CHAPTER TWO

CLASSIFICATION OF MANUFACTURING ENGINEERING AND PROCESS

2.1 Introduction:-Engineering makes the most important sector of industry; it provides the
national economy with machines of different purpose. The economic and industrial growth as a
whole, largely depend on the development of the engineering industries. Machine building holds
a prominent place in the plans for the economic development of industrialized and developing
countries. Machine building produces advanced machinery for all branches of industry. A
number of industries owe their high technological level to the permanent development of
engineering industries, production engineers have carried out a great deal of practical work to
improve the manufacturing methods for different kinds of engineering products, while scientist
have made a tangible contribution to the development of theoretical principles of manufacturing
engineering. Manufacturing engineering is the art of making machines of the specified of quality
on the planned production scale with the minimum consumption of materials and the maximum
productivity of labor.
One of the main problems of manufacturing engineering is to study laws typical of production
processes and to determine process characteristics that can be controlled for higher productivity
and accuracy. The quality of a product, primarily its accuracy, provided by manufacturing
methods is an urgent problem. In engineering accuracy is of great importance, since it is
conducive to better machine performance and longer service life, and also to efficient machine
manufacture.

Manufacturing engineering as an applied science ranks high importance in training students for
process engineers. This discipline equips them with the knowledge necessary for the efficient
activity in the fields of engineering production and design.

Technical progress in engineering involves continuous improvement in manufacturing methods

as well as the development of the new machines. It is essential that a new machine should be
manufactured in time at the minimum costs and meet the specified quality standards, which take
high-production equipment, tooling, advanced manufacturing methods, etc. The reliable
operation and effective use of engineering products largely depend on, the manufacturing
process.
2.2 Manufacturing

Manufacturing is a human activity that spread through every part of all phases of our life.
Derived from the Latin (manus = hand, factus = made), the word is used to describe “the
making of goods and article by hand, or, especially by machinery, often on a large scale and with
division of labour”

Manufacturing changes the form of materials to create products. If the enterprise makes
optimum use of resources to produce products, it earns a profit.

A manufacturing system coordinates elements of input, process, and output. An industrial

activity requires resources to produce Products.

2.3 Manufacturing Must be Planned

There are five basic steps needed in planning a manufacturing system:

a) Identifying consumer demand

b) Designing and engineering products

c) Planning production

d) Tooling-up for production: All tools or machines must be made ready to do specific jobs. And

e) Planning quality control

2.4 Production Procedure

The methods used to produce finished products are different because products are different.
There are six basic steps in this procedure:

a) Converting raw materials

b) Making standard stock: This means that the material is formed into a standard size and shape.
c) Making components: Standard stock is made into the components (individual parts) of a
product. Some products such as a comb, a key or a coin have one component.

d) Assembling component into sub assemblies.

e) Making finished products

f) Preparing for distribution

2.5 Historical Developments

The history of manufacturing is marked by gradual developments; however some developments

were of such substantial social consequences that they can rightly be regarded as revolutionary.
Manufacturing has been practiced for several thousand years, beginning with the production of
stone, ceramic, and metallic articles.

The first industrial revolution: At the end of the 18th century, the development of the steam
engine made power available in large quantities and at many locations. This spurred advances in
manufacturing processes and facilitated the growth of production, providing abundance of
goods and, with the mechanization of agriculture, or agricultural products.

The second industrial revolution: Beginning with the second half of the 20th century, further
developments have taken place. Computers have begun solid-state electronics growing out of
the transistor-permitted, the fabrication of devices of great versatility at ever decreasing cost. A
characteristic of the second industrial revolution is that, in addition to the possibility of
replacing most or potentially all physical labour, it is now also feasible to enhance and
sometimes even replace mental effort.
2.6 Basic Manufacturing Processes

Based on the way parts are produced manufacturing processes can be classified

in four broad categories:

 Shaping (casting or molding, forming or metal work processes and machining)

 Assembling
 Finishing
 Miscellaneous (heat treating and quality control)
Based on the basic function of manufacturing processes in the production of parts,
manufacturing processes can be classified:-

1. Casting or molding processes

2. Forming or metal working processes

3. Machining processes

4. Joining (assembling) processes

5. Finishing processes

6. Heat treating and quality control

7. Others
 I. Shaping
Shaping processes usually involve molding and casting. The resulting product is usually at or
near the final desired shape, and many require little or no further finishing operations. Note that
the words forming and shaping are used together in the part title.

1. Casting Processes.

Casting is caricaturized by the following points:

- Is relatively simple and inexpensive compared to some other

- Is used to cast metals, plastics and ceramics;

- Can be classified by the type of mold used

- Parts produced by casting processes vary in size accuracy, surface finish, complete
production rate, production cost and quality.
Example: - sand casting produce parts with rough surfaces.

- Die shell, injection, transfer, vacuum and investment castings produce parts with relatively
smooth surfaces.

- Die casting considered high production rate process while sand casting is a slow production
process.

The selection of the proper casting process depends on the following factors:

1. Complexity shapes size and thickness.

2. Cost of the pattern and size.

3. Tolerance required.

4. Quantity of part required.

5. Surface finish.

2. Mechanical forming processes:-

Forming of parts by application of mechanical force is considered the most important shaping
process in terms value of production and method of production. Forming processes can be
classified on the basis of how the force is applied.

- Bending - Shearing - Compression - Tension

- Folding - Piercing - Forging - Drawing

- Spinning - Trimming - Extrusion – Upsetting

3. Material removal (machining) processes:

Machining operations represent the most versatile and most common manufacturing
processes. These processes are used to shape parts of such materials like metals, plastics,
ceramic and wood. Machining is a relatively time consuming and material wasting process.
However it is very accurate and can produce smooth surface finish.

Machining processes are classified as Traditional and Non-traditional processes.

a) Traditional:- lathe. Miling, boring, broaching, turning etc...

b) Non-Traditional:-Electro chemical machining (ECM), Laser beam machining (LBM), etc.

Machining:- Machining is the process of cold working the metals into different shapes by using
different types of machine tools. This process is mainly used to bring the metal objects produced
by means of different fabrication techniques to final dimensions. Machining processes includes:-
shaping, drilling, turning, milling, sawing, broaching and abrasive process.

Fig.2.1 Principal machining methods.