Manufacturing Processes

ME - 222
This course provides an introduction to the various manufacturing
processes employed in the industry. Emphasis will be on the classical
manufacturing techniques, and gradually progressing to the advance
processes, giving students an in-depth knowledge of how the
manufacturing industry has evolved over the last century.

Instructor
M. Saqib Hameed
Aerospace Engineer

Department of Mechanical Engineering,

HITEC University – Taxila
Wednesday 21st September, 2011
 Weekly Distribution of Course Contents Week No.
Introduction to Manufacturing Processes 1
Metal Casting Processes & Equipment 2&3
Forming & Shaping Processes (Rolling) 4
Forming & Shaping Processes (Extrusion and Drawing) 5
Sheet Metal Forming 6
1st Sessional Exam 7
Forming & Shaping Processes for Plastics 8
Forming & Shaping Processes for Composite Materials 9
Joining Processes & Equipment (welding) 10 & 11
Joining Processes & Equipment (Forging) 12
Powder Metallurgy 13
2nd Sessional Exam 14
Surface Treatment, Coating and Cleaning 15
Advance Manufacturing Processes 16
Rapid Prototyping 17
End Term Examination 18
Course Duration Credit Hours
v 18 Weeks v 2 Credit Hours

Recommended Books
vFundamentals of Modern Manufacturing,
By M.P.Groover (John Wiley & Sons)
vManufacturing Engineering and Technology,
By Kalpakjian (Prentice Hall)
vMaterials and Processes in Manufacturing ,
By E.P. Degarmo (Prentice Hall)
vAny other book available in library may be consulted for contents covered in class

Evaluation Criteria
vPopup Quizzes (4 minimum) ………………………….…………………………………… 15%
vRandom Assignments (As many as required)………………………….……………….5%
vFirst Sessional-Term Exam [1 hr]…………………………………………..……………...15%
vSecond Sessional-Term Exam [1 hr]………………………………………..………….….15%
vFinal Exam…………………………………………………………………………………………...50%
 Introduction to Manufacturing

v Manufacturing is important- technologically, economically and

historically

v Manufacturing can be defined in two ways

o Technologically:
It is the application of physical and chemical processes to alter the
geometry, properties, and/or appearance of a given starting material to
make parts or products
o Economically:
It is the transformation of materials into items of greater value by means
of one or more processing and/or assembly operations
 Manufacturing (Technical Process)

Starting Manufacturing Process Processed

Material Part

Scrap &
Waste
 Manufacturing (Economic Process)

Manufacturing Process

Value Addition

Starting Material in Processed

Material processing Part
 Materials in Manufacturing
v Most Engineering materials can be classified into one of three basic
categories:

o Metals
Ferrous Metals (Relating to or containing iron)
Nonferrous Metals
o Ceramics
Crystalline Ceramics (an artifact made of hard brittle material produced from
nonmetallic minerals by firing at high temperatures)
Glasses (A brittle transparent solid with irregular atomic structure)
o Polymers
Thermoplastic (Having the property of softening or fusing when heated and of
hardening and becoming rigid again when cooled)
Thermosetting (Having the property of becoming permanently hard and rigid when
heated or cured)
Elastomers (Resumes its original shape when a deforming force is removed)
 Venn Diagram for Engineering Materials
Metal-Polymer
Composites

Metals Polymers

Metal-Ceramics
Composites Polymer-
Ceramics Ceramics
Composites
 Classification of Manufacturing Processes

v Manufacturing Processes

o Processing Operations
Shaping Processes
Property Enhancing Processes
Surface Processing Operations

o Assembly Operations
Permanent Joining Operations
Mechanical Fastening
 Shaping Processes
v Altering the shape and size of input material by applying
heat , mechanical force or a combination of both

oThey are further classified as

•Solidification Processes (The process of becoming hard or solid by cooling
or drying ,"the solidification of concrete")

•Particulate Processes (A small discrete mass of solid or liquid matter that

remains individually dispersed in gas or liquid emissions , “Such examples
include pharmaceutical companies that may mix powders in open vessels
holding or containing liquid during a manufacturing process”)

•Deformation Processes (Alteration in the shape or dimensions of an object

as a result of the application of stress to it)

•Material Removal
 Property Enhancing Processes

v Processes to improve mechanical or physical properties

of the work material.

v These processes do not intend alter the shape of the part.

v These processes are commonly called Heat Treatment

Processes and they include various annealing (Hardening
something by heat treatment) , sintering (Cause, ores or powdery
metals, to become a coherent mass by heating without melting) and
strengthening processes.
 Surface Processing Operations

v Operations to alter the surface of a work material

are called surface processing operations . These
include

o Cleaning
o Surface Treatments
o Coating and Thin Film Deposing
 Assembly Operations
v Permanent Joining Operations
oWelding
oSoldering
oBrazing
oAdhesive Bonding

v Mechanical Fasteners
oThreaded fasteners
oRivets
oPress fittings
oExpansion fittings
• Casting is a manufacturing process by
which a liquid material is usually
poured into a mold, which contains a
hollow cavity of the desired shape, and
then allowed to solidify.

• Molding or Moulding (see spelling

differences) is the process of
manufacturing by shaping raw material
using a rigid frame called a pattern.

• A mold or mould is a hollowed-out

block that is filled with a liquid like
plastic, glass, metal, or ceramic raw
materials. The liquid hardens or sets
inside the mold, adopting its shape.
Rapid prototyping
is the automatic
construction of
physical objects
using additive
manufacturing
technology.
History of Manufacturing
History of Manufacturing
History of Manufacturing
 Reading Assignment

Read Chapter No. 1 of your text book

Thank You!
See you next week