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Introduction To Manufacturing Processes
Introduction To Manufacturing Processes
MANUFACTURING
PROCESSES
Asst. Prof. Sadia Riaz
Course Outline
2
Title:
ME-221: Manufacturing Processes
Books
Materials and Processes in Manufacturing, Paul Degarmo
Fundamentals of Modern Manufacturing, Mikell P. Groover
Grading
Quizzes (3-4) 10%
Assignment+Pres+ Report) 10%
Sessionals (2) 30%
Final 50%
Tentative Plan
3
Topic Week/
Lecture
Introduction to Manufacturing processes and materials 1-2
Metal Casting 3-4
Foundry, sand casting, Die casting, permanent mold casting etc.
Forming and Shaping of Plastic and Composite
Compression/Transfer/Injection molding etc. 5-6
Forming and shaping of metals (Bulk & Sheetmetal)
Rolling, Forging, Extrusion, Forming, Drawing, etc. 7-9
Metal Cutting
Lathe, Milling, Shaper, Planner, Drilling, Tools, Grinding, Broaching 10-11
etc.
Joining Processes and Equipments
Temp/Perm joining, Welding, Soldering, Brazing, tec. 12-15
Quality, Measurement and Inspection
16
Course Learning Outcomes
4
Metal Casting
Foundry, sand casting, Die casting, permanent mold casting etc.
Forming and Shaping of Plastic
Compression/Transfer/Injection molding etc.
Forming and shaping of metals
Rolling, Forging, Extrusion, Forming, Drawing, etc.
Metal Cutting
Lathe, Milling, Shaper, Planner, Drilling, Tools, Grinding etc.
Joining Processes and Equipments
Temp/Perm joining, Welding, Soldering, Brazing, tec.
Quality, Measurement and Inspection
7
INTRODUCTION
Ch. 1
INTRODUCTION
8
What is Manufacturing?
Materials in Manufacturing
Manufacturing Processes
Production Systems
What is Manufacturing?
9
Examples?
Manufacturing Capability
13
Metals
Usually alloys, which are composed of two or more
elements, at least one of which is metallic
Ceramics
compounds containing metallic/semi-metallic and
nonmetallic elements. Typical nonmetallic elements are
oxygen, nitrogen, and carbon
Polymers
compounds formed of repeating structural units called
“mers”, whose atoms share electrons to form very large
molecules
Materials in Manufacturing
In addition to the three basic categories, there
are: Composites
Non-homogeneous mixtures of the other three basic
types rather than a unique category
Manufacturing Processes
20
Processing operations
Transform a work material from one state of completion
to a more advanced state
Consist of operations that change the geometry,
properties, or appearance of the starting material
Assembly operations
Join two or more components in order to create a new
entity
Processing Operations
21
Shaping operations
Alter the geometry of the starting work material
Property-enhancing operations
Improve physical properties of the material without
changing its shape
Solidification processes
starting material is a heated liquid or semi-fluid that solidifies to form
part geometry
Particulate processing
Starting material is a powder, and the powders are formed into desired
geometry and then sintered to harden
Deformation processes
Starting material is a ductile solid that is deformed
MECHANICAL PROPERTIES
OF MATERIALS
Self Study for revision of concepts
Mechanical Properties in
Design and Manufacturing
31
Stress-Strain Relationships
Hardness
Effect of Temperature on Properties
Fluid Properties
Stress-Strain Relationships
33
Elastic region
Hooke's Law : e = E ɛ
Plastic region
After yielding of the material
The stress-strain relationship is no longer guided by Hooke's
Law
As load is increased beyond Y, elongation proceeds at a
much faster rate than before, causing the slope of the curve
to change dramatically
Necking
36
True stress-strain curve
37
K n
Brittle Materials
39
Hot Hardness
Recrystallization in Metals
44
Fluids flow
They take the shape of the container
that holds them
Many manufacturing processes are
accomplished on materials converted
from solid to liquid by heating
Examples:
Metals are cast in molten state
Glass is formed in a heated and highly
fluid state
Viscosity in Fluids
49
PHYSICAL PROPERTIES
OF MATERIALS
Ch. 4
Physical Properties in Manufacturing
51
Thermal expansion
Melting point
Density
54
Heat of fusion
heat energy required at Tm to accomplish transformation from solid to
liquid
Importance of Melting in Manufacturing
59
Metal casting
the metal is melted and then poured into a mold cavity
Metals with lower melting points are generally easier to
cast
Plastic molding
melting characteristics of polymers are important in
nearly all polymer shaping processes
Mass Diffusion
60
THE END