pes of Manufacturing Processes

What is Manufacturing Process?

Manufacturing process is basically a

complex activity, concerned with
people who've a broad number of
disciplines and expertise and a wide
range of machinery, tools, and
equipment with numerous levels of
automation, such as computers,
robots, and other equipment.
Manufacturing pursuits must be
receptive to several needs and
developments.
ypes of Manufacturing Processes
2 Joining/ welding

Every joining approach has particular

design needs, while certain joint
needs may propose a particular
joining approach. Design for
assembly, and fastener selection
apply their own specifications.

However, all joint patterns must

consider features such as load
factors, assembly effectiveness,
operating surroundings, overhaul
and upkeep, and the materials
chosen.
Welding is generally a cost-
effective approach to fabricate. It
doesn't require overlapping
materials, and so it removes
excess weight brought on by other
fastening methods. Fasteners
don't have to be purchased and
3 Forming

Metal forming is the approach of

creating the metallic components by
deforming the metal but not by
removing, cutting, shredding or
breaking any part. Bending, spinning,
drawing, and stretching are a few
important metal forming process in
manufacturing. The metal press such
as die and punching tools are
implemented for this manufacturing
process.
4 Casting

Casting is a manufacturing process in which a solid is dissolved int

o a liquid, heated to appropriate temperature (sometimes processe
d to change its chemical formula),
and is then added into a mold or cavity. Thus, in just one step,
complex or simple shapes can be crafted from any kind of metal
that has the capability to be melted. The end product can have
practically any arrangement the designer wants.
 CLASSIFICATION OF MACHINE
TOOLS IN MACHINING

 A- According to the geometrical shapes of

the workpieces.
 B-According to the number of the
workpieces.
 C-According to the functions of the
machines.

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 A- According to the geometrical
shapes of the workpieces.
1 Machine tools for machining flat
surfaces (shapers, planers)
2 Machine tools for machining
cylindrical surfaces (lathes)
3 Machine tools for making holes
(drilling machines)
4 Machine tools for machining profiles
(milling, hobbing machine tools)

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 B-According to the number of the
workpieces.
1 Simple Machine Tools
2 Universal Machine Tools (general purpose)
3 Production Machine Tools (special
purpose)

4 Special Machine Tools (limited

purpose)

5 Transfer Machine Tools

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A simple machine

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2
Production Machine Tools
 These machines are only for special
usage or aim. These machines
provide the work to be done in a
short time without the necessiy of
qualified worker. These kind of
machines can be used for bulk
production in small scales.For
example, all turning machine.

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Special Machine Tools

  These machines can be used

for special aims and these
machines are more economic
and have high efficiency.

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 C-According to the functions of
the machines
1. Turning Machines
2. Drilling Machines
3. Milling Machines
4. Shaping Machines
5. Grinding Machines
6. Sawing Machines
7. Broaching Machines
8. Gear Cutter Machines
9. Super Finish Machines

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What is Machining ????

Machining is the process of cutting,

shaping, or removing material from a work
piece using a machine tool.
Short history of machine tools in
machining

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Egyptians used these rollers for transporting the required stones
from a quarry to the building site.
 The first deep hole drilling machine was built by Leonardo da
Vinci (1452–1519).

 In 1840, the first engine lathe was introduced. added the lead
screw, back gears, and the tool post to the previous design.

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1 Machining

Tools used for machining are

immobile power-driven units used to
form or shape solid materials,
specifically metals. The forming is
done by removing extra materials
from a work-piece. Machine tools
make up the foundation of advanced
industry and are utilized either
indirectly or directly in the
manufacturing of tool parts.
Basic Process
Turning

Fig-2 Basic scheme of Turning

 To produce rotational, axis-symmetric parts.

 Feed motion
 Feed relative to work piece.
 Turning Operations
 Facing
 Parting
 Grooving
 Drilling
 Screw cutting

Workpiece
•Materials
Aluminum
• Brass
• Plastics
• Cast Iron
• Mild
Steel
Ref: Manufacturing Engineering and Technology
Ref: Manufacturing
- Serope Kalpakjian
Scienceand
- Ghosh
Steven
and
R. Schim
Mallik
Effect of Turning on Work Material
Properties
 Mechanical
 Creates residual stresses, micro cracks
• Advantages
• Increased production with medium and high
turret lathes.

