MAE364

Manufacturing Processes
Spring 2005

Instructor: T. Kesavadas (Prof. Kesh)

Associate Professor,
Mechanical and Aerospace Engineering,
1006 Furnas Hall.

http://wings.buffalo.edu/courses/sp04/mae/364/

Teaching Assistants (more details later):

Govindarajan Srimathveeravalli Sridhar Seshadri
 What is Manufacturing?
(1)
(2)
(3)
(4)
(5)
Manu Factus : Latin for ‘made by hand’

Definition:
A Well organized method of converting raw material to end
product

End Product: Value and utility added to output.

Manufacturing Process
 History of Manufacturing

• Manufacturing started during 5000 – 4000 BC

Wood work,ceramics,stone and metal work
• Steel Production 600-800 AD
• Industrial Revolution 1750 AD: Machine tools run by
invention of steam engine
• Mass Production and Interchangeable Parts
• Computer Controlled Machines 1965
• CNC,FMS systems
 Historical development of materials
- The Early Days
Period Metals and Casting Forming Process
Egypt ~3100 B.C. to ~ Before 4000 Gold,copper and meteoritic Hammering
300 B.C B.C iron
Greece ~1100 B.C. to 4000-3000 Copper casting,stone and Stamping Jewelry
~146 B.C B.C. metal molds,lost wax
Roman Empire ~500 process,silver,lead,tin,bron
B.C. to 476 A.D ze
Middle Ages 476 to 3000-2000 Bronze casting Wire by cutting
1492 B.C. and drawing, gold
Renaissance 14th to leaf
16th centuries
2000-1000 Wrought iron,brass
B.C.
1000-1 B.C. Cast iron, cast steel Stamping of coins
1A.D – 1000 Zinc steel Armor,coinage,for
A.D ging steel swords
1000-1500 Blast furnace, type Wire drawing,gold
A.D. metals,casting of silver smith work
bells,pewter
 Historical development of materials
- The Industrial Revolution
Industrial Revolution 1500-1600 A.D. Cast iron cannon, tinplate Water power for metal
1750-1850 working,rolling mill for
coinage

1600-1700 A.D. Permanent mold casting,brass Rolling(lead,gold,silve

from copper and metallic zinc r)
Shape rolling(lead)

1700-1800 A.D. Malleable cast iron,crucible Extrusion (lead pipe),

steel deep drawing,
rolling(iron bars and
rods)

1800-1900 A.D. Centrifugal casting,Bessemer Steam hammer, steel

process,electrolytic rolling,seamless tube
aluminum,nickel steels,Babbitt, piercing,steel rail
galvanized steel, powder rolling, continuous
metallurgy, tungsten steel, open rolling , electroplating
hearth steel
 Historical development of materials
- The Modern Age
WW I and WW II 1900-1920 Tube rolling, hot
A.D. extrusion
1920-1940 Die casting Tungsten wire from
A.D. powder
1940-1950 Lost wax for engineering Extrusion
A.D. parts (steel),swaging, powder
metal for engineering
parts
Space Age 1950-1960 Ceramic mold, nodular Cold extrusion
A.D. iron, (steel),explosive
semiconductors,continuou forming,thermo
s casting mechanical treatment

1960-1970 A.D Squeeze casting, single Hydrostatic

crystal turbine blades extrusion,electroforming
1970-1980 s Compacted Precision
graphite,vacuum forging,isothermal
casting,organically bonded forging, super plastic
sand,automation of forming,die design by
molding and pouring, large analytical methods, net
aluminum castings for shape forming
aircraft structures rapid
solidification technology
Req. for a good manufacturing
system
Requirements of a good manufacturing system

• Product should meet design requirement

• Economical Process
• Quality should be built into the system
• Should be flexible and responsive to new technology
• High productivity: Best utilization of man, material,
machine, capital and available resources.
 Steps in Modern Manufacturing

