ME 1107

Manufacturing Process

Introduction to Manufacturing Process

Dr. Md. Mahbubur Rahman

Assistant Professor
Department of Mechanical Engineering
Khulna University of Engineering & Technology (KUET)
Khulna-9203, Bangladesh
Email: [email protected]
 Production Process
 Manufacturing Engineering : Manufacturing is derived from the Latin word manufactus,
means made by hand. In modern context it involves making products from raw material by
using various processes, by making use of hand tools, machinery or even computers. It
is therefore a study of the processes required to make parts and to assemble them
in machines.
 Production Process: It is the process followed in a plant for converting semi- f inished
products or raw materials into f inished products or raw materials into f inished products. The
art of converting raw material into finished goods with application of different types of tools,
equipments, machine tools, manufacturing set ups and manufacturing processes, is known
as production. Generally there are three basic types of production system that are given as
under-

1. Job production
2. Batch production
3. Mass production

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Production Process

Figure : Types of Production

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 Process Planning
 Process planning consists of selection of
means
of production (machine-tools, cutting tools,
presses, jigs, f ixtures, measuring tools etc.),
establishing the efficient sequence of operation,
determination of changes in form, dimension or
f inish of the machine tools in addition to the
specification of the actions of the operator.
 It includes the calculation of the machining time,
as well as the required skill of the operator. It also
establishes an ef ficient sequence
manufacturin minimizing
of stepsmateria
handling
g which ensuresfor l work will be done
that the
at the minimum cost and at maximu
m
productivity.
 The basic concepts of process planning are generally concerned with the
machining only. Although these concepts may also be extended to other
pr oce sse s su ch a s ca st i n g, f or gi n g, sh e e t m e t a l f or m i n g,
assembling and heat treatment as well.
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 Manufacturing Process
 Manufacturing Process : Manufacturing process is that part of the production process
which is directly concerned with the change of form or dimensions of the part being
produced. It does not include the transportation, handling or storage of parts, as they are
not directly concerned with the changes into the form or dimensions of the part produced.

 Can be defined as the transformation of materials and information into goods for the satisfaction of human
needs.

Figure: Flow diagram of manufacturing process

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 Types of Manufacturing Process
Manufacturing process can be classified as:
 Based on primary shaping processes: Primary shaping processes are manufacturing
of a product from an amorphous material. Some processes produces f inish products or
articles into its usual form whereas others do not, and require further working to f inish
component to the desired shape and size.

 Some of the important primary shaping processes: (1) Casting, (2) Powder metallurgy,
(3) Plastic technology, (4) Gas cutting, (5) Bending and (6) Forging.

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 Secondary or Machining Processes
 Based on Secondary or Machining Processes: Large number of components require
further processing after the primary processes. These components are subjected to one
or more number of machining operations in machine shops, to obtain the desired shape
and dimensional accuracy on flat and cylindrical jobs.

 Thus, the jobs undergoing these operations are the roughly f inished products received
through primary shaping processes.

 The process of removing the undesired or unwanted material from the

workpiece or job or component to produce a required shape using a cutting tool is
known as machining. This can be done by a manual process or by using a machine
called machine tool (traditional machines namely lathe, milling machine, drilling,
shaper, planner, slotter).

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 Secondary or Machining Processes
 Some of the common secondary or machining processes are— (1) Turning, (2)
Threading, (3) Knurling, (4) Milling, (5) Drilling, (6) Boring, (7) Planning, (8) Shaping, (9)
Slotting, (10) Sawing, (11) Broaching, (12) Hobbing, (13) Grinding, (14) Gear cutting,
(15) Thread cutting and (16) Unconventional machining processes namely machining
with Numerical Control (NC) machines tools or Computer Numerical Control (CNC)
machines tools using ECM, LBM, AJM, USM setups etc

