Part 2

ESSENTIAL OF MANUFACTURING SYSTEMS

 Organization and Information Processing in Manufacturing

 Production Concepts and Mathematical Models
 MANUFACTURING OPERATIONS

The factory activities are:

(1) processing and assembly operations.

(2) material handling.

(3) inspection and test.

(4) coordination and control.

PROCESSING AND ASSEMBLY OPERATIONS

Manufacturing
processes

Assembly Processing
.Operations .Operations
 PROCESSING OPERATIONS

A processing operation transforms a work material from one state of

completion to a more advanced state that is closer to the final desired
part or product.
It adds value by:
1. changing the geometry properties
2. appearance of the starting material.
 ASSEMBLY OPERATIONS

An assembly operation joins two or more components to create a

new entity. which is called an assembly. sub assembly, or some
other term that refers to the specific joining process.
 PROCESSING OPERATIONS
A processing operation uses energy to alter a work part's
1. shape
2. physical properties
3. appearance

add value to the material.

 PROCESSING OPERATIONS
The forms of energy include
• Mechanical
• Thermal
• Electrical
• Chemical
 PROCESSING OPERATIONS
Human energy may also be required
• Control the machines.
• Oversee the operations.
• Load and unload parts.
 PROCESSING OPERATIONS
Most production operations produce waste or scrap
• Removing material.
• Defective pieces.

Important objective in manufacturing

is to reduce waste.
 PROCESSING OPERATIONS
Three categories of processing operations are distinguished:

Shaping operations

.Surface processing operations

.property-enhancing operations
 SHAPING OPERATIONS
Most shape processing operations apply
• Heat.
• Mechanical force.
• Combination of these
 Shaping operations

material
removal deformation particulate solidification
 Solidification processes
The important processes in this category are:
the starting material is a heated liquid or semifluid,
casting (for metals).
molding (for plastics and glasses).
 Particulate processes

pressing the powders in a die cavity. The starting material is a powder

then heated to bond the individual particles together.

metals (powder metallurgy) and ceramics can be formed.
 Material removal processes
The starting material is solid
Most important in this category are machining operations such as (turning, drilling,
and milling
using cutting tools
the tools harder and stronger than the work metal.
Grinding has abrasive grinding wheel is used to remove material.
 Material removal processes

Other material removal processes are known as nontraditional

processes.
 CLASSIFICATION OF NTM PROCESSES
classification of NTM processes is carried out depending on the nature of energy used for material •
.removal
Mechanical Processes .1 •
Abrasive Jet Machining (AJM) •
Ultrasonic Machining (USM) •
Water Jet Machining (WJM) •
Abrasive Water Jet Machining (AWJM) •
Electrochemical Processes .2 •
Electrochemical Machining (ECM) •
Electro Chemical Grinding (ECG) •
Electro Jet Drilling (EJD) •
Electro-Thermal Processes .3 •
Electro-discharge machining (EDM) •
Laser Jet Machining (LJM) •
Electron Beam Machining (EBM) •
Chemical Processes .4 •
Chemical Milling (CHM) •
Photochemical Milling (PCM) •
 Property-Enhancing Processes

The second major type of part processing is performed to improve

mechanical or physical properties of the work material. These processes
do not alter the shape of the part, except unintentionally in some cases.
The most important property enhancing processes involve heat
treatments, which include various annealing and strengthening processes
for metals and glasses. Sintering of powdered metals and ceramics is also
a heat treatment that strengthens a pressed powder metal workpart.
 Property-Enhancing Processes

Precipitation hardening: (a) phase diagram of an alloy system consisting of metals A and B that can be precipitation
hardened; and (b) heat treatment: (1) solution treatment, (2) quenching, and (3) precipitation treatment.
 Surface Processing Processes

Surface processing operations include

(1) cleaning,
(2) surface treatments
(3) coating and thin filmed position processes.
 Surface Processing Processes
Cleaning includes both chemical and mechanical processes to remove
dirt, oil, and other contaminants from the surface.
 Surface Processing Processes
Surface treatments include mechanical working such as shot peening and
sand blasting, and physical processes such as diffusion and ion
implantation.
 Surface Processing Processes
Coating and thin film deposition processes apply a coating of material to
the exterior surface of the work part. Common coating processes include
electroplating, anodizing of aluminum, organic coating (call it painting),
and porcelain enameling.
 Surface Processing Processes
Thin film deposition processes include physical vapor deposition and
chemical vapor deposition to form extremely thin coatings of various
substances.
 ASSEMBLY OPERATIONS
The second basic type of manufacturing operation is assembly,
two or more separate parts are joined
Permanent joining processes include
Welding
Brazing
Soldering
adