Workshop Manufacturing

Practices: Introduction to
Manufacturing Processes

Lecture By:
M K PODDAR
Asst. Professor
ME Dept., SIT Sitamarhi
Personal Web: www.ajourneywithtime.weebly.com
Mail Id: [email protected]
Marks Evaluation Under AKU Patna:
Theory Evaluation:
• University Exam: 70 marks
• Internal Exam : 30 marks
Total= 100 marks
Practical Evaluation:
Internal: 20 marks
External: 30 marks
Total: 50 marks
 Introduction
 Mechanical Engineering Workshop is a place where students
acquire knowledge on the operation of various processes involved
in manufacturing and production. The Workshop Practice course
makes students competent in handling practical work in
engineering environment. Mechanical Engineering Workshop is
also involved in different maintenance/repair works for University.
Manufacturing – Need and concept
• Production or manufacturing can be simply defined as
value addition processes by which raw materials of low
utility and value due to its inadequate material
properties and poor or irregular size, shape and finish
are converted into high utility and valued products with
definite dimensions, forms and finish imparting some
functional ability.
 5 ‘M’
• Materials
• Machine
• Money
• Men
• Manufacturing Process
Production Engineering covers two domains:
• (a) Production or Manufacturing Processes
• (b) Production Management

Manufacturing Processes
This refers to science and technology of manufacturing
products effectively, efficiently, economically and
environment-friendly through
• Application of any existing manufacturing process and
system
• Proper selection of input materials, tools, machines and
environments.
• Improvement of the existing materials and processes
• Development of new materials, systems, processes and
techniques
Production Management
This is also equally important and essential in the
manufacturing world. It mainly refers to planning,
coordination and control of the entire manufacturing in
most profitable way with maximum satisfaction to the
customers by best utilization of the available resources like
man, machine, materials and money.
Classification of Manufacturing Process
A. Foundry Process
B. Forming or Metal Forming process
C. Conventional metal cutting process
D. Non-conventional metal cutting process
E. Metal finishing process
F. Joining & Assembly process
G. Metal Coating process
H. Regenerative manufacturing
F. Powder Metallurgy Technique
Casting and Foundry Processes
In one step raw materials are transformed into a
desirable shape
Parts require finishing processes
Excess material is recyclable

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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
Steps:
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
Forming and Metalworking Processes:
Utilizes material that has been cast
Modify the shape, size, and physical properties of
the material
Hot and cold forming

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 Forming and Metalworking Processes
Rolling – Material passes through a
series of rollers, reducing its thickness
with each pass

Forging – Material is shaped by the controlled

Wire, rod, and tube drawing – Material is pulled

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 Forming and Metalworking Processes
Cold forming and forging – Slugs of material are
squeezed into dies
 Machining – Purpose, Principle and Definition
Purpose of Machining
Most of the engineering components such as gears, bearings,
clutches, tools, screws and nuts etc. need dimensional and
form accuracy and good surface finish for serving their
purposes. Preforming like casting, forging etc. generally cannot
provide the desired accuracy and finish. For that such
preformed parts, called blanks, need semi-finishing and
finishing and it is done by machining and grinding. Grinding is
also basically a machining process.

Principle of Machining
A metal rod of irregular shape, size and surface is converted
into a finished rod of desired dimension and surface by
machining by proper relative motions of the tool-work pair.
 Turning process

Definition of Machining
Machining is an essential process of finishing by which
jobs are produced to the desired dimensions and surface
finish by gradually removing the excess material from
the preformed blank in the form of chips with the help of
cutting tool(s) moved past the work surface(s) .
 Machining requirements

• The blank and the cutting tool are properly mounted (in fixtures) and moved
in a powerful device called machine tool enabling gradual removal of layer of
material from the work surface resulting in its desired dimensions and
surface finish. Additionally some environment called cutting fluid is generally
used to ease machining by cooling and lubrication
 Basic functions of Machine Tools
Machine Tools basically produce geometrical
surfaces like flat, cylindrical or any contour on the
preformed blanks by machining work with the
help of cutting tools.
The physical functions of a Machine Tool in
machining are:
• firmly holding the blank and the tool
• transmit motions to the tool and the blank
• provide power to the tool-work pair for the
machining action.
• control of the machining parameters, i.e., speed,
feed and depth of cut.
Machining Processes
Turning Processes
Lathes and turning centers:
Processes include: Straight, taper, contour
turning, facing, forming, necking, parting,
boring, threading, and knurling

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Machining Processes
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
Machining Processes
Milling Processes
Mills – Vertical and horizontal
Processes include: Surfacing, shaping, forming,
slotting, T-slotting, angle, straddle,
dovetailing, and slab milling
Machining Processes
Drilling Processes
Operations that create holes
Cutting tools rotate and are fed into
nonmoving secured work pieces
Machining Processes
Drilling Processes
Drilling and boring machines
Processes include: Drilling, counter drilling, step
drilling, boring, counter boring, countersinking,
reaming, spot facing, and tapping
 Joining and Assembly Processes
Can you think of a product with only one part?
Most products consist of multiple parts that are
assembled to form a finished product.
Typical assembly processes include: Mechanical
fastening; soldering and brazing, welding;
adhesive bonding
 Joining and Assembly Processes
Mechanical Fastening
Use physical force to hold parts together
Mechanical fasteners or part design
Screws, bolts, nails, rivets, cotter pins, retaining
clips, and edge design

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 Joining and Assembly Processes
Welding
Operations that use heat, pressure, or both to
permanently join parts
Gas, arc, stud, spot, forge, roll laminating,
resistance, and induction welding

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 Joining and Assembly Processes
Adhesive bonding
Bonding of adjoining surfaces by filling the gap
between each surface with a bonding material
Glue, cement, thermoplastic, thermosetting,
and elastomers

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 Joining and Assembly Processes
Soldering and Brazing
Operation in which metal surfaces are bonded
together by an alloy
Heated molten alloy flows between the
adjoining surfaces
When the heat is removed, the molten metal
solidifies and the metal surfaces are bonded

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 Rapid Prototyping
Additive process
Parts are produced directly from software
applications
Common rapid prototyping systems include:
stereolithography (SLA), selective laser sintering
(SLS), fused deposition modeling (FDM),
laminated object manufacturing (LOM), digital
light processing (DLP)
 References
1. ‘Manufacturing Technology by P.N. Rao, Tata McGraw
Hill, New Delhi
2. ‘Production Technology’ by R K Jain, Laxmi Publisher
3. Ghosh A. and Mallik A. K., Manufacturing Science, EWP
Pvt. Ltd
4. http://nptel.ac.in/courses