Introduction To MP

MCT-113: MANUFACTURING PROCESSES
Course Objectives:
The course will aim to impart knowledge about

the basics of engineering materials and many
of the latest manufacturing processes being
used in the industry. Other than manufacturing
processes, students will be introduced to
various machine tools and their operations.
Instructor:
Dr. Imran Ali
Topics Covered:
Materials: Metals: Ferrous and non ferrous metals, polymers: Properties of Materials
Non- Machining Processes:
Introduction to manufacturing processes, quantitative and qualitative study of manufacturing
processes for metals, plastics and ceramics
Casting& Molding processes: casting, expandable and non-expendable casting, Moulds, Mould
making, casting materials,
Forming Processes: Metal forming processes, Polymer processing, injection molding, injection
blow molding,
Joining &Assembly Processes: Powder metallurgy, Welding, Brazing, Adhesive bonding, paint
and coating processes
Machining Processes: Conventional machines (lathe, milling, shaper, grinding), non-conventional
machining, metal cutting theory and cutting mechanics, tool selection and machining methods of
different materials
CNC (Computer numerical Control): Classification of CNC Machines, Machining Centers.
Introduction to part programming
Suggested Text:
1. Machine Tool Technology by Steve Krar, Arthur Gill, Peter Smid and Paul Wanner
2. Manufacturing Processes for Engineering Materials by S Kalpakjian and SR Schmid
3. Workshop Technology Part – I, II, III by WA Chapman
Manufacturing
 The word manufacture is derived from two Latin words, manus

(hand) and factus (make); the combination means made by hand.
 The English word manufacture is several centuries old, and
‘‘made by hand’’
 Manufacturing is the process of converting raw materials into
products.
WHY STUDY
MANUFACTURING PROCESSES………..
 The designer and the drafter must have a working knowledge of the
various processes that could produce a part in order to: lower cost and
reduce production time.
What is Manufacturing?
 Manufacturing is the application of physical and chemical processes to alter the geometry,
properties, and appearance of a starting material to make parts or products for a given
application
 When iron ore is converted into steel, value is added.
 When sand is transformed into glass, value is added.
 When petroleum is refined into plastic, value is added.
 When plastic is molded into the complex geometry of a patio chair, it is made even more
valuable.
Purpose of Manufacturing
 Manufacturing is the transformation of materials into items of
greater value by means of one or more processing and/or
assembly operations
Classiﬁcation of manufacturing processes.
(1) Processing operations. A processing operation
transforms a work material from one state of completion
to a more advanced state.
(2)Assembly operation joins two or more components to

create a new entity, called an assembly, subassembly
PROCESSING OPERATIONS
 A processing operation uses energy to alter a workpart’s shape, physical properties, or
appearance to add value to the material.
 The forms of energy include mechanical, thermal, electrical, and chemical.
 The energy is applied in a controlled way by means of machinery and tooling.
 Human energy may also be required, but the human workers are generally employed to
control the machines.
Three categories of processing operations:
1. Shaping operations - alter the geometry of the starting work material
2. Property-enhancing operations - improve physical properties of the material without
changing its shape
3. Surface processing operations - clean, treat, coat, or deposit material onto the exterior
surface of the work
Shaping
 1. Solidification Processes - starting material is a heated liquid that solidifies to
form part geometry
2. Deformation Processes - starting material is a ductile solid

that is deformed
Material removal processes
 Excess material removed from the starting workpiece so what remains is the desired
geometry
 Examples: machining such as turning, drilling, and milling; also grinding and
nontraditional processes
 It is desirable to minimize waste and scrap in converting a starting workpart into its
 subsequent geometry.
Property-Enhancing Processes
 Performed to improve mechanical or physical properties of the work material
 Part shape is not altered, except unintentionally
 Controlled heating and cooling of a material to alter its properties while
maintaining its shape
 Properties include: Strength, toughness, machinability, wear resistance, and
corrosion resistance
 Examples:
Heat treatment of metals and glasses

Surface Processing
1. Cleaning - To remove dirt, oil, and other contaminants from the surface
2. Surface treatments - Sand blasting, and physical processes like diffusion
3. Coating and thin film deposition - coating exterior surface of the workpart
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.

• Examples: welding, brazing, soldering, and adhesive bonding
2. Mechanical assembly – fastening by mechanical methods
• Examples: use of screws, bolts, nuts, other threaded fasteners; press

fitting, expansion fits
• Techniques form a more permanent connection; these include rivets,

press fitting, and expansion fits.
MANUFACTURING SUPPORT SYSTEMS

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MCT-113: MANUFACTURING PROCESSES

The course will aim to impart knowledge about

 The word manufacture is derived from two Latin words, manus

(2)Assembly operation joins two or more components to

 The forms of energy include mechanical, thermal, electrical, and chemical.

 The energy is applied in a controlled way by means of machinery and tooling.

2. Deformation Processes - starting material is a ductile solid

 Part shape is not altered, except unintentionally

 Controlled heating and cooling of a material to alter its properties while

maintaining its shape

 Properties include: Strength, toughness, machinability, wear resistance, and

Heat treatment of metals and glasses

2. Surface treatments - Sand blasting, and physical processes like diffusion

 Types of assembly operations:

1. Joining processes – create a permanent joint.

2. Mechanical assembly – fastening by mechanical methods

• Examples: use of screws, bolts, nuts, other threaded fasteners; press

• Techniques form a more permanent connection; these include rivets,

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