Introduction to

Manufacturing
Week 1
Manufacturing

Societal pressures, Government regulations,

company plans and policies, etc
Customer
needs

manufacturing Products
Raw
material

People, money, machines and automation

 What is Manufacturing?
 A sequence of operations, often done on a
machine or at a given area.
 Manufacturing is the application of physical
and chemical processes to change the
geometry, properties, and appearance of a
starting material to make parts or products for
a given application

3
(a)
 Purpose of Manufacturing

 Manufacturing is the transformation of materials

into items of greater value by means of one or more
processing and/or assembly operations

4
Manufacturing a Product: General
Considerations

 Material Selection
 Processing Methods
 Final Shape and Appearance
 Dimensional and Surface Finish
 Economics of Tooling
 Design Requirements
 Safety and Environmental Concerns
Choosing Methods of Manufacturing
Manufacturing Processes for Metals

 Casting: expendable mold and permanent mold.

 Forming and Shaping: rolling, forging, extrusion,
drawing, sheet forming, powder metallurgy, molding

 Machining: turning, boring, drilling, milling, planing,

shaping, broaching, grinding, ultrasonic machining,
chemical machining, electrical discharge machining (EDM),
electrochemical machining, high-energy beam machining

 Joining: welding, brazing, soldering, diffusion bonding,

adhesive bonding, mechanical joining

 Finishing: honing, lapping, polishing, burnishing,

deburring, surface treating, coating, plating
Casting Processes

Introduction of molten metal into a mold cavity;

upon solidification, metal conforms to the shape
of the cavity.

Die Casting Sand Casting

Forming and Shaping Processes

Bulk deformation processes that induce shape

changes by plastic deformation under forces
applied by tools and dies.

Forging

Extrusion
Machining Processes

Material removal from a work piece: cutting,

grinding, nontraditional machining processes.

Lathe Machine
Milling
NC Machine Tool and Controller
NC Punch Press Machine
Manufacturing Processes for Plastics

 Plastics are shipped to manufacturing plants

as pellets or powders and are melted just
before the shaping process. Polymers melt at
relatively low temperatures and are easy to
handle.

 Plastics can be molded and formed, as well as

machined and joined, into many shapes with
relative ease.
Injection Molding of
Plastics
Selective Laser Sintering
System
 Manufacturing Industries

ISIC Code
 Food, beverages, tobacco 31
 Textiles, apparel, leather and fur products 32
 Wood and wood products, cork 33
 Paper, printing, publishing, bookbinding 34
 Chemicals, coal, petroleum, & their products 35
 Ceramics, glass, mineral products 36
 Basic metals, e.g., steel, aluminum 37
 Fabricated products, e.g., cars, machines, etc. 38
 Other products, e.g., jewelry, toys 39
 Production Quantity (Q)

 Number of units of a given part or product produced

annually by the plant
 Three quantity ranges:
1. Low production – 1 to 100 units
2. Medium production – 100 to 10,000 units
3. High production – 10,000 to millions of units
 Product Variety (P)

 Number of different product or part designs or types

 ‘Hard’ product variety – products differ greatly
 Few common components in an assembly

 ‘Soft’ product variety – small differences between

products
 Many common components in an assembly
 Low Production Quantity (Qlow)

Job shop – makes low quantities of specialized and

customized products
 Products are typically complex (e.g., specialized

machinery, prototypes, space capsules)

 Equipment is general purpose

 Plant layouts:

 Fixed position

 Process layout
Fixed-Position Layout
Process Layout
 Medium Production Quantities (Qmed)

1. Batch production – A batch of a given product is

produced, and then the facility is changed over to
produce another product
 Changeover takes time – setup time
 Typical layout – process layout
 Hard product variety
2. Cellular manufacturing – A mixture of products is
made without significant changeover time between
products
 Typical layout – cellular layout
 Soft product variety
Cellular Layout
 High Production (Qhigh)

1. Quantity production – Equipment is dedicated to the

manufacture of one product
 Standard machines tooled for high production
(e.g., stamping presses, molding machines)
 Typical layout – process layout
2. Flow line production – Multiple workstations
arranged in sequence
 Product requires multiple processing or assembly
steps
 Product layout is most common
Product Layout
PQ Relationships

Q
Production quantity and variety

Production quantity: low (<100), medium

(102-104), high
(>104)
Production variety: low, medium,
high
soft, hard
Selecting manufacturing processes

