MANUFACTURING PROCESS 1

(DPT 110)
Introduction Manufacturing 1
By: Mr. Leong Kean Wei
 https://www.powtoon.com/c/ebsBSXd94M1/1/m

Definition of Manufacturing
According to Serope Kalpakjian & Steven R. Schmid:
⚫ Manufacturing is the process of converting raw
materials into products.

(It includes;
⚫ The design of products.
⚫ The selection of raw materials.
⚫ The sequence of processes through which the product will be
manufactured.)
 Definition of Manufacturing
According to Mikell P Groover :
Manufacturing is the application of physical and chemical
processes to alter the geometry, properties, and/or appearance of a
starting material to make parts or products.
 Definition of Manufacturing
According to Mikell P Groover :
Manufacturing is transformation of materials into items of
greater value by means of one or more processing and/or
assembly operations.
 Manufacturing Process
Manufacturing processes are the steps through which raw
materials are transformed into a final product.
The manufacturing process begins with the creation of the
materials from which the design is made.
These materials are then modified through manufacturing processes
to become the required part.
Manufacturing processes can include treating (such as heat treating
or coating), machining, or reshaping the material.
The manufacturing process also includes tests and checks for
quality assurance during or after the manufacturing, and planning
the production process prior to manufacturing.
Classification of Manufacturing
Processes
 Process Overview

1. Subtractive
2. Additive
3. Continuous
4. Net shape
 Process Overview
1. Subtractive
Example: Milling, Turning, Grinding, etc.
2. Additive
Example: Rapid Prototyping, Welding, etc
3. Continuous
Example: Plastic extrusion, etc
4. Net shape (or Near Net Shape)
Example: Metal casting, Powder Compaction, etc
Basic Manufacturing Processes
1. Casting and Foundry
2. Forming or Metalworking
3. Machining
4. Joining and Assembly
5. Rapid Prototyping
6. Other (Testing, Material Handling,
etc)
 Casting and Foundry
⚫ In one step raw materials are transformed into a desirable shape
⚫ Parts require finishing processes
⚫ Excess material is recyclable
 Casting and Foundry
Basic Casting Process

1. A mold is created – A cavity that holds the molten material in a

desired shape until it is solidified
Multiple-use mold
Single-use molds
2. Material is heated to a specified temperature
3. Molten material is poured into a mold cavity
4. Molten material solidifies into the shape of the cavity
5. Casting or mold is removed
6. Casting is cleaned, finished, and inspected
 Forming and Metalworking
⚫ Utilizes material that has been cast
⚫ Modify the shape, size, and physical properties of the material
⚫ Hot and cold forming
 Forming and Metalworking
⚫ Rolling – Material passes through a series of rollers, reducing
its thickness with each pass
⚫ Forging – Material is shaped by the controlled application of
force (blacksmith)
 Forming and Metalworking
⚫ Extrusion – Material is compressed and forced through a die
to produce a uniformed cross section
 Forming and Metalworking
⚫ Wire, rod, and tube drawing – Material is pulled through a die
to produce a uniformed cross section.

⚫ Cold forming and forging – Slugs of material are squeezed into

dies.
 Machining
⚫ Controlled removal of material from a part to create a
specific shape or surface finish
⚫ Cutting element is used
⚫ Movement must exist between the part and cutting
element
 Joining and Assembly
Can you think of a product with only one part?
⚫ Most products consist of multiple parts that are
assembled to form a finished product.
⚫ Typical assembly processes include: Mechanical
fastening; soldering and brazing, welding; adhesive
bonding
 Rapid Prototyping
⚫ Additive process
⚫ Parts are produced directly from software applications
⚫ Example of rapid prototyping systems :
⚫ stereolithography (SLA),
⚫ selective laser sintering (SLS),
⚫ fused deposition modeling (FDM),
⚫ laminated object manufacturing (LOM), etc.
Other Manufacturing Processes
⚫ Testing

⚫ Transportation

⚫ Material handling
⚫ Packaging
 Technology
⚫ Technology is the application of science or knowledge to
commerce and industry. Many fields of science have
benefited from technology, as well as commerce and
industry over the many centuries of human history.
Perhaps the earliest known use of technology was in the
Stone Age when the first knife or shovel was made from a
piece of stone or obsidian. Technology has obviously
come a long way since then.
 Traditional v/s Non-traditional
Manufacturing Processes
⚫ Traditional / Conventional Manufacturing process is a
process rely on harder tool to remove material. There must
have a contact between tools/cutter with material to be cut.
 Non- Traditional/Advanced manufacturing Process
⚫ Non-traditional manufacturing processes is defined as a group of
processes that remove excess material by various techniques involving
mechanical, thermal, electrical or chemical energy or combinations of
these energies but do not use a sharp cutting tools as it needs to be used
for traditional manufacturing processes.

⚫ Extremely hard and brittle materials are difficult to machine by

traditional machining processes such as turning, drilling, shaping and
milling.

⚫ Some reason for Advanced manufacturing process:

⚫ Very hard fragile materials difficult to clamp for traditional machining

⚫ When the workpiece is too flexible or slender
⚫ When the shape of the part is too complex
 A Major With An Impact

“Technology is the link between science and people, and

manufacturing engineering technologists are leaders in
technology and managers of innovation.”