MANUFACTURING IDEAS

Milling Process :
 Used to get a flat surface.
 Instrument used to do is called milling cutter.
 There are multi -milling cutter, which can be used depending on the needs.
 In milling process, the cutter will rotate constantly at some RPM.
 In milling process, the work piece is moved according to the desired shapes.

Types :
 Plane Milling/Slap Milling
 Face Milling
 Stabbed Milling
 Gang Milling
 End Milling
 Form Milling
 Angular Milling
 T Milling
 Gear Milling
--Milling Machine are the instrument used to do milling process, Most commonly used Milling
machine are :
 Vertical Milling machine - Spindle axis vertically orientated
 Horizontal Milling machine - Spindle axis Horizontally orientated
 CNC Milling machine - Controlled by Computer, either vertical or Horizontal.

CNC Machine :
 3 Axis Machine -- 1). CNC Milling
2). CNC Turning

 Multi Axis Machine/ 5 Axis machine

⃰ If the Hole Diameters are less than material Thickness,then it will not be
produced by using “Laser cutting” ,so We can use “Milling process” for the
Cutting .
⃰ For Milling process - PDF file of the drawing is preferred.
⃰ For Laser cutting - DXF file of the part is preferred .
⃰ IGES or step file - These Two are the neutral files in which we used to view or
work particular part or component in other software like Auto-desk,catia etc.
Tap :
 Used to cut thread inside a hole .
 Female Thread
 Used by tap Wrench .

Die:
 Used to cut thread on outer surface of a rod , Pipe.
 Male Thread

Selection of materials for manufacturing before design :

 Product Requirement :
Before Choosing materials ,clearly define the products requirement such as Strength,
durability,flexibility,Thermal Resistance, Electrical Conductivity, Corrosion Resistance.
Consider the environment in which the product is going to be used
(Eg: Temperature,Humidity, Exposure ).

 Consider Manufacturing Process :

Different Materials are used for different manufacturing process.Some Materials may be
easier or more cost effective to process than others.

 Asses Material Properties :

Evaluate properties like Mechanical properties,Physical Properties,Thermal
Properties,Chemical Properties and Electrical properties .

 Cost Analysis :
Consider Cost of Raw materials ,Processing cost ,Manufacturing cost and the cost of
Finishing .

 Availability :
Check the Availability of the materials in market and also consider the opportunities for
recycling or reuse .

 Compatibility & Interactions :

If the product is used along with other materials ,then check whether it can make any
change in properties if combine with other materials.
Define :
 Strength :
 Capacity of a material to withstand force, stress or pressure without
breaking ,deforming or failing .
Yield Strength :The stress at which a material begins to deform plasticity.
 Durability :
Ability to withstand wear , pressure or damage over time .
 Flexibility :
Capacity to bent ,adjusted or modified without breaking .
 Thermal Resistance :
Ability of a material to resist flow of heat .
 Electrical Conductivity :
Ability to conduct electric conduct.
1). Conductors - Copper,Aluminium,Gold and Silver.
2). Insulators - Glass, Rubber and plastics.
3). Semiconductors - Silicon and Germanium.
 Corrosion Resistance :
Ability to withstand damage caused by Chemical Reactions .
Various materials exhibit natural composition resistance , They are :
1) Stainless Steel -Contains Chromium which forms oxide layer .
2) Aluminium Alloys - Forms oxide player when expose to air .
3) Titanium and Titanium Alloy
4) Nobel metals - Gold ,Platinum and Palladium -Less Reactive
5) Non metallic materials - Plastics,rubber and ceramics.

