Manufacturing engineering I

Chapter # 1
Introduction to production process
Production process in metal industries
The word manufacture is derived from the Latin
manu factus, meaning “made by hand.”

The word manufacturing first appeared in 1683,

and the word production, which is often used
interchangeably with the word manufacturing, first
appeared sometime during the 15th century.

Manufacturing is concerned with making products.

 A manufactured product may itself be used to make
other products.

 A major advance in manufacturing occurred in the

early 1800s with the design, production, and use of
interchangeable parts, conceived by the American
manufacturer and inventor Eli Whitney (1765-1825).

 Toward the ends of C with the invention of electricity

and better engineering materials mfg operations
become more productive.
There are a large number of processes available
for the engineer for manufacture. These processes
can classified as:
1. Casting processes: is one of the oldest
manufacturing process and the only process w/r
liquid metal is used.
2. Forming processes: this are solid state mfg
processes involving minimum amount of material
wastage and faster production.
 In this process the metal may be heated to a w/c is
slightly below the solidus and then a large force is
applied such that the material flows and takes the
desired shape.𝑇 𝑂 𝑇 𝑂

 Generally this process is economical and used for

large scale production rates.

 Some of the metal forming processes are rolling, drop

forging, extrusion, wire drawing, press forging, sheet
metal operation, etc.
3. Fabrication processes: this are secondary mfg
processes w/r the starting raw materials are processed by any
of the previously described mfg processes.

 It involves joining of pieces either permanently or

temporarily so that they would perform necessary functions.

 The joining can be achieved by either both of heat and

pressure and or a joining material.

 Gas welding, electric arc welding, electric resistance

welding, soldering, brazing, cold welding are some of the
processes under this category.
4. Metal removal processes: this are also secondary
mfg processes w/r the additional unwanted material is
removed in the form of chips from blank material by
a harder tool so as to obtain the final desired shapes.

This process is normally the most expensive mfg

process b/c more energy is consumed and also a lot
of waste material is generated in the process.
Production Processes in metal working industries
Manufacturing processing is the procedure by
which materials are formed into the desired shapes.
In industries materials are formed into preliminary
shapes, near net shapes, and then the final shaping
and finishing operations are performed.
Final treatments for material property improvement
or surface improvement and assembly operations
are the final stages in the manufacturing process.
 Shaping processes can be classified into two main
categories: primary shaping processes and secondary
processing.

 The primary shaping processes form the overall shape of

the product or of the components that will be joined to
form the final product shape.

 The most common primary shaping processes are casting,

bulk deformation processes such as forging and extrusion,
sheet metal working, powder metallurgy and machining.
One process, machining, is also frequently used as
a secondary step for the other primary shaping
processes.
Thus, machining is used to improve the basic shape
produced by casting or deformation processing as
well as to produce the basic shape.
Machining is the only process considered to be
both a primary shaping process and a secondary
shaping process.
 The purpose of the secondary processing is to provide the

final shape surfaces to meet some of the product

requirements such as surface or dimensional tolerances.

1. Casting
 Casting is one of the oldest and best-known manufacturing
processes.

 It consists of pouring a liquid material, usually a metal,

into a mold and letting it cool and solidify into the desired
shape.
There are four major areas of the casting process.

 Pattern making, mold and core making, melting,

cooling and solidification.

 There are several different types of casting processes.

These processes may differ particularly in the type of
mold used, the type of pattern, and the type of
production.

 Sand casting, permanent mold casting, investment

casting, and die casting are common types of casting.
2. Powder Processing
 Powder processing is a primary shape forming process.
 Ceramic products and powder metallurgy are two major
processes that utilize powders.
 It is a near-net-shape forming process, generally used for
small, thin parts.

 A part produced via powder metallurgy generally requires few

machining operations, because the part usually has a good
surface finish.