 Manufacturing process decisions

 Deformation processes
 Casting processes
 Sheet metalworking
 Polymer processing
 Machining
 Finishing
 Assembly
 Material compatibilities / Process capabilities
 Material costs, Tooling costs, Processing costs
How would we manufacture a mountain bike ?
Top Handle Bar
Tube
Seat
Saddle
Post
Rear Brake Fork
Down Front
Tube Brake

Rear Pedal
Derailleur
 Manufacturing process decisions

 How do we choose the specific manufacturing

processes?
 How do the selected materials influence the choice of
manufacturing processes?
 Would product function or performance issues
influence our choice of processes?
 What criteria should we use to select processes?
 Which criteria are more important?
 Who will make the final decisions?
 Parts undergo sequence of processes

 Primary - alter the (“raw”) material’s basic shape or form.

Sand casting
Rolling
Forging
Sheet metalworking
 Secondary - add or remove geometric features from the basic forms
Machining of a brake drum casting (flat surfaces)
Drilling/punching of refrigerator housings (sheet metal)
Trimming of injection molded part flash
 Tertiary - surface treatments
Polishing
Painting
Heat-treating
Joining
 Types of manufacturing processes

Manufacturing
Processes

Sheet Polymer
Deformation Casting Metal Processes Machining Finishing Assembly

Extrusion Centrifugal Bending Blow molding Boring Anodizing Automated

Forging Die casting Blanking Casting Drilling Honing Bonding
Rolling Investment Drawing Compression molding Facing Painting Brazing
Bar drawing Permanent mold Punching Extrusion Grinding Plating Manual
Wire drawing Sand casting Shearing Injection Molding Milling Polishing Riveting
Spinning Thermoforming Planing Soldering
Transfer molding Turning Welding
Sawing
ECM, EDM
Deformation processes

 Rolling
 Extrusion
 Drawing
 Forging
 Rolling (of ductile materials)

Rollers in compression

thick
slab

thin
sheet

Plastic deformation
 Rolling

bloom
structural

ingot
coil
slab sheet

billet bar rod

Extrusion

Extrusion
die

Cross
sections
Ram

Billet
Drawing

Drawing die

Cross
sections

Pulling
Billet force
 Forging (closed-die)

Ram pressure

Flash
Blocked
preform

Gutter
Casting Processes

 Sand casting
 Die casting
 Investment casting
 Sand casting (closed-mold)

Cope
Riser
Core
Flask Sprue

Parting Runner
line
Drag Gate
Die casting

Stationary Moving
die die

Molten
metal

Plunger Ejector pins

Sprue

Parting line
Investment casting
Ceramic mold
4-part pattern tree (hardened slurry)

Wax pattern
is cast

Wax removed Molten metal Ceramic mold is

by melting solidifies in cast removed
Sheet Metalworking

 Bending
 Blanking
 Drawing
 Punching
 Shearing
 Spinning
Sheet metal drawing

Punch ram
Punch

Blank
holder
Clamp
Die force

Blank
Drawn part
Polymer Processes

 Compression molding
 Transfer Molding
 Blow molding
 Injection molding
Compression molding

Heated
mold Ram Pressure

Charge

Part
Transfer molding

Ram pressure

Ram

Heated
mold
Sprue

Charge
Part
 Blow molding

Air
Molten Mold blown
parison is halves into Part is
extruded close parison removed

Extruder
air injector

parison
 Injection molding

Cavity half Core half

of mold of mold

Pellets

Feed hopper
Barrel

Ejector pins

Shear-heating Sprue

Mold closure direction

Parting
plane/surface Fixed Moving
 Machining processes

Manufacturing
Processes

Sheet Polymer
Deformation Casting Metal Processes Machining Finishing Assembly

Extrusion Centrifugal Bending Blow molding Boring Anodizing Automated

Forging Die casting Blanking Casting Drilling Honing Bonding
Rolling Investment Drawing Compression molding Facing Painting Brazing
Bar drawing Permanent mold Punching Extrusion Grinding Plating Manual
Wire drawing Sand casting Shearing Injection Molding Milling Polishing Riveting
Spinning Thermoforming Planing Soldering
Transfer molding Turning Welding
Sawing
ECM, EDM
 Machining – removal of material…

Sawing –using a toothed blade.

