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7 Manufacturing Process 1

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17 views38 pages

7 Manufacturing Process 1

Uploaded by

Kamal Suren
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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LJMU HD in AME

Module Name with Code -Automotive materials and


manufacturing processes -5501ICBTAE
Semester - Semester 3
Batch Number -
Lecturer Name -
Center Name -

LJMU Higher Diploma 1


Content

• Manufacturing process 1

LJMU Higher Diploma 2


Manufacturing

“The Process of Converting Raw Materials Into Products”

Consideration for manufacturing a Product:


• Material Selection
• Processing Methods
• Final Shape and Appearance
• Dimensional and Surface Finish
• Economics of Tooling
• Design Requirements
• Safety and Environmental Concerns
• Before raw materials can be turned into industrial goods, they must first be
obtained and then converted using the primary manufacturing process.

Obtaining Raw Materials

Mining- digging

Drilling- pumping

Harvesting- cutting
Selection Chart
Manufacturing Processes for Metals

• 1. Casting: expendable mold and permanent mold.


• 2. Forming and Shaping: rolling, forging, extrusion, drawing, sheet forming,
powder metallurgy, molding
• 3. Machining: turning, boring, drilling, milling, planing, shaping, broaching,
grinding, ultrasonic machining, chemical machining, electrical discharge
machining (EDM), electrochemical machining, high-energy beam machining
• 4. Joining: welding, brazing, soldering, diffusion bonding, adhesive bonding,
mechanical joining
• 5. Finishing: honing, lapping, polishing, burnishing, deburring, surface treating,
coating, plating
1. Casting
Casting and Foundry Processes
In one step raw materials are transformed into a desirable shape
Parts require finishing processes
Excess material is recyclable
Basic Casting Process
• A mold is created – A cavity that holds the molten material in a
desired shape until it is solidified
Multiple-use mold
Single-use molds
• Material is heated to a specified temperature
• Molten material is poured into a mold cavity
• Molten material solidifies into the shape of the cavity
• Casting or mold is removed
• Casting is cleaned, finished, and inspected
Casting Processes
• Introduction of molten metal into a mold cavity; upon solidification, metal
conforms to the shape of the cavity

1. Die Casting 2. Sand Casting


1. Sand Casting
2. Die Casting
2. Forming and Shaping
Forming and Metalworking Processes
• Utilizes material that has been cast
• Modify the shape, size, and physical properties of the material
• Hot and cold forming
Forming and Metalworking Processes
Cold forming and forging – Slugs of material are squeezed
into dies
Forming and Shaping Processes
1. Forging

Material is shaped by the controlled application of force

Open die forging Close die forging


2. Rolling

Material passes through a series of rollers,


reducing its thickness with each pass
3. Extrusion
Material is compressed and forced through a die to
produce a uniformed cross section
4. Drawing

Material is pulled through a die to produce a uniformed cross section.


Eg- Wire, rod, and tube drawing
5. Sheet metal forming
Shearing and Blanking

When a great enough shearing force is applied, the tensile stress in


the material will exceed the ultimate strength and the material will
fail and separate at the cut location.
Bending
• Bending is a manufacturing process that produces a V- shape, U-shape, or
channel shape. Similar to other forming processes it does not cause any
change in the volume of the material.

• Usually this sheet metal bending process can be carried out cold but may
require to heat the metal sometimes.

LJMU Higher Diploma 21


Stretching
Where the tensile load is applied along the longitudinal axis of
the work piece.
Spinning
Basically a metal disk or cylinder is rotated at high speed by using
specially designed tool through which symmetric product are formed.
Deep Drawing
A flat sheet metal blank is formed into a hollow body open on one
side or a hollow body is formed into a hollow body with a smaller
cross-section.
3. Machining
Machining Processes

Machining is any of various processes in which a piece of raw material is


cut into a desired final shape and size by a controlled material-removal
process.

Machining is a part of the manufacture of many metal products, but it can


Also be used on materials such as wood, plastic, ceramic, and composites.
• Controlled removal of material from a part to create a specific shape or
surface finish

• Cutting element is used

• Movement must exist between the part and cutting element

LJMU Higher Diploma 27


• Material removal from a work piece: cutting, grinding, nontraditional
machining processes.
Manufacturing Machines
1. Lathe Machine
2. Drilling Machine
Drilling Processes
• Operations that create holes
• Cutting tools rotate and are fed into nonmoving secured
work pieces
Drilling Processes
• Drilling and boring machines
• Processes include: Drilling, counter drilling, step drilling, boring, counter boring,
countersinking, reaming, spot facing, and tapping
3. Milling Machine
Milling Processes

• Operations that create flat or curved surfaces by


progressively removing material
• Cutting tools rotate as the work piece is secured and fed into
the tool
Milling Processes

• Mills – Vertical and horizontal


• Processes include: Surfacing, shaping, forming, slotting,
T-slotting, angle, straddle, dovetailing, and slab milling
What is CNC machining ?

• Computer numerical control Machining


it is a automated process.
• It requires software andprogramming,
usually in the G- code language, to
guide a machining tool in shaping the
workpiece according to preset
parameters.

LJMU Higher Diploma 36


Advantages of CNC Machine

• High production cycles: Once the CNC machine has been properly coded, it
usually needs minimal maintenance or downtime, allowing for a faster
production rate.
• Low manufacturing costs: Due to its turnover speed and low manual labor
requirements, CNC machining can be a cost-efficient process, particularly
for high-volume production runs.
• Uniform production: CNC machining is typically precise and yields a high
level of design consistency among its products.

LJMU Higher Diploma 37


Recommended readings

LJMU Higher Diploma 38

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