 Powder metallurgy also allows for high production levels and

good reproducibility.
3. Bulk Deformation Process:
It is a metalworking or metal forming process in
which extensive plastic deformation occurs, and the
changes in the dimensions of the workpiece are
large.
The starting material is generally in the form of
semi finished shapes that have a high volume-to-
surface-area ratio, or high modulus.
The most common bulk deformation processes are
forging, extrusion, wire drawing, and rolling.
 Forging involves applying controlled pressure by use
of presses, hammers, dies, or other related machinery
to form the material into the desired shape.

 Extrusion is a plastic deformation process in which

metal or plastic is forced to flow through the shaped
orifice of a die.

 The parts generally formed by extrusion are of

constant cross-sectional area, with close tolerances
and good surface finishes.
 Wire drawing is similar to extrusion, since it also
involves forcing the material through a small orifice in
a die.
 However, extrusion generally involves pushing the
metal through the die.
 whereas wire drawing involves pulling the metal
through the die.
 The parts produced by wire drawing, such as wire and
bars, are generally longer and thinner than those
produced by extrusion.
 Rolling, the most common metalworking process,
involves the continuous forcing of metal between two
rotating rolls on opposite sides of the workpiece.
 Rolling is used to form final products such as structural
beams, and is also used in many cases to form
preliminary parts for other processes, such as billets,
slabs, and sheet metal.
 Parts formed by deformation processing are noted for
good surface finishes and tolerances, especially for
cold-formed parts.
4. Sheet Metal Process
Sheet metal, or sheet-forming, processes have as
the starting material rolled sheet, which has a low
volume-to-surface-area ratio, or low modulus.
The sheet metal (sheet-forming) processes change
the part's shape, but do not greatly alter the value of
the modulus.
Generally, in sheet metal forming processes, the
thickness change of the workpiece is small.
Sheet metal processing involving a press is known
as stamping.

The most common sheet metal processes are

shearing, drawing, bending, and spinning.

Shearing is used for the cutting of the sheet metal.

This procedure is used primarily to produce the
initial workpiece, called a blank, for another sheet
metal process.
Bending is a common process in which a straight
workpiece is plastically deformed into an angle.
This process is, in many cases, part of another
sheet metal process.
Spinning involves pressing a tool into a rotating
blank to form hollow shapes such as cylinders,
cones, tubes, and hemispheres.
It is usually performed on a lathe or similar
machine.
Sheet metal processing is used frequently, because
most other processes have difficulty in processing
thin materials.
High production rates are often attained, and large
production quantities are frequently produced.
Tooling costs are lower than for bulk deformation
processing because the forces required are lower
and the processing is usually done at room
temperature.
5. Machining (Metal Removal Or Cutting)
Machining involves the shaping of a part through
removal of material.
A tool constructed of a material harder than the part
being formed is forced against the part, causing
metal to be cut from it.
Machining is the dominant manufacturing process,
because it is the only process used for both primary
processing and secondary processing.
Mechanical machining is the most common type of
machining process.

The basic mechanical machining operations are

turning, drilling, milling, and shaping.

Machining is the most widely used manufacturing

process, because it can used as a primary shaping
process as well as a finishing shaping process.
6. Joining Process
Joining is concerned primarily with the assembly of
the components into subassemblies or final products.

The joining processes can be divided into three

major categories: fasteners, welding, and adhesives.

Joining focuses primarily on assembly of

components or parts into subassemblies or final
products.
1. Fasteners: These are mechanical devices that join
materials via clamping forces, pressure, or
friction, which do not involve molecular bonding
between the surfaces as the primary bonding force.

Some examples would be a threaded fastener, pins,

and riveting.
 2 . Cohesion (welding): This involves the joining of
two or more pieces of material by means of heat,
pressure, or both, with or without a filler metal, to
produce a localized union through fusion or
recrystallization creating a chemical bond.

 Welding process are classified by their energy source.

 The different energy sources used in welding are:

electrical, mechanical, chemical, and optical (beam,
ray).
3. Adhesion (gluing): This is the joining of two or
more material components through the forces of
attraction between the adhesive and the materials
being joined (adherends).

Gluing processes depend primarily upon adhesive

bonding.

Some of the other adhesive processes are brazing,

soldering, and epoxy bonding.
Thank you