2022

AGRICULTURAL AND BIOSYSTEMS ENGINEERING

BOARD EXAM REVIEWER

MANUFACTURING
PROCESSES
by

Engr. Alexis T. Belonio, MS

Agricultural and Biosystems Engineer
ASEAN Engineer

Volume 5 – Design and Testing of Agricultural Machines

 INTRODUCTION

n Manufacturing of agricultural machines in the Philippines begun as

early as Spanish period when tools and small equipment are
fabricated for farm use.
n In early 60’s, manufacturing was concentrated on the fabrication
of small farm tools and attachment for four-wheel tractors used in
sugar plantation.
n Locally-made hand tractors started to appear in 1972. The design
of hand tractor was adopted from manufacturers in Bicol and at
IRRI. About 33 manufactures and enterprises assemble farm
machines then.
n In the middle of 70’s, hand tractors produced locally have
captured 40% of the market. Most of the manufacturers
fabricating hand tractors have the capability in producing other
farm machines.
n In 1984, the DA-IRRI Program for Extension of Small Farm
Equipment reported that there were about 206 cooperating
manufactures in the country producing various agricultural
machines.
n This handout gives the brief description and classifications of
manufacturing agricultural machinery in the Philippines.
 SHEARING

n This is done by placing a piece of metal, usually in the form of

sheet, plate, strip, or rod, between two blades of knives.
n The machine used for metal shearing is called metal shears.
n Bench shears are used for cutting heavy metal sheets and metal
plates.
n Tin shear or snip is used for cutting metal sheets using hand.
 SAWING

n Process of moving hard metal saw blade with teeth along its edge
across a metal to be cut.
n Hand Hacksaw – manually- operated saw used for cutting metals
by pushing and pulling the blade on the metal being cut.
n Power Hacksaw – is simply an improvement of hand hack saw. It is
an extremely economical and efficient way of cutting bigger sizes of
metal bars.
n Blades of power hack saw are available from 3 to 10 teeth per inch.
n For mild steel, aluminum, and copper, 4 to 6 teeth per inch blades are
used. For tubing and small section 10 to 14 teeth per inch are used.
n Stroke per minute is between 40 to 150 strokes. Soft metal uses
high speed while hard metal uses low speed.
n Band saw – uses an endless blade that moves past the piece
being cut in only one direction.
n Cutting hard metals requires blades with small teeth while soft
materials require larger blades.
n The use of too coarse blade on hard metal will cause the blade
to become dull very quickly. However, saw with very small
teeth requires longer time to cut metal.
n The rule is that at least two teeth should be used when cutting a
piece of metal.
 FLAME CUTTING

n One of the fastest method of cutting bars or steel plates having a

thickness of 1/16 to 6 inches.
n In flame cutting, the piece of steel is heated to its kindling
temperature of approx. 1600°F.
n Acetylene gas, pure oxygen, and cutting torch are usually used
for flame cutting.
 PLASMA CUTTER

Uses electricity and compressor to carryout cutting of metals,

especially stainless steel, at a faster rate compared with other
cutting tools and equipment.
 MILLING PROCESSES

n Facing - process of cutting or squaring of the end of a piece of

work.

n Center Drilling – done with a combination of drill and

countersink.

n Straight Turning – the work is first placed on the centers, and the
cutting tool is set for cutting.

n Drilling Reaming and Counter Boring – commonly performed

with a drill press or by a lathe. In here, the work piece is held in a
lathe chuck while the drill, reamer, countersink, or counter boring
tool is held in the tailstock.
n Knurling – process of making the handles of hand tools rough
in order to give a better grip.

n Boring – cutting and enlarging of a round hole to make a more

exact size and accurate with its axis.

n Threading – process of making threads on screw either right-

hand, left-hand, external, or internal threads.
 WELDING PROCESSES

n Soldering
n Brazing
n Oxyacetylene Welding
n Arc Welding
n Resistance Welding
n MIG Welding
n TIG Welding
¾ Soldering

¡ It is the common method of joining metal sheets, especially

non-ferrous metal.
¡ Soldering is done at a relatively lower temperature of
427°C compared with other methods such as brazing and
arch welding.
¾ Brazing

¡ The joining technique of metal using oxyacetylene welding

equipment by melting a non-ferrous filler rod at a
temperature above 427°C but below the melting point of
metal being joined.
¡ Brazing is much stronger joint compared with soldering.
¾ Oxyacetylene Welding

¡ The common gas welding process using oxygen and

acetylene gases in providing heat to melt and join metal by
means of fusion.
• Regulator – special valve that properly mixes the oxygen
and the acetylene gases.
• Hose – carries the gases from the cylinder to torch. Red
hose is used for acetylene gas; while, green hose is for
oxygen gas.
• Blow pipe or torch
¾Arc Welding

¡ The process of welding metal by passing high current into

a flux-coated welding rod. The flux serves as shield to
prevent oxidation to produce stronger weld.
¡ The arc welding electrodes melt and provide filler metal to
the joint.
¾Resistance Welding

¡ It uses the heat generated by electric current passing

through a small area of the metal being joined. The
pressure forces heat the area together until they have fused.
¡ Spot welding is the common form of resistance welding.
¾MIG Welding

¡ Metal inert gas (MIG) welding – uses continuous roll-fed

welding rod.
¡ An inert gas is used to protect the weld from oxidation. For
steel, MIG uses carbon dioxide while for aluminum and
other metals, a mixture of argon and helium is used.
¡ MIG welding is easier than arc welding in terms of heat
setting, rate of wire feed, and mixture of gases.
¾TIG Welding

