Manufacturing Processes

ME 335
3Ch
INTRODUCTION
 Manufacturing

It is the application of physical and chemical

processes to alter the geometry, properties
of a given material to make product.

•It can be also defined as: the transformation

of material into product of greater value by
physical or mental effort.
Two ways to define manufacturing:
(a) as a technical process and
 Two ways to define manufacturing:
(b) as an economic process
 Table1: Manufactured Products

Industry Typical Products

Aerospace Commercial and military aircraft
Automotive Cars, trucks, buses, …….
Basic Metals Iron and steel, Aluminum, Copper
Computers Main frame and personal computer
Electronics TVs, VCR, Audio equipments
Machines Workshop machines for cutting
Glass, Ceramic
Heavy machinery
Materials in Manufacturing
Metal,
•Metals
Ceramic, Metals
Metal,
composite
• Ceramics Polymer,
composite
• Polymers
• Composites
Ceramics Polymers

Ceramic,
Polymer,
composite
 Idea

Traditional Steps Required to Convert an

Original concept (invention – research)

Idea into a finished

Design sketches Product
(preliminary design)

Working drawing (development)

First model (prototypes)

Testing (verification)

Revised model (innovation)

Production
drawing

Material specification Tool selection and

design
Production planning Tool selection and
and scheduling design
Process selection Tool installation and
checking

Manufacturing
Manufacturing system versus production
system
• A collection of operations and processes
used to obtain a desired product.

Material
Energy Goods, products
Demand Manufacturing Information
Social political System Service
Information Defectives and scrap
Manufacturing system ≡ Arrangement of
manufacturing processes

Controlling of this system means controlling

of:
• material movement
• inventory level
• product quality
• output rate
 Production System

Production system includes: people, money,

equipments, material and supplies,
markets, managements and the
manufacturing system
 Classification of Manufacturing
Systems

• Job shop
• Flow shop or flow line
• Cellular shop
• Project shop
• Continuous process
 Types and examples of manufacturing systems
Type of Examples
Manufacturing Service a Product b
System
Job shop Auto repair, Hospital, Machine shop, Metal fabrication,
Restaurant, University Custom jewelry FMS
Flow shop or X-ray, Cafeteria, College TV factory, Auto assembly line
flow line registration, Car wash
Cellular shop c Fast-food restaurant Family of "turned" parts, Composite
(Kentucky Fried Chicken, part families, Design families,
Wendy's), Food court at Manned cells, Robotic cells
mall, 10-minute oil change
Project shop Producing a movie, Locomotive assembly, Bridge
Broadway play, TV show construction, House construction
Continuous Telephone company, Oil refinery, Chemical plant
process Phone company

a) Customer receives a service or perishable product.

b) Products can be for customers or for other companies.
c) New design of manufacturing system.
 Characteristics of basic manufacturing system

Characte Continuou
Job Shop Flow Shop Project Shop Linked Cells
ristics s Process
General purpose; Specialized
Types of Single purpose; single Simple, customized
Flexible, general purpose mobile, manual , high
machines function single- cycle
automation technology
U-shaped, sequenced to
Design of Project or fixed-
Functional or process Product flow layout Product flow for family of parts,
processes position layout
overlapping
Setup Rare and
Long, variable, frequent Long and complex Variable, every job Short, frequent, one touch
time expensive
Workers Single functioned; highly One function; lower-
Specialized, highly Sill level
skilled: one worker-one skilled one worker- Multifunctional, respected
skilled varies
machine one machine

Inventori Large inventory to Large to provide Variable, usually

Very small Small
es (WIP) provide for large variety buffer storage large
Lot sizes Small to medium Large lot Small lot Very large Small
Manufact
Long, variable Very fast,
uring Long, variable Short, constant time Short, constant
lead constant
lead time
 Cycles of activities in a computer-integrated
manufacturing system
Computer Integrated Manufacturing
(CIM)
 Computer Aided Design
1- Geometric modeling
2- Engineering analysis
3- Design review and evaluation
4- Automated drafting

Database relationship to design and manufacturing

 Computer-Aided Manufacturing

– Numerical control and CNC programming

– Production planning and scheduling
– Tool and fixture design

CAPP (computer aided process planning)

can be variant or generative
Classification of Manufacturing Processes

Casting, Forming Machining Joining and Surface Heat Electronic

boundary, or (material assembly possessing treatment manufacturing
molding removal) operations technologies
processes

1- Bulk 2- Sheet metal 3- Powder metallurgy

 1- Casting process

Some of casting techniques are following:

• Sand casting
• Die casting
• Centrifugal casting
• Investment casting
• Continuous casting
Continuous casting
Sand Casting
• Die casting
Centrifugal casting

Horizontal Vertical
Investment casting
 2- Forming

(a) Hot forming processes (bulk forming)

• Rolling
• Forging
• Extrusion
• Drawing of sheets and plates
• Pipe welding
• Piercing
Rolling
Forging

Closed Die

Open Die
Extrusion
Drawing of sheets and plates
(b) Cold forming process (sheet metal forming)

• Bending
• Shearing
• Deep drawing
• Stretch bending
• Spinning
(c) Powder metallurgy

• Mixing and blending

• Compacting
• Sintering
• Hot isostatic pressing
 3- Machining Process

(A) Traditional machining

• Turning
• Boring
• Drilling
• Milling
• Broaching, Sawing, Filling
• Shaping and planning
• Grinding (abrasive machining)
 3- Machining Process

(A) Traditional machining

• Turning
• Boring
• Drilling
• Milling
• Broaching, Sawing, Filling
• Shaping and planning
• Grinding (abrasive machining)
Turning
Drilling
Milling
(B) Non-traditional machining processes

– Abrasive jet machining

– Water jet machining
– Ultrasonic machining
– Electrochemical machining
– Laser machining
– Electro-discharge machining
 4- Joining and assembly

• Gas flame process (Oxyfuel gas welding)

• Electric arc welding
• Resistance welding
• Brazing and soldering
• Adhesive bonding and mechanical
fasteners.
5- Surface processing operations

–Chemical cleaning
–Mechanical cleaning
–Diffusion and ion implantation
–Electro plating
–Physical vapor deposition
–Chemical vapor deposition
–Organic coating
–Porcelain and ceramic coating
6- Heat treatment
»Hardening
»Tempering
»Annealing
»normalizing
Casting Movie