MT- 206

Manufacturing Process
Lect. # 3
General Introduction

Engr. Dr. Nazeer Ahmad Anjum

Mechanical Engineering Program
University of Engineering Taxila
 Manufacturing capability

Manufacturing capability refers to the

technical and physical limitations of any
manufacturing firm
We can identify several dimensions of this
capability:
 Technological processing capability
 Physical product limitations
 Production capacity.

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 Manufacturing capability
Technological processing capability: it’s
the available set of manufacturing process
 Examples:
Certain plants or firm performing machining
operations, roll steel sheet, casting, forging….
Machine job can not produce car.

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 Manufacturing capability
Physical product limitations: one of the
most important thing that identify the
capability of firm is the weight and size of
product.
 Examples:
Large and heavy products are difficult to
move, to move these products the firm must
be equipped with cranes of required load.
Smaller parts and products made in large
quantities can be moved by conveyer or
other means. 5
 Manufacturing capability
Production capacity: is the production
quantity that can be produced in a given
time (e.g. month, or year).
 Plant capacity: maximum rate of
production the company can achieve
under assumed operations conditions.
Shift per hours
Direct labors.

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Manufacturing Industries and Products
• Manufacturing is important to our lives. Yet, we do not
manufacture stuff just for the sake of manufacturing. We
manufacture because we want to make money!
• Industries in manufacturing is divided into three major
categories; Primary, Secondary and Tertiary
Industries.
1. Primary industries are those that cultivate and exploit
natural resources, such as agriculture and mining.
2. Secondary industries are those that take the outputs
of the primary industries and convert them into
consumer and capital goods. (This type is of our
concern because it is engaged directly in
manufacturing).
3. Tertiary industries constitute the service sector of the
economy..
Manufacturing Industries and Products
• Manufactured products: Final products by
industries such as Aerospace, Automotive, Basic
Metals, Computers, Electronics, Glass, Ceramics
can be divided into two major classes:

1. Consumer Goods: Products purchased directly by

consumers, such as cars, PCs, TVs, etc.

2. Capital Goods: Products purchased by other

companies to produce goods and supply services,
such as aircrafts, mainframe computers, railroad
equipment, machine tools, construction equipment,
etc.
 Type of Production
Mass Production: the manufacturing of large
quantities of standardized products utilizing
assembly line technology such as mass
production of airline and automobile using special
purpose machines. The concepts of mass
production are applied to various kinds of products
to assemblies of such parts such automobile .
(over 100,000 piece/year)
Batch Production: refer to a method of
manufacturing where several of the same item are
put together at the same time. Batch production is
most common in bakeries and in the manufacture
of sports shoes, pharmaceutical ingredients 100-
5000 piece/year
 Type of Production
Job Shop Production:
Sometimes called jobbing or one-off production,
involves producing custom work, such as a one-off
product for a specific customer using general purpose
machines (making railings for a specific house,
building/repairing a computer for a specific customer,
making flower arrangements for a specific wedding
etc.) (10-100 piece/year)

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 Selecting Materials

A wide variety of materials is now available, each

having
 Its own characteristics
 Composition
 Applications
 Costs
 Advantages
 And limitations

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 Selecting Materials
 Many factors have to be considered when selecting possible
materials to fit a design and manufacturing requirement:
1. Dose the material posses the necessary mechanical,
electrical and thermal properties?
2. Can the material be formed to the desired shape?
3. Will the properties of the material alter with time during
service?
4. Will the material adversely affected by the environmental
conditions and resist corrosion and other forms of attack?
5. Will the material be acceptable on aesthetic grounds?
6. Will the material give sufficient degree of reliability and
quality? And, of course:
7. Can the product be made at an acceptable cost? 12
Classification of Engineering Materials
 Engineering materials can be classified into two or three
classifications:
1. Metallic:
 Ferrous: (iron, steel, cast iron, wrought iron)
 Non ferrous(Al its alloys, Cu its alloys, Mg its alloys
2. Non Metallic.
 Organic (polymers, wood)
 Inorganic(ceramic, glasses) Matrix polymer
3. Composite materials ??
 Metal matrix composite Reinforcement
 Ceramic matrix composite fiber glass
 Polymer matrix composite

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Composite Materials

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 Selecting Materials
Why do we study materials?
 Many engineers, whether mechanical, civil,
chemical, electrical or mechatronics will be exposed
to design problem, and the reason for this design
problem is selecting the material.
 Ex: transmission gear, the superstructure for building
or an integrated circuit board.

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Criteria to Select Proper Material

Service conditions must be characterized.

 In rare occasions dose the material posses the ideal
combination of properties- trade off one characteristic
for another.
 Ex: a material having a high strength will have a limited
ductility. In such case a reasonable compromise
between two or more properties may be necessary.

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Machinability versus Formability
Machinability: the operation where certain a mount
of the material is removed from the surface as chips.
Or the ability of the material to be shaped by removing
a certain a mount from the surface to reach the desired
shape.
Formability: it is an operation of forming the
material but without removing a certain a mount from
the surface, it can be done by knocking on or pulling
the material and delivering in another shape [ the mass
of the material before and after the process will be the
same].

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Manufacturing Characteristics of
Alloys

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Important Considerations: Selecting
Manufacturing Processes
 A wide range of manufacturing processes are used to
produce a variety of parts, shapes and sizes.
 There is usually more than one method of manufacturing a
part from a given material. Each of these processes has its
own advantages, limitations, production rates and cost
 Casting, Forming , Machining, Joining, Nanofabrication
 Selection of a particular manufacturing process depends not
only on the component or part shape to be produced, but also
on many factors such as properties of the martials.
 Brittle and hard materials, can not easily be shaped whereas
they can be cast or machined by various method

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 Solidification Processes
• Starting material is heated sufficiently to
transform it into a liquid or highly plastic state
• Examples: Casting for metals, molding for
plastics
 Deformation Processes
• Starting workpart is shaped by application of
forces that exceed the yield strength of the
material
• Examples: (a) forging, (b) extrusion
Material Removal Processes
• Excess material removed from the starting
workpiece so what remains is the desired
geometry
• Examples: machining such as turning, drilling,
and milling; also grinding and nontraditional
machining processes
 Particulate Processing
• Starting materials are powders of metals or
ceramics
• Usually involves pressing and sintering, in which
powders are first squeezed in a die cavity and
then heated to bond the individual particles
Waste in Manufacturing Processes

It is desirable to minimize waste and scrap in part

shaping
– Material removal processes tend to be
wasteful in the unit operation, simply by the
way they work
– Casting and molding usually waste little
material
 Near Net-shape Manufacturing
 Because not all manufacturing operations produce finished
products or products to desired specifications, additional
finishing operations may be necessary.
 For example, a forged part may not have the desired
dimensional accuracy; thus additional operations such as
machining may be necessary.
 Likewise, it may be difficult to produce a product using only
one manufacturing process, a part that, by design, has a
number of holes in it, necessitating additional process such as
drilling.
 Also, the holes produced by drilling process may not have the
proper roundness, dimensional accuracy, or surface
finish, thus necessitating the need for additional operations,
such as honing.
 These additional operations can contribute significantly to the
cost of a product