MANUFACTURING PRACTICES

MANUFACTURING PRACTICES
Byy
Mr.NABAL SINGH
Assistant Professor,
Professor
Department of Mechanical Engineering,,
Jagannath University,
University Chaksu ,Jaipur
Jaipur
Mail ID:- nabaliitb10@gmail.com
 Manufacturing
“The Process of Converting Raw 
Materials Into Products”
 Manufacturing processes
Manufacturing processes
• Manu Factus
Manu Factus : Latin for 
: Latin for ‘made
made by hand
by hand’

• Definition:
• A Well organized method of converting raw material 
to end product
to end product

• End Product: Value and utility added to output
End Product: Value and utility added to output
Manufacturing a Product: General 
Considerations
• Material Selection 
• Processing Methods
Processing Methods
• Final Shape and Appearance
• Dimensional and Surface Finish
• Economics of Tooling
• Design Requirements           
• Safety and Environmental Concerns 
Safety and Environmental Concerns
Choosing Methods of Production
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Use a Selection Chart
Economic and Technolgical defination 
of Manufacturing
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Survey  of Manufacturing Processes
• Casting: expendable mold and permanent mold.
• Forming and Shaping:
F i d Sh i rolling, forging, extrusion, drawing, sheet 
forming, powder metallurgy, molding 
• Machining: turning, boring, drilling, milling, planing, shaping, 
turning boring drilling milling planing shaping
broaching, grinding, ultrasonic machining, chemical machining, 
electrical discharge machining (EDM), electrochemical machining, 
high‐energy
high energy beam machining 
beam machining
• Joining: welding, brazing, soldering, diffusion bonding, adhesive 
bonding, mechanical joining 
• Finishing: honing, lapping, polishing, burnishing, deburring, surface 
treating, coating, plating
 Casting Processes
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Introduction of molten metal into a mold cavity; upon 
solidification, metal conforms to the shape of the cavity. 
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Die Casting Sand Casting
 Forming and Shaping Processes
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Bulk deformation processes that induce shape changes 
by plastic deformation under forces applied by tools 
and dies.

Forging

Extrusion
 Manufacturing Processes
for Plastics

• Plastics are shipped to manufacturing plants as 
pellets or powders and are melted just before the
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
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Materials
 Properties of Materials
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Mechanical Properties: strength, toughness, ductility, 
hardness elasticity fatigue creep
hardness, elasticity, fatigue, creep. 
Behavior Under Loading: tension, compression, 
bending torsion shear
bending, torsion, shear.
Physical Properties: density, specific heat, thermal 
expansion, thermal conductivity, melting point, electrical 
expansion thermal conductivity melting point electrical
and magnetic properties.
Chemical Properties: oxidation, corrosion, degradation, 
Chemical Properties: oxidation corrosion degradation
toxicity, flammability.
 Types of Materials
Ferrous Metals: iron and steel. 
Nonferrous Metals and Alloys: aluminum, 
magnesium, copper, nickel, titanium, superalloys, 
magnesium, copper, nickel, titanium, superalloys,
beryllium, zirconium, low‐melting alloys, precious metals.

Pl ti : thermoplastics, thermosets, elastomers.
Plastics th l ti th t l t

Ceramics: glass, graphite, diamond. 
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Composite materials: reinforced plastics, metal‐matrix 
and ceramic matrix composites honeycomb structures
and ceramic‐matrix composites, honeycomb structures. 
 Ferrous Metals: Applications
Ferrous Metals: Applications
• Structural:
Structural: building structures, concrete 
building structures, concrete
reinforcement 
• Automotive: chassis, engine parts, drive train, body 
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parts 
• Marine: ship hulls, structure, engines 
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• Defense: tanks, weapons 
• Consumer
Consumer Products: appliances, recreational vehicles, 
Products: appliances recreational vehicles
toys, utensils and tools 
 Nonferrous Metals: Applications
Nonferrous Metals: Applications
• Architectural: aluminum windows and doors 
Architectural: aluminum windows and doors
• Automotive: aluminum engine blocks, copper 
wiring mag wheels 
wiring, mag wheels
• Marine: brass/bronze fittings, bearings, propellers 
• Defense: brass shell casings 
• Consumer Products: electrical wiring, utensils, 
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jewelry, electronics 
 Plastics (Polymers)
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• Compared to metals, plastics have lower density, 
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strength, elastic modulus, and thermal and 
electrical conductivity, and a higher coefficient 
of thermal expansion 

• The design of plastic parts should include 
considerations of their low strength and 
stiffness, and high thermal expansion and low 
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resistance to temperature. 
 Plastics: Applications
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• Architectural: electrical and thermal insulation, weather 
c ec u a e ec ca a d e a su a o , ea e
seals, carpets, wall coverings, paint 

• Aerospace:
Aerospace: electrical and thermal insulation, instrument 
electrical and thermal insulation instrument
panels, upholstery, seals 

• A
Automotive: body panels, instrument panels, upholstery, 
t ti b d l i t t l h lt
electrical and thermal insulation, seals, hoses, tires 

• Consumer Products: toys, sporting goods, appliances, tools, 
utensils, clothing, shoes, packaging