mechanical Design and Production Engineering)
• 2015 : Master of Science degree ,(Zagazig University)
• 2019 : PhD of Science degree ,( Minia University)
• Experience
• 2010 - 2013: Academic Assistant (Obour High Institute for Engineering &Technology)
• 2013 - 2023: in miser international technology university in Cairo
• Training:
• 2016 : Mechanical instructors training program, Koica Organization, South korea
• 2019 : Exams preparation and Quality systems in teaching Training, pearson education
Part 2
Manufacturing processes
Manufacturing process
selection
Mother
nature
• object geometry
• number of parts
• use of part Material Machines

6 M’s of
production
Men Money

Methods
Definition of
Final product
product need
What is manufacturing ?

Is the process of converting


Production raw materials into
Assembly Inspection
drawing production
Through used tool
,machinery and chemical
processing
Material
Production part
selection

Equipment
Design analysis
selection
Types of manufacturing processes

Forming Casting Molding

Injection molding
Forging Die casting
Blow molding
Extrusion Sand casting
Compression molding
Rolling Investment casting

Machining Joining Additive

Turning
Welding 3D printing
Drilling
Soldering Laser sintering
Mailing
Fastening
Forming

Forging Rolling Drawing Extrusion


Forming
Forging
• Involves applying forces or pressure and
plastically deformation the material to produce
the desired shape

• Most forging process can be done when the


metals heating (Hot Working) or (Cold
working)

• Improve mechanical properties


• Equipment can be expensive
Forming

Extrusion
• Extrusion is a simple compressive metal
forming process. In this process, piston or
plunger is used to apply compressive force
at work piece.

• Excellent surface finish


• Only suitable for 2D shapes
Forming

Rolling
• Rolling is the process of reducing the
thickness or changing the cross section of
a long workpiece by compressive forces
applied through a set of rolls.

• Improved mechanical properties


• Can be fully automated
• Cannot produce complex shapes
• High tooling costs
Casting

Die casting Sand casting Investment casting


Casting

Die casting
• Die castings, sometimes known as
pressure die casting, in which molten
metal is forced into the mould called
“Dies” at high pressures ranging from
0.7 to 700 MPa, where it solidifies into a
metal cast.

• Excellent surface finish


• Mostly used for non-ferrous metals
• High start-up cost
Casting

Sand casting
• Sand casting is a type of metal casting
manufacturing technique that involves
the use of sand to create a mold.

• Can be used for a wide range of metal


• Can produce large and complex parts
• Very low initial costs
• Poor surface finish
Casting

Investment casting
• in which a wax pattern is used to shape a
disposable ceramic mold. A wax pattern is made in
the exact shape of the item to be cast. This pattern is
coated with a refractory ceramic material.
• Once the ceramic material is hardened, it is turned
upside-down and heated until the wax melts and
drains out. The hardened ceramic shell becomes an
expendable investment mold. Molten metal is
poured into the mold and is left to cool. The metal
casting is then broken from of the spent mold.
• good for parts with complex geometry
• High cost
Molding

Thermoplastics Thermosets
Molding

Injection molding
• Injection molding is a process in which
polymer is heated above its melting point,
resulting in the conversion of the solid
polymer to a molten fluid with a reasonably
low viscosity.

• Mostly used for thermoplastics


• Very fast process
• Can be fully automated
• High start-up costs
Molding

Compression molding
• Compression molding is a process of
molding in which a feeding material is
placed into an open, heated mold cavity.
The mold is then closed with a top plug
and compressed with large hydraulic
presses in order to have the material
contact all areas of the mold.
• Used for thermosets
• Low tool cost
• Slow process
• Not well suited for complex designs
Machining

Advanced
Machining Finishing
Machining
Machining

Turning
• Turning is a machining process used to
make cylindrical parts, where the cutting
tool moves in a linear fashion while the
workpiece rotates.
Joining

Welding Fastening

Arc welding Resistance welding Gas welding

Soldering
Joining

Welding
• Welding is a fabrication process that joins
two or more parts are fused together by
means of heat, pressure or both , usually
metals or thermoplastics, by using high
heat to melt the parts together and
allowing them to cool, causing fusion.

• low cost joining method


• Need high energy
• Different material can be welded
• It can be automated
Additive

3D Printing
• 3D printing or additive manufacturing is
the construction of a three-dimensional
object from a CAD model or a digital 3D
model.

• It can be done in a variety of processes


in which material is deposited, joined or
solidified under computer control, with
material being added together (such as
plastics, liquids or powder grains being
fused), typically layer by layer.
REFERENCES

• Alting, Leo. (1982). Manufacturing Engineering Processes. Marcel


Dekker, New York.
• Amstead, B.H; et. al. (1987). Manufacturing Processes. John-Wiley
and Sons, New York.
• Brown, Steve. (2000). Manufacturing the Future: Strategic Resonance
for Enlightened Manufacturing. Addison-Wesley Longman, Singapore.
Thank you

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