Department of Technical Education

Telangana

Name : Ch.Srikanth
Designation : Contract. lecturer
Branch : Mechanical Engineering
Institute : GPT, Korutla
Year/Semester : I Year
Subject : Workshop Technology
Subject Code : 18M105
Topic : Basic Workshop Tools and operations
Duration : 100 mins
Sub Topic : Manufacturing process (Introduction)
Teaching Aids : PPT, Photos

1
 Objectives

On completion of this period you would be able to

• Understand what is a manufacturing process

• State importance of manufacturing processes

2
 Introduction

• Have you seen manufacturing of gates, grills etc ?

• What type of manufacturing process is it ?

• It is a welding process

3
 Introduction (Contd..)

• It is a fabrication process involving welding as joining method

4
 Introduction (Contd..)

• In a similar way all the articles we use in daily life are

produced by different manufacturing processes

• In this lesson we will introduce ourselves to some basic

manufacturing processes

5
 What is a manufacturing process ?

• It is an activity of making goods and articles by hand or machine

• It is a transformation of raw materials or semi finished products

into finished products
• It can be done either
• by hand or
• by machine

6
 Block diagram of production

Raw Primary Secondary

materials Manufacturing process Mfg process

Semi finished
Finished products
products
With shape, size & finish

Fig 1 Block diagram of production

7
 Fig.1
Manufacturing Process-By hand Manufacturing Process-By machine

Fig.2

8
Semi finished product Finished product

Fig.3

9
 Manufacturing process of Steel

• The iron ore (raw material)

is converted in to steel
(finished product) by the
following manufacturing
process

Fig.4

10
• Let us consider a manufacturing process of steel bars starting
from converting raw material in to finished product

11
 Manufacturing process of Steel bars

• Ferrous scrap metal

is used for
manufacturing of
steel bars

• Scrap metal is
brought into the
melt shop where it
will go through two-
step melting process

Fig.5 Iron scrap

12
 Manufacturing process of Steel bars

• The raw material is heated in

the Electric Arc Furnace
(EAF)

• The EAF uses electric power

to heat the scrap to over
3,000 degrees Fahrenheit and
melt it into liquid form
Fig.6 Heating of raw material

13
 Manufacturing process of Steel bars

• The refined molten steel is

then transferred to five- strand
continuous caster

• The steel is poured into

moulds, cooled and
shaped into the desired cross
section, essentially forming a
long bar called a billet
Fig .7 Formation of a billet

14
 Manufacturing process of Steel bars

• As the billets move through

the continuous caster, they are
cut by torches into desired
lengths

Fig.8 billet of desired length

15
 Manufacturing process of Steel bars

• The completed billets

are used as the
feedstock for other
rolling mill

Fig.9 semi finished product

16
 Manufacturing process of Steel bars

• The billets are

reheated in the hot
rolling furnace until
they turn into a
plastic state
.

Fig.10 Heating in the furnace

17
 Manufacturing process of Steel bars

• The reheated billets exit the

reheat furnace and proceed
to two rolling mills
• Each containing a set of
rollers that compress and
lengthen the billets and then
finish them into the desired
shape
• Each rolling mill consists of
a series of "stands",
Fig.11 Hot rolling mill

18
 Manufacturing process of Steel bars

• Hot rebar arrives on the

right from the rolling mill
stands and cools as it
progresses to the left

• The formed product is

transferred to the cooling
bed where it is allowed to
cool before it is cut and
bundled
Fig.12 cooling the heated bar

19
Manufacturing process of Steel bars

Fig.13 Finished products

20
 History and Development

• In its earliest form, manufacturing was usually carried out by a

single skilled artisan

• Before the industrial revolution, most manufacturing occurred

in rural areas, with household-based manufacturing

21
 History and Development (Contd..)

• Modern manufacturing is intended for large scale production

• Modern manufacturing uses specialized equipment and tools for

production

22
 Importance of manufacturing process

• Economic use of resources i.e men materials machines & energy

• Economic development

• Competing on global basis

23
Importance of manufacturing process (Contd..)

• Large scale production

• Low manufacturing cost

• High manufacturing rate

24
 Summary

In this period we have learnt about

• What is manufacturing processes

• Importance of manufacturing processes

25
 Quiz

1) Manufacturing process is done by

a . Either by hand or machine

b . By machine only

c . By hand only

d . None of the above

26
 Quiz

2) Modern Manufacturing aims for

a . More production

b . Limited production

c . No production

d . None of the above

27
 Frequently asked questions

1) What is the importance of Manufacturing process ?

2) What is a manufacturing process ?

28