Milling – from a flat surface by a rotating cutter tool.
Planing – using a translating cutter as workpiece feeds.
Shaping - from a translating workpiece using a stationary cutter.
Boring - increasing diameter of existing hole by rotating the workpiece.
Drilling- using a rotating bit forming a cylindrical hole.
Reaming – to refine the diameter of an existing hole.
Turning - from a rotating workpiece.
Facing - from turning workpiece using a radially fed tool.
Grinding - from a surface using an abrasive spinning wheel.
Electric discharge machining - by means of a spark.
Shaping processes

General aim: Minimize waste and scrap!!!

- Net shape processes  no subsequent machining

- Near net shape processes  minimum machining

Turning Drilling Milling

Master Engineering &
Management
Surface roughness
Machining process considerations
solid material machining material removed

sawing, turning, boring, milling,

drilling, grinding, ECM

hardness, strength of material

shear forces = strong jigs & fixtures
tool/bit wear, replacement
size of workpiece, fit machine?
volume removed
rate of removal, hp needed
tolerances
operator skill, CNC
Add to your costs (materials, tooling, processing)
notes
Manufacturing processes

1) Processing operations
2) Assembly operations
- Permanent joining: welding, brazing, adhesives
- Mechanical assembly: bolts, screws, rivets, etc.
3) Production machines and tooling
- Machine tools: lathe, milling machine, etc.
- Presses, forge hamers, rolling mills
- Welding machines and equipment
- General and special purpose equipment
- Tooling
Master Engineering &
Management
 Finishing processes

Manufacturing
Processes
protection?
Sheet Polymer
Deformation Casting Metal Processes Machining Finishing Assembly

Extrusion Centrifugal Bending Blow molding Boring Anodizing Automated

Forging Die casting Blanking Casting Drilling Honing Bonding
Rolling Investment Drawing Compression molding Facing Painting Brazing
Bar drawing Permanent mold Punching Extrusion Grinding Plating Manual
Wire drawing Sand casting Shearing Injection Molding Milling Polishing Riveting
Spinning Thermoforming Planing Soldering
Transfer molding Turning Welding
Sawing
ECM, EDM
 Assembly processes
– fastening / joining of 2 or more components

Manufacturing
Processes

Sheet Polymer
Deformation Casting Metal Processes Machining Finishing Assembly

Extrusion Centrifugal Bending Blow molding Boring Anodizing Automated

Forging Die casting Blanking Casting Drilling Honing Bonding
Rolling Investment Drawing Compression molding Facing Painting Brazing
Bar drawing Permanent mold Punching Extrusion Grinding Plating Manual
Wire drawing Sand casting Shearing Injection Molding Milling Polishing Riveting
Spinning Thermoforming Planing Soldering
Transfer molding Turning Welding
Sawing
ECM, EDM permanent?
Summary

 Manufacturing process decisions

 Deformation processes
 Casting processes
 Sheet metalworking
 Polymer processing
 Machining
 Finishing
 Assembly
What is Manufacturing - Dimensions

 Product Creative Characteristics (How new products

differ from previous ones)
 Product Size (physical dimension)
 Product Complexity/Sophistication
 Scale
 Material Flow
 Degree of Automation
 Organization
Product Creative Characteristics

 How new products differ from previous ones

 Selection design (Lego houses)

 Configuration design (automobiles)

 Parametric design (portable generators)

 Redesign (New VCR)

 Original design (the original VCR, the Space

Shuttle)
Product Size (physical dimension)

 A individual device on a computer chip

 A computer chip
 A television
 An automobile
 A Navy cruiser
 Number of parts/amount of
electronics/intelligence

 A nail
 A TV
 A car or truck
 A 777 aircraft
 A satellite
 Mars sojourner
 A CPU chip (5 million
components)
Scale

 Number of people and disciplines involved

 Artisan

 Garage machine shop

 General Motors, Arlington Plant

 Boeing Commercial Aircraft

 Engineering firms who make bridges, chemical

plants or dams
 Material Flow

 How the work is organized on the shop floor

 Discrete parts (traditional job shop)

 Cellular (New machine shops)

 Semicontinuous

 Continuous flow (bottle making)

 Process (chemical industry and oil refineries)

 Degree of Automation

 How much automation exists on the shop floor

 Manual

 Machine assisted

 Computer controlled - islands of automation

 Computer integrated manufacturing

Company Organization

 How the enterprises organize to produce

 Traditional

 Lean

 Agile

 Next Generation