• Disadvantages
• Limited to rotational parts.
• High equipment cost.
• Low production rate.
• Large amount of scrap.
Drilling

Drilling Operations
 Reaming
 Tapping
 Counterboring
Fig-3 Basic scheme of Drilling
 Countersinking
 Centering
 Spot facing
Effect of Drilling on Work Material Properties
Work piece Materials
• Aluminum alloys
• Magnesium alloys
• Copper alloys
• Stainless steels
• Cast iron
• Plastics
Mechanical
 Very thin layer of highly stressed and disturbed
material on new surface.
Advantages
 High production rate.

Disadvantages
 Skilled labor is required according to the hole
location and accuracy.
Milling

Fig-4 Basic scheme of Milling

Milling Operations

Up milling
Down Milling
Slab Milling
Face Milling
End Milling

Fig-5 Slab Milling Fig-6 Face Milling

 This machine perhaps most
Up milling widely used in manufacturing
industries after the
lathe machine.
However, In the case of lathe
machine, the tools used there
single point cutting tool but In
the case of the milling machine,
the tools used are multi-point
cutting tools.
The milling is a process of metal-
removing by feeding the work
past a rotating multipoint cutter.
The diagram is shown below:
This machine can hold one or
more, number of cutters at a
time and rotates at high speed to
remove the metal at a faster
rate.
The metal removal rate is faster
as compared to a lathe machine.
This machine is used to make
gears like Spur gears, and
also drill the workpiece bore, and
•Down Milling:
•The down milling is also
called a Climb down milling.
•In case of down milling, the
cutter rotates in the same
direction as that of the feed.
•In down milling, there is less
friction involved between the
cutter and the workpiece as
both.
Sl.N
Up Milling Down Milling
o
This machine is also called as
Down milling is also called a
1. conventional milling or climb up
climb down milling.
milling.
2. The cutting forces act upward. The cutting forces act downward.

Up milling is mostly used for Down milling is used for finishing

3.
rough cutting operations. operations.

Due to more tool wear rate, the Due to less tool wear rate, the
4.
durability of the tool is less. durability of the tool is more.

Tool wear rate is more, as the Tool wear rate is less, as the
5. direction of the rotary cutter is direction of a cutter is the same
against the feed. direction as the feed.

This process is mostly used in Nowadays, down milling is a

6. the conventional way of cutting better operation choice then up
the surface. milling machine.
Workpiece Materials
1. Aluminum
2. Brass
3. Magnesium
4. Nickel
5. Steel
6. Thermostat plastics
7. Titanium
8. Zinc
Advantages
 Variety of shapes can be obtained

Disadvantages
 Skilled labor is required
 Low to medium production rate
 Limited shape complexity
 High equipment cost
 Significant tool wear
 Large amount of scrap
Boring

Fig-7 Boring operation

 Boring Operations
 Single-Edge
Boring
 Multi-Edge
Boring
 Step Boring
 Reaming
Workpiece
Materials
• Aluminum
• Brass
• Plastics
• Cast Iron
• Mild Steel
Ref: Manufacturing Processes Reference Guide – Robert
Ref: www.coromant.sandvik.com/boring
H. Tadd, Dell K. Allen and Leo Alti
 Effect of Boring on Work Material
Properties
 Mechanical
 Creates residual stresses, micro cracks
 May cause workhardening of unhardened materials
 Physical
 Little effect
 Chemical
 Little effect

Advantages
Finish machining of cylindrical surfaces on very large workpi

Ref: Manufacturing Processes Reference Guide – Robert H. Tadd, Dell K. Allen and Leo Alti
 Broaching

Broaching Operations
Fig-8 Broaching Tool
 Surface Broaching
 Pull down Broaching
 Push Broaching
 Pot Broaching

Ref: Tool and Manufacturing Engineers Handbook– Tom Drozda, Charles Wick, John T. Benedict,
Image Raymond
Courtesy:-
F. Veille
wiki
 Workpiece Materials
 Aluminum
 Brass
 Bronze
 Plastic
 Malleable Iron

Ref: Tool and Manufacturing Engineers Handbook– Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veille
Advantages
 External and internal flat surfaces
 Good surface finish
 High production rate
 Less skilled labor is required
 Reduced cycle times
 Increased tool life
 Reduced maintenance
 Complex and irregular shapes.

