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1 MEEG217-intro (Compatibility Mode)

The document provides an overview of basic manufacturing processes, including definitions, classifications, and various techniques used in manufacturing. It covers primary shaping, machining, metal forming, joining, surface finishing, and processes that modify material properties. The goal of manufacturing is to produce quality products efficiently while meeting specific tolerances and production costs.

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kapun kumar nayak
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12 views32 pages

1 MEEG217-intro (Compatibility Mode)

The document provides an overview of basic manufacturing processes, including definitions, classifications, and various techniques used in manufacturing. It covers primary shaping, machining, metal forming, joining, surface finishing, and processes that modify material properties. The goal of manufacturing is to produce quality products efficiently while meeting specific tolerances and production costs.

Uploaded by

kapun kumar nayak
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Basic Manufacturing Processes

Module I Introduction

Ashok Acharya, MEEG217, September 2016


Department of Mechanical Engineering
School of Engineering

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Manufacturing-
to make a product suitable to use
Manufacturing
• Manufacturing: to make or process a raw material into a
finished product, esp. at industrial scale
• Variety of equipment are employed following series of steps
to come up with desired product
• Manufacturing- creates some product that has useful form
• Form is predetermined, with specific geometry
• All geometry has certain tolerance to meet, to be considered
acceptable
• Tolerance outlines the geometric accuracy that must be
achieved in manufacturing process

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Process
• A series of operation to create specified product
• Process of converting material into product
• Manufacturing processes (MP) are carried out in specific shop
called Job Shops
• Job shops are for specific manufacturing processes with
related machines and machine tools

Change in properties
Job Piece Finished Product
Manufacturing Process

Series of process
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Manufacturing business
• Production of merchandise for use or sale
• Using labor and machine, tools
• Process or set of production order
• Raw material to finished goods
• Simple to complex
• Household appliances to space techs
• Directed towards mass production
• Planned economy through massive sale
• Goal of all manufacturing processes:
– Meeting performance requirement like tolerance, weight,
property of material used
– Meeting cost of production requirement
– Ability to reproduce quality in mass production
– Maintain uniform material property throughout the
component

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Product creation cycle

Design Material Selection Process Selection

Feedback Inspection Manufacture

• A constant feedback must exist between manufacturing


process and process/material optimization

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Basic Classification of MP
• Primary Shaping Processes
• Secondary Machining Processes
• Forming/deforming Processes
• Joining Processes
• Surface Finishing Processes
• Material properties modification processes

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(Primary) Shaping Processes
• remelting of ingots (available in the market) in cupola or some
foundry furnace
• molten metal is poured into the moulds to obtain the casting
• sometimes, ingots are converted into useable form by forging
or other primary processes viz.

(a) Casting (b) Forging (c) Smithy (d) Drawing


(e) Rolling (f) Bending (g) Extruding (h) Squeezing
(i) Shearing (j) Crushing (k) Spinning (l) Piercing
(m) Forming (n) Embossing

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Casting
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Machining Process
• machining operations performed on various machine tools
like lathe, shaper, milling machines
• machining processes are required to make complex shapes,
profiles, contours, etc

• different machining operations are:


shaping, turning, milling, drilling, grinding, boring, threading, slotting,
planing, gear cutting, knurling, sawing, broaching, hobbing

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Machining in Lathe
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Drilling – machining process
Assembly of Section 41 of a Boeing 787 Dreamliner
Metal forming Processes
• Encompasses wide variety of processes that make use of
suitable force, pressure, stress or combination to cause
permanent deformation of raw materials into required shape

• Mechanical working processes: hot working, cold working

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Metal forming contd...
• Hot working:
– Forging, rolling, spinning, extrusion

• Cold working:
– Cold forging, cold rolling, wire drawing, coining, squeezing

• No material is removed, but displaced, deformed to produce


required shape
• Can produce directly usable articles like kitchen utensils,
tubes, bottles, etc

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Joining Processes
• used for joining two or more metal pieces of metal parts

• used to join two or more work-parts either temporarily or


permanently

• various joining processes are:


Welding, soldering, brazing, riveting, screwing, adhesive joining, sintering,
pressing, coupling key and cotter joints, nut and bolt joints

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Surface Finishing Processes
• used to provide good surface finish to the metal surface of the
processed product
• either a negligible amount of material is removed or a small
amount of material is added to the surface of the product

• various surface finishing processes are:


sand blasting, buffing, lapping, belt grinding, polishing, honing,
electroplating, metal spraying, anodizing, pickling, hot dipping,
galvanizing, painting

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Grinding- surface finishing processes
Processes affecting
change in material properties
• used to impart specific properties to the metal parts for
specific properties of use

• processes used for this purpose are:


Annealing, hardening, tempering, age hardening, shot peening, grain
refining, homogenizing

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Welding Technology
and Processes

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NEXT LECTURE: GAS WELDING

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