Casting :
Process of Producing metal /alloy components parts of desired shapes by pouring molten
metal/alloy into a prepared mould(of the shape) and then allowing the metal/alloy to cool and
solidify.
The Solidified piece of metal /alloy is known as Casting .
 CASTING TYPES

(Easy)Conventional Unconventional(Difficult)

Green sand Co2 Moulding

Dry Sand Permanent

Shell Moulding

Investment (Wax)

Centrifugal

Continuous

Selection of Steel :
Types of steel :
 Carbon
 Alloy
 Stainless
 Tool steel
 Carbon Steel :
- Main content of steel is carbon.
-Highly versatile and depends on carbon content .
-Three Types of carbon steel
 Low Carbon steel/Mild steel (0.3% carbon)
 Medium Carbon steel (0.3 to 0.6 % carbon)
 High Carbon steel (0.6% to 1 % carbon)
Low Carbon steel :(0.3% carbon)
- Highly malleable, ductile, tough and easy to weld and one of the cheaper forms of steel
and has lower tensile strength .
- Eg : AISI 1018, AISI 1020, AISI 1010, ASTM A36 .
(AISI - American iron and steel industry ) (ASTM -American Society of Testing& Materials)
Medium Carbon steel :(0.3 to 0.6 % carbon)
- Stronger than Low carbon steel but , it is more difficult to weld or form
-Harder ,less malleability ,less ductile and good corrosion resistance
-Eg : AISI 1040, AISI 1045, AISI 1050, AISI 4140, AISI 4340.
High Carbon Steel :(0.6 to 1 % carbon)
-Very strong and very hard
-Poor Ductility and poor malleability and better corrosion resistance and very difficult to
bend and form .
-Eg : AISI 1060, AISI 1080, AISI 1095 .
 Alloy steel:
-Steels alloyed with additional elements like manganese, Nickel, Chromium, Boron,
Silicon.
-Adding other elements to iron and carbon can improve strength, hardness, toughness,
wear resistance.
-Two groups of alloy steels :
1). Low alloy - 1 to 5 % alloy content
2). High alloy - Excess of 10 %
Eg : AISI 4130, AISI 4140, AISI 4340,etc.
 Stainless steel :
- Contain minimum of 10 % of chromium
- The high chromium and carbon content give stainless steel its iconic corrosion
resistance, hardness and strength .
- Eg : AISI 304, AISI 316, AISI 430, AISI 441 .
 Tool steel :
-Well suited for making tools
-Different types of Tool Steels
 High speed steel
 Cold Work steel
 Hot Work steel
 Shock resistance steel
  Water hardening steel
 Mold steel
Solid works Drawing :
 Surface finish :
Surface finish in manufacturing refers to the texture, quality, and smoothness
of the surface of a manufactured part.
There are many grades of surface finish ,they are :
 N1-N4: These are very fine finishes, typically achieved through
processes like grinding, lapping, or super-finishing. They are used for high precision
and low friction surfaces, such as bearings, seals, and surfaces requiring high aesthetic
quality.
 N5-N8: These are medium finishes, common for general
machinery and applications where a good surface quality is needed
 N9-N12: These are rough finishes, usually sufficient for surfaces
not in contact with seals or those not critical to function

what are the manufacturing process in industry :

1. Casting : (aluminum, brass, steel, cast iron),plastics, and glass

In casting, liquid material (often metal) is poured into a mold, which contains a
hollow cavity of the desired shape, and is then allowed to solidify. The solidified part
is also known as a casting. This process is used for making complex shapes that
would be difficult or uneconomical to achieve by other methods.

2. Forming :(steel, aluminum), plastics.

Forming processes involve shaping materials by deforming them in some way

without removing material. This category includes various techniques:

 Rolling: Reducing the thickness or changing the cross-section of a long work

piece by compression forces applied through a set of rolls.
 Forging: Shaping metal using localized compression forces.
 Extrusion: Forcing material through a die to shape it into a continuous profile.
 Deep Drawing: Forming sheet metal into a hollow shape by stretching it into a
die.
3. Machining :(steel, aluminum, brass, copper), plastics, and wood.

Machining involves removing material from a work piece to shape it into the desired
form. This can be done through various processes, such as:

 Turning: A cutting tool removes material from a rotating work piece to form
cylindrical parts.
 Milling: A rotating tool removes material from a work piece by advancing in a
direction at an angle with the axis of the tool.
 Drilling: A drill bit is used to create or refine holes in a work piece.

4. Joining :(steel, aluminum, stainless steel), thermoplastics

Joining involves assembling two or more components to create a complex structure.