Disadvantages
 Costly tooling

Ref: Manufacturing Engineering and Technology - Serope Kalpakjian and Steven R. Schim
Shaping

Fig-9 Basic scheme of Shaping

Image Courtesy:- Ghosh and Mallik; Manufacturing Scienc

Fig-10 Shaper Mechanism

Image Courtesy:- http://www.roymech.co.uk/images9/shaper_mechanism_6.

Advantages
 Suitable for low quantity production.
 Flat surfaces and straight profiles can be obtained
on relatively small surfaces.

Disadvantages
 Complex parts require skilled labor.

Ref: Manufacturing Science - Ghosh and Mallik

Planing

Fig-11 Basic scheme of Planing

Image Courtesy:- Ghosh and Mallik; Manufacturing Scienc

Advantages
 Suitable for low quantity production.
 Flat surfaces and straight profiles can be obtained
on large surfaces.

Disadvantages
 Complex parts require skilled labor.

Ref: Manufacturing Science - Ghosh and Mallik

 Introductio
n
 Abrasive machining involves material removal
by the action of hard, abrasive particles.
 The use of abrasives to shape parts is probably
the oldest material removal process.
They are important because
 They can be used on all types of materials
ranging from soft metals to hardened steels and
hard nonmetallic materials such as ceramics
and silicon.
 Extremely fine surface finishes (0.025 µm).
 For certain abrasive processes, dimensions
can be held to extremely close tolerances.
Types ofAbrasive Machining
Processes
 Grinding
 Honing
 Lapping
 Superfinishing
 Polishing
 Buffing
 Abrasive water jet
machining
 Ultrasonic machining
 Difference between grinding and
milling
 The abrasive grains in the wheel are much
smaller and more numerous than the teeth
on a milling cutter.

 Cutting speeds in grinding are much higher

than in milling.

 The abrasive grits in a grinding wheel are

randomly oriented.

 A grinding wheel is self-sharpening.

Particles on becoming dull either fracture
to create new cutting edges or are pulled
out of the surface of the wheel to expose
new grains.
Surface
Grinding

Horizontal Surface Grinding

Vertical Surface Grinding

 Surface
Grinding

Horizontal Grinding Machine

Cylindrical
Grinding

Two types of cylindrical grinding:

(a) external, and (b) internal
External Centerless
Grinding
 Chip
Formation

 The importance of the grit shape can be easily realized

because it determines the grit geometry e.g. rake and
clearance angle.
 The grits do not have definite geometry and the grit rake
angle may vary from
+45 to -60 or more.
 Grit with favorable geometry can produce chip in shear
mode. However, grits having large negative rake angle or
rounded cutting edge do not form chips but may rub or
make a groove by plowing leading to lateral flow of the
References
Books
 Manufacturing Science by Amitabha Ghosh and Asok Kumar
Mallik, East-West Press Pvt Ltd.
 Tool and Manufacturing Engineers Handbook, Volume 1 –
Machining by Tom Drozda, Charles Wick, John T. Benedict,
Raymond F. Veilleux, Society of Manufacturing Engineers
Publications Committee
 Troubleshooting Manufacturing Processes by Laroux K. Gillespie,
Society of Manufacturing Engineers Publications Committee
 Manufacturing Engineering and Technology by Serope Kalpakjian
and Steven R. Schimid, Pearson Education
 Manufacturing Processes Reference Guide by Robert H. Tadd, Dell
K. Allen and Leo Alting, Industrial Press
Websites
 http://www.roymech.co.uk/images9/shaper_mechanism_6.gif
 http://itdc.lbcc.edu/cps/machineTool/machiningOperations.htm
 http://www.coromant.sandvik.com/boring
Types of machining tools
Electrical discharge machining
Grinding (abrasive cutting)
Multiple edge cutting tools
Single edge cutting tools