Manufacturing Technology II

Dr. Abdullah Elfar

Mechanical Engineering
Helwan University

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 Introduction to the staff

• Instructor Dr. Abdullah Abdullatif Elfar

• Office Engineering Building A
• E-Mail Abdullah.Elfar@bue.edu.eg
elfarabdo@gmail.com
• Classroom According to the group
• Class Schedule Saturday
•Assistant Eng. Ibrahim Elshimi

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 Textbooks
• “S. Kalpkjian, S.R. Schmid: " Manufacturing
Engineering and Technology" 4th edition,
Prentice Hall, 2001
• Hwaiyu Geng: "Manufacturing Engineering
Handbook" McGraw Hill, 2004
• Lecture Notes
• Lecture Slides

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 Course Overview
• The course provides the fundamentals of manufacturing
technology. It clarifies the applications and limitations of the
different processes focusing on machining.
• It also points out the design considerations of the parts for
each type of process. It also pinpoints the basics of
manufacturing systems and production systems.

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 Grading Scheme

weighted in-class

Final Assessment
Mid-Term Exam

Assignments
assignments
Two equally

Workshop
Course Name

Manufacturing
20 % 30 % 10 % 40 %
Technology II

• Homework are due at the beginning of class on the due

date
• No late homework is acceptable 5
Chapter 1: Introduction and
overview of manufacturing
processes

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 Role of Manufacturing in our life
• The standard of living in any society is
determined, primarily, by the goods and services
that are available to its people
• Added Value: it is the value when converting the
material from one form to another ( ex: a clay is
mined with a value but when it is used to make a
diner plate, electrical insulator, the added value is
high)
• The more efficiently materials can be produced
and converted into the desired products, the
higher the added value

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 Role of Manufacturing in our life
• In manufacturing: materials, men, methods
and equipment are interrelated factors that
must together achieve low cost, superior
quality and on-time delivery.
• This is achieved by better understanding of
materials, processes and equipment +
understanding of the Manufacturing systems
by the decision makers

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 Engineering Products

• Section of an automotive engine - the Duratec V-6 - showing various components and the materials used
in making them. Source: Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian
and Steven R. Schmid.
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Role of Engineers in Manufacturing

Manufacturing cost vs selling cost of a product

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Role of Engineers in Manufacturing

• Design for manufacturing

• Design for usability 11
Role of Engineers in Manufacturing

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Manufacturing and Production
Systems

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 Manufacturing and Production
Systems
• Production Systems includes the
manufacturing system and services
(transportation, banking, finance, savings,
insurance, health care, communication,
entertainment etc..). It is the total company

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Manufacturing Processes: Casting

Schematic illustration of various casting processes

 Manufacturing Processes: Forming and Shaping

Extrusion and drawing

Schematic illustration of various bulk deformation processes

Manufacturing Processes: Forming and Shaping

Schematic illustration of various sheet metal forming processes

Manufacturing Processes: Forming and Shaping

Schematic illustration of various

polymer processing methods
Manufacturing Processes: Machining

Schematic illustrations of various machining

and finishing processes.
 Manufacturing Processes: Joining

Schematic illustration of various joining processes

 Importance of understanding process
technology
• Understanding the process technology of the
company is very important for everyone in the
company.
• Manufacturing technology affects the design
of the product and the manufacturing system,
the way in which the manufacturing system
can be controlled, the types of people
employed, and the materials that can be
processed.

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 Course Contents
• Introduction
• Overview of Machining Technology
• Theory of Metal Cutting
• Centre Lathe and Special Purpose Lathes
• Reciprocating and Milling Machines
• Abrasive Process, Sawing, Broaching & Gear
Cutting
• CNC Machine Tools
• Micromachining
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 An Example for the workshop
assignments

Fill in the following table for the part you are producing only:

Operation No Operation Name Machine Tool

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 Review Questions
• What is the role of manufacturing in the standard of living of a
country? Give an example in Egypt
• What are the items of the selling price-manufacturing cost?
• Discuss the role of engineers in manufacturing
• What is the manufacturing system and what is the production
system?
• Is a cutting tool the same thing as a machine tool?
• What are the main types of manufacturing processes? Give
examples
• What are the traditional steps required to convert an idea into a
finished product
• Select a product, dismantle it, find the different components and
suggest a material and a manufacturing process for it.

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