Introduction to

Manufacturing Processes

Quoc-Nguyen Banh, PhD

Faculty of Mechanical Engineering
Ho Chi Minh City University of Technology

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Outline

• Manufacturing – Manufacturing Processes?

• Fundamental approaches of Manufacturing
• Classification of Manufacturing Processes
• Materials in Manufacturing

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Manufacturing – Manufacturing Processes?

• Manufacturing = Manu + Factus

– “made by hand”
• Producing goods for Human Being

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Manufacturing – Technological Way
• Sets of Physical and Chemical Processes to change
the Raw Materials to Products.
– Physical: Heat, force
– Chemical: doping, atomization
• Product’s function depends on:
– Geometric: Size, Shape
– Properties/Characteristics: Physical, Mechanical
– Surface finish, dimensional tolerance

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Manufacturing – Economical Way
• Value added process
• Make goods for service or use of human
being to support and improve the standard of
living

Bending

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Manufacturing Process

• Science and Technology of Manufacturing a

product
– Effectively
– Efficiently
– Economically
– Environmental Friendly
• Make more Goods with less Resources
– “5 Ms” approach: Material, Machine, Man, Method,
Money!
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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Factors to New Manufacturing Processes

• Productivity: cope with the global

competition
• Miniaturization of Products: electrical,
medical fields
• Processing of New Materials

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Basic types of Manufacturing Processes

• 1. Processing operations – transform a work

material from one state of completion to a
more advanced state
– Operations that change the geometry, properties, or
appearance of the starting material
• 2. Assembly operations – join two or more
simple components to create a new product.

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Fundamental approaches of Manufacturing
• Primary forming/shaping: solidification and
deformation base processes
• Material removal process: unwanted material is
removed to make product. Conventional and
advanced machining processes.
• Semi-finishing/finishing processes: surface finish,
closed tolerance
• Improving properties of material: Bulk material and
surface properties
• Joining: simple parts combined to make products,
such as welding, brazing, adhesive 9
ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
Classification of Manufacturing Processes
Solidification
processes

Deformation
processes
Shaping processes

Particulate processes
Conventional
machining processes
Material removal
processes
Processing Advanced machining
operations processes
Properties enhancing
Bulk material
processes

Cleaning and surface

treatments
Surface processing
operations
Coating and
deposition processes
Manufacturing
processes

Welding

Permanent joining
Brazing, soldering
processes

Adhesive bonding
Assembly operations

Threaded fasteners

Mechanical fastening
Permanent fastening
processes

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Processing Operations
• Alters a material’s shape, physical
properties, or appearance in order to add value
• 3 categories of processing operation
– 1. Shaping operations – alter the geometry of the
starting work material
– 2. Property-enhancing operations – improve the
physical properties without changing shape
– 3. Surface processing operations – to clean, treat,
coat, or deposit material on exterior surface of the
workpiece
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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Shaping processes

1. Solidification processes – starting material

is heated liquid or semifluid
2. Particulate processes – starting material
consists of powders
3. Deformation processes – starting material is
a ductile solid (commonly metal)
4. Material removal processes – starting
material is a ductile or brittle solid
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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Solidification processes

• Starting material is heated sufficiently to

transform it into a liquid or highly plastic state.
– Examples: sand casting, plastic injection molding,

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Particulate Processing

• Starting materials are powders of metals or

ceramics
– Usually involves pressing and sintering, in which
powders are first compressed to a primary shape and
the heated to bond the individual particles.

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Deformation processes
• Starting workpiece is shaped by application
of forces that exceed the yield strength of the
material, forging, extrusion, drawing, etc.

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Material Removal Processes
• Excess material removed from the starting
stock so what remains is the part with desired
geometry.
– Conventional machining: turning, milling, planning,
grinding, etc.
– Advanced machining: photolithography, chemical
mechanical planarization, EDM, laser cutting, etc.

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Waste in shaping processes

• Desirable to minimize waste in part shaping

– Material removal processes are wasteful in unit
operations, simply by the way they work
– Most casting, molding, and particulate processing
operations waste little material
– Terms for minimum waste processes:
• Net shape processes – when most of the starting material is
used and no subsequent machining is required
• Near net shape processes – when minimum amount of
machining is required
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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Property-enhancing processes

• Performed to improve mechanical or

physical properties of work material
– Part shape is not altered, except unintentionally
(warping of heat treated part)
– Examples: heat treatment of metals and glasses,
sintering of powdered metals and ceramics

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Surface Processing Operations

• Cleaning – chemical and mechanical

processes to remove dirt, oil, and other
contaminants from the surface.
• Surface treatments – mechanical working
such as sand blasting, and physical processes
like diffusion
• Coating and thin film deposition – coating
exterior surface of the workpiece. PVD, CVD,
etc.
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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Assembly processes
• Two or more separate parts are
joined to form a new product
• Types of operations:
1. Joining processes – create a
permanent joint.
• Solid state welding, fusion welding,
brazing, soldering and adhesive bonding
2. Mechanical assembly –
fastening by mechanical methods
• Threaded fasteners (screws, bolts, and
nuts); press fitting, expansion fits, etc.
1,050,846 rivets 20
ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Materials in Manufacturing
• Most engineer materials can be classified
into one of three basic categories:
– Metals
– Polymers
– Ceramics
• Their chemistries and also their mechanical
and physical properties are different
– These differences affect the manufacturing
processes that can be used to produced products from
them. 21
ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Material - Metals
• Usually alloy, which are composed of two or
more elements, at least one of which is
metallic.
• Two basic group:
– Ferrous metals – based on iron, comprises about
75% of metal tonnage in the world: steel (low,
medium, high carbon), stainless steel, cast iron,
wrought iron.
– Nonferrous metals – all other metallic elements and
their alloys: aluminum, copper, magnesium, nickel
titanium, etc. 22
ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Ceramics
• Compounds containing metallic
(or semi-metallic) and nonmetallic
elements
• Typical nonmetallic components
are oxygen, nitrogen, and carbon
• For processing, ceramics divided
into:
1. Crystalline ceramics – includes:
traditional ceramics: clay, modern
ceramics: alumina (Al2O3)
2. Glasses – mostly based on silica
(SiO2) 23
ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Polymers

• Compound formed of repeated structural

units called Monomers, whose atoms share
electrons to form very large molecules

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Polymers – 3 categories
1. Thermoplastic polymers – can
by subjected to multiple heating
and cooling cycles without
altering molecular structure
2. Thermosetting polymers –
molecules chemically transform
(cure) into a rigid structure –
cannot be reheated
3. Elastomers – show significant
elastic behavior 25
ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 In addition - composite
• Non-homogeneous mixtures of the other
three basic types rather than a unique category

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 Material - hierarchy

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ME2071 – Manufacturing Processes Q-N Banh, Dept. Manufacturing Engineering
 THANK YOU
FOR YOUR ATTENTION!

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