Manufacturing

Processes-I
BTMC401

Lecture 1
Introduction To Manufacturing
April 4, 2022

B A J A J I N S T I T U T E O F T E C H N O L O G Y
Introduction
▪ Observe the objects around you
▪ Can they be found in nature?
▪ Raw materials →assembled products
▪ Some objects are
▪ Single parts: nails, bolts, wires, forks etc.
▪ An assembly of a number of parts: engines, pens etc.
Introduction
▪ Manufacturing (Definition 1)
▪ Process of converting raw materials into products
▪ It includes/encompasses
▪ The design of the product
▪ The selection of raw materials
▪ The sequence of processes for making a product
▪ It is a backbone of industrialized nation
Introduction
▪ Manufacturing (Definition 2)
▪ Technological
▪ Physical & chemical process to alter geometry, properties
and/or appearance.
▪ Carried out as a sequence of operations
▪ Each operation brings material closer to final state
Introduction
▪ Manufacturing (Definition 3)
▪ Economical
▪ Transformation of materials into items of greater value.
▪ Example 1: iron ore → steel
▪ Example 2: sand → glass
▪ Example 3: petroleum → plastic
Introduction
• Materials in
manufacturing
Introduction
▪ Manufacturing Processes
▪ Processing operations
▪ One state of completion → more advanced state
▪ Assembly operations
▪ Joins 2 or more components to create assembly
Introduction
▪ Processing operations
▪ Shaping operations
▪ Property-enhancing operations
▪ Surface processing operations
Introduction
▪ Processing operations
▪ Shaping operations (To alter shape/geometry)
▪ Solidification processes
▪ Particulate processing
▪ Deformation processes
▪ Material removal processes
Introduction
▪ Processing operations
▪ Property-enhancing operations
▪ Surface processing operations
▪ Assembly operations
▪ Permanent: welding, brazing, soldering and adhesive
bonding
▪ Semi-permanent: screws, bolts and other fasteners
▪ More permanent: rivets, press fitting etc.
Introduction
Introduction
▪ Selection of manufacturing processes
▪ More than 1 method for manufacturing a part
▪ Selection
▪ Not only on shape but also on many other factors.
▪ Material properties:
▪ Example hard & brittle materials cannot be shaped. Can be
casted & machined
▪ Manufacturing processes alter the properties.
▪ Challenge to find new solutions to mfg. problems.
▪ Example: sheet metal parts.
Introduction
▪ Selection
▪ Dimensional accuracy & surface finish
▪ Better in cold working than hot working
▪ Operational & manufacturing cost
▪ Cost of tooling: Example dies can be substantial
▪ Lead time required for beginning production
▪ Effect of workpiece material on tool & die life
▪ Parts made from expensive material: lower scrap rate desired
(machining may not be more economical)
▪ No. of parts required and required production rate
▪ Net-shape manufacturing
Syllabus
▪ Unit I: Casting
▪ Unit II:
▪ Rolling & forging
▪ Extrusion & drawing
▪ Unit III: Joining
▪ Unit IV: Machining
▪ Turning
▪ Unit V: Machining
▪ Milling
▪ Broaching
▪ Gear manufacturing
Google Classroom
• Code: de5r7zn