Common joining processes include:

 Welding: Fusing two pieces of material using heat, pressure, or both.

 Soldering and Brazing: Joining pieces with a filler metal at a lower melting
point than the work pieces.
 Adhesive Bonding: Using a glue, epoxy, or other adhesives to bond materials
together.

5. Additive Manufacturing (3D Printing)

Additive manufacturing involves creating objects by adding material layer by layer,

based on a digital model. It allows for the production of complex shapes with
potentially less material waste. Technologies include:

 Stereo lithography (SLA)

 Fused Deposition Modeling (FDM)
 Selective Laser Sintering (SLS)
 Direct Metal Laser Sintering (DMLS)

6. Powder Metallurgy :(iron, steel, titanium, tungsten, brass)

This process involves mixing fine powdered materials, pressing them into a desired
shape (compaction), and then heating the compressed material in a controlled
atmosphere to bond the particles (sintering).

7. Finishing Processes
Finishing processes are used to improve the appearance, surface finish, or mechanical
properties of a manufactured part. Examples include:

 Grinding: A machining process that uses an abrasive wheel to achieve a very

fine finish or to remove small amounts of material from a part.
 Polishing: Smoothing a surface with abrasives or other techniques to achieve a
high gloss or mirror finish.
 Plating: Depositing a layer of material on a surface to improve corrosion
resistance, wear resistance, or appearance.

What are the manufacturing and selection formula that a Mechanical Designer
should know :

 Stress & Strain :

Stress = Force (or) Load /Cross section area

= P/A (N/m2)

Strain = Change in Length /Original Length

 Factor of Safety :

FoS = Strength of material / Expected stress

“The Factor of Safety is used to ensure that structures or components remain

operational and safe under various conditions, including unexpected loads, material
defects, wear”

“ Strength of material - maximum load or stress that a material or component

can withstand before failure”

“Expected stress -the maximum load or stress expected during normal operation”
 Here are some general guidelines and typical FoS values for various
situations :

 General Engineering Applications :

1. Static Load - Range 1.5 to 3

2. Dynamic Load - Range 3 to 5

 Material Type :

 Ductile Materials (such as steel,Aluminium, copper ):

Lower FoS values can sometimes be used because these materials typically undergo significant
deformation before failure, providing warning signs. FoS might range from 1.5 to 3.
 Brittle Materials (such as ceramics or certain types of cast iron):
Higher FoS values are advisable (e.g., 3 to 6) because these materials can fail suddenly without
much warning.
 Specific Applications :
 Buildings and Civil Structures: Codes often specify minimum FoS
values. For example, the American Institute of Steel Construction (AISC) provides
specific safety factors for different types of steel structural components.
 Aerospace: Given the critical nature and the extreme conditions
experienced, FoS values can be higher. However, due to weight constraints, the
aerospace industry also focuses on precisely understanding material behavior and load

conditions to optimize FoS values without over designing.

 Automotive: Safety-critical components often have FoS values from 2
to 3 or more, depending on the component and its failure mode.
 Machinery and Equipment: Depending on the application, FoS values
typically range from 2 to 4. Components subject to wear or fatigue might require
higher safety factors.

 Beam Bending :

The maximum bending moment is ==> M = FL/4

F- Force , L- Length of beam

  Gear Design :

The basic formula for the dimensioning of gears involves the module (m), which relates
the pitch diameter (D) to the number of teeth (z):

m=D/z

And the gear ratio (i) is:

i= Number of teeth on output gear / Number of teeth on input gear

 Thermal Expansion :

ΔL=αL0ΔT

where ΔL is the change in length, α is the coefficient of thermal expansion, L0is the
original length, and ΔT is the change in temperature.
Ashby charts used for Material selection :

- By using Ashby charts , we can select the materials for the manufacturing process
according to certain properties as required .

- In ashby charts ,There are two axis in which we can compare properties with each
others .

- Vertical axis Y axis Strength ,Young’s modulus

- Horizontal axis X axis Density , Cost .

- In the chart ,there is a whole bunch of materials and their classes .

- By using the Shape of the materials plot ,we can find the range of the properties