Definition of product need,

marketing information Design CAM and CAPP
analysis;codes/standards
review; physical and Production
Conceptual design and analytical models

evaluation Feasibility study

Prototype production
Inspection and quality
testing and evaluation
assurance

CAD
Production drawings; Packaging; marketing and
Instruction manuals
sales literature

Material Specification;
process Product
and equipment selection;
safety review

Pilot Production
 Manufacturing of a Paper Clip
• What is the function
• How long does it last
• How critical is the part
• Material Metallic - what type
Non metallic – plastic
• Dimension Diameter of clip
Shape of clip
• Method of manufacturing Manual
Automated
• Function based design Stress, Strain
Life of clip
Stiffness
• Style Appearance,Color,Finish
Plating,painting
 AISI 1010 welded tubing,
assembly resistance welded Aluminum alloy forging,
Forged aluminum
and electrostatically polished and buffed
tubing(alloy similar to
painted
6063), polished and buffed
AISI 1010,swaged
and cadmium plated
AISI 1008,press formed
resistance welded and
Manufacturing AISI 1020,forging painted
of a bicycle and chromium plated

AISI 1010, luster finished AISI 1008, press

coil stock,profile formed,welded and plated
milled,resistance welded
and chromium plated
formed,welded and plated

Cold drawn medium

carbon steel,( similar to
AISI 1035) bright zinc
plated

AISI 1020 tubing, machine

threaded and painted

AISI 1010,stamped and

Seamless AISI 1020 tubing
coined and chromium
swaged tube sections
plated
brazed into fork
crown,painted
AISI 1010, stamped and
chromium plated

Headed brass,nickel plated

AISI 1040
forging,carburized and
Aluminum permanent mold
chromium plated
casting,machined , polished
Hardened high-carbon Case hardened forging
and buffed AISI 1010,stamped and
steel,thread rolled and quality steel parts, black
chromium plated
chromium plated oxide coating
 Assignment 1
• Select a simple product of your choice
– Try to analyze the different materials,
processes, etc
– Use library resources
– We will discuss this in the class on Friday
 Selection of Process: Topic to be
covered
Casting
• Sand/Expandable Mold,Permanent Mold

Forming and Shaping

• Rolling,forging,extrusion,powder metallurgy

Machining
•
Turning,Boring,Drilling,Milling,Planing,Broaching,Grinding
 Selection of Process

Unconventional Method
• EDM,ECM,Ultrasound,High Energy Beam,machining
Joining
• Welding,Brazing,Soldering
Finishing
• Honing,Lapping,Polishing,Burnishing,Deburring
 Objectives of this course and what is
expected of you
• Manufacturing processes and fundamentals
• Selection of appropriate process to meet design
requirements
• Effect of process parameters and variables on the
quality of parts produced
• Effect of material properties on a given process
• Decision and methods for different product size and
mix
• Effect of design on manufacturability
• Overview of computer aided methods in traditional
manufacturing processes
Two methods of forming a dish shaped part from sheet metal
Left: conventional hydraulic/mechanical press using male and female dies
Right: explosive forming using only one die.

pressure
Upper die

Explosive

water

work piece

Lower Die
Three methods of casting turbine blades
A: conventional casting with ceramic mold
B: directional solidification
C: Method to produce single crystal blade
 Selection of Process depends on

• Dimensional and surface finish requirements

• Operational Cost
• Design and strength requirements
• Consequences of various methods
 Design for Assembly

• Design of the product to permit assembly

• Possibility of multipurpose parts
• Capability of manufacturing process to consistently
produce parts which can be assembled without
problem
• Method or process of assembly
Automated Systems,Manual Systems etc
Design for Assembly
Automation and Impact of Computers

Machine Control Systems

Computer Numerical Control machines,
Robots,Machines,Processes
Computer Integrated Technology
• Responsive to market change
• Better use of process,man,machining management etc
• CAD/CAM: Computer Aided Design And Manufacturing
• FMS: Flexible Manufacturing System
• GT: Group Technology
• VR: Virtual Reality