Hobbing Knurling

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 Metal Forming Processes
 Based on Metal Forming Processes :Forming processes encompasses a wide variety of
techniques, which make use of suitable force, pressure or stresses, like compression,
tension and shear or their combination to cause a permanent deformation of the raw
material to impart required shape.
 Some of the important metal forming processes are:

 Hot working Processes

(1) Forging, (2) Rolling, (3) Hot spinning, (4) Extrusion, (5) Hot drawing

 Cold working processes

(1) Cold forging, (2) Cold rolling, (3) Cold heading, (4) Cold drawing,
(5) Wire drawing, (6) Stretch forming, (7) Sheet metal working processes such as piercing,
punching, lancing, notching, coining, squeezing, deep drawing, bending etc

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 Joining Processes
 Based on Joining Processes:The process of putting the parts together to form the
product, which performs the desired function, is called assembly. An assemblage of
parts may require some parts to be joined together using various joining processes.

 But assembly should not be confused with the joining process. Most of the products
cannot be manufactured as single unit they are manufactured as different components
using one or more of the above manufacturing processes, and these components are
assembled to get the desired product.

 Joining processes are widely used in fabrication and assembly work. In these process
two or more pieces of metal parts are joined together to produce desired shape and size
of the product. The joining processes are carried out by fusing, pressing, rubbing,
riveting, screwing or any other means of assembling.
These processes are used for assembling metal parts and in general fabrication work.

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 Joining Processes
 Some of the important and common joining processes are:

(1) Welding (plastic or fusion), (2) Brazing, (3) Soldering,

(4) Riveting,(5) Screwing, (6) Press f itting,

(7) Sintering, (8) Adhesive bonding, (9) Shrink f itting,

(10) Explosive welding, (11) Diffusion welding,(12) Keys and cotters joints,

(13) Coupling and (14) Nut and bolt joints

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 Surface Finishing Processes
 Based on Surface Finishing Processes: f inishing processes are utilized for imparting
intended surface f inish on the surface of a job. By imparting a surface f inishing process,
dimension of part is not changed functionally; either a very negligible amount of material
is removed from the certain material is added to the surface of the job.

 These processes should not be misunderstood as metal removing processes in any

case as they are primarily intended to provide a good surface f inish or a decorative
or protective coating on to the metal surface

 Some of the commonly used surface finishing processes are: (1) Honing,
(2) Lapping, (3) Super f inishing, (4) Belt grinding, (5) Polishing, (6)
Tumbling, (7) Organic f inishes, (8) Sanding, (9) deburring, (10)
Electroplating, (11) Buf fing, (12) Metal spraying, (13) Painting, (14)
Inorganic coating, (15) Anodizing, (16) Sheradising, (17) Parkerizing, (18)
Galvanizing, (19) Plastic coating, (20) Metallic coating, (21) Anodizing
and (22) Sand blasting.

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 Surface Finishing Processes
 Honing is an abrasive machining process that produces a precision surface on a
metal workpiece by scrubbing an abrasive grinding stone or grinding wheel
against it along a controlled path.

 Lapping is a machining process in which two surfaces are rubbed together

with an abrasive between them, by hand movement or using a machine.
 Polishing is the process of creating a smooth

and shiny surface by rubbing it or by

applying a chemical treatment, leaving a
clean surface with a signif icant specular
ref lection. In some materials,

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 Processes Effecting Change in Properties

 Based on Processes Effecting Change in Properties: Processes effecting change in

properties are generally employed to provide certain specif ic properties to the metal
work pieces for making them suitable for particular operations or use. Heat treatments
affect the physical properties and also make a marked change in the internal structure of
the metal.

 A few such commonly used processes are given as under: (1) Annealing, (2)
Normalising, (3) Hardening, (4) Case hardening, (5) Flame hardening, (6) Tempering, (7)
Shot peeing, (8) Grain refining and (9) Age hardening.

Slides courtesy: Mr. Raju Ahammad , Lecturer (ME,KUET)

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The End

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