¡ The tungsten inert gas (TIG) welding - is widely used for

welding aluminum, stainless steel and other non-ferrous
metals.
¡ It is similar to oxyacetylene welding in that the filler rod is
separated from the torch and is fed with the opposite hand.
 Classification of Manufacturer
According to Manufacturing
Capability

n By Piece – The manufacturer fabricates the machine by piece,

only one at a time. Usually one to two persons are commissioned
to do the entire work to produce the machine. The machine
basically is directly contracted from individual farmer or user.

n By Batch – The manufacturer fabricates the machine in several

number of pieces as per contract with the dealer.

n Mass Production – The manufacturer produces the machine

beyond the number of pieces produced in the batch system. Even
without direct order or purchase from the customer or dealer, the
manufacturer still produces the machine for possible unseen
market.
 Classification of Manufacturer
According to Size

n Small Manufacturer – small manufacturing enterprises that are

usually capable of manufacturing agricultural machines by piece
only. They are usually backyard fabrication in operation and
basically use common fabrication equipment such as hand saw,
welding machines, and some power drill and sanders.
n Medium-Size Manufacturer – capable to operate and produce
agricultural machines by batch and do mass production of small
machines, if ever needed. They have more equipment and
facilities to do manufacturing than small manufacturers do.
Special process needed in the manufacture of a certain machine
is done by subcontracting to other machine shops.
n Large-Size Manufacturer – capable of mass producing
agricultural machines because they have almost complete line of
equipment needed in manufacturing. Small and medium
manufacturers sometimes request subcontracting job fromo
large-size manufacturers.
 Classification of Agricultural
Machinery Manufacturing
Industry

n Manufacturers – are those producing one or several types

of farm machinery and usually do not sell other items from
other manufacturers.
n Manufacturer-Dealers – manufacture their own line of item
but also sell either consigned items or several brands of
single-cylinder engines, pumps, pump set, and other types of
farm machinery.
n Dealers – carry several items and brands from various
sources and are not usually engaged in manufacturing and
fabrication.
QUESTIONS AND PROBLEMS
1. Method of treating metal by 4. Process of making products by
applying welding deposit to pouring melted metal into a mold
strengthen the peg-tooth of a rice and then allowing it to cool.
thresher. a. Hot working process
a. Heat treatment b. Casting
b. Welding c. Powder metallurgy
c. Hard facing d. None of the above
d. None of the above
5. Cutting of holes on a material by
2. Filing is classified as ____. means of shearing process.
a. cold working a. Drilling
b. hot working b. Punching
c. casting c. Boring
d. None of the above d. None of the above

3. Heat treatment method to 6. Welding process wherein

increase the hardness of steel by current is allowed to pass through
rapid cooling. the prongs of the welding machine
a. Tempering joining two metal sheets together.
b. Quenching a. Resistance welding
c. Annealing b. Oxyacetylene welding
d. None of the above c. Arc welding
d. None of the above
7. Mixing of two or more substances 10. Welding process commonly
one of which is iron. used for thin metal sheets.
a. Casting a. Brazing
b. Forging b. Soldering
c. Alloying c. Spot welding
d. None of the above d. None of the above

8. Gas-metallic arc welding that uses 11. Welding process that uses an
inert gas shielding to produce a electrode.
cleaner and sounder weld compared a. Gas welding
with that of conventional welding. b. Resistance welding
a. Gas welding c. Arc welding
b. MIG welding d. None of the above
c. TIG welding
d. All of the above 12. Tool that can cut metal bars
faster.
9. Widely used method of welding a. Shear cutter
aluminum, copper, stainless steel, and b. Band saw
other difficult-to-weld metals. c. Grinding wheel
a. TIG welding d. None of the above
b. MIG welding
c. Gas welding
d. All of the above
13. Welding job is to be performed at 16. Basic hand tools that must be
the engine drive of a multiple-pass rice provided by manufacturers to buyers of
mill. What would you recommend to engines.
prevent possible accident during the a. Open wrench and adjustable wrench
repair work? b. Philip and flat-screw driver
a. Remove the engine from the drive. c. Spark-plug wrench
b. Disconnect the line from the terminal d. All of the above
of the battery.
c. Remove the ground line of the 17. Welding rod electrode is designated
welding machine from the engine drive. as E6013, what is the tensile strength
d. None of the above of the joint when welded properly?
a. 120ksi (kips per square inch)
14. Device suitable for cutting stainless- b. 60ksi
steel plates. c. 30ksi
a. Shear cutter d. None of the above
b. Plasma cutter
c. Acetylene gas cutter 18. C-300 sand paper is finer than
d. All of the above ____.
a. C-120
15. Machine tool used to reduce the b. C-400
diameter of a metal. c. C-600
a. Router d. None of the above
b. Power drill
c. Lathe
d. None of the above
19. If a welding rod is 1/8in. in diameter 22. Producer of one or several types of
E6013, the recommended amperage for farm machinery and usually does not sell
the welding machine is ____. other items from other manufacturers.
a. 75 amp a. Manufacturer
b. 100 amp b. Manufacturer-dealer
c. 125 amp c. Dealer
d. 150 amp d. None of the above
e. None of the above
23. These producers manufacture their
20. In what position does the electrode in own line of items and sell together with
Item 19 can be used? either consigned items or several brands
a. Flat of single cylinder engines, pumps, pump
b. Horizontal set, and other types of farm machinery.
c. Vertical a. Manufacturer
d. Overhead b. Manufacturer-dealer
e. All of the above c. Dealer
f. None of the above d. None of the above

21. Which of the following positions is 24. They carry several items and brand
not possible to be weld with arc welding from varied sources and usually do not
method. engaged in manufacture and fabrication.
a. Flat a. Manufacturer
b. Horizontal b. Manufacturer-dealer
c. Overhead c. Dealer
d. None of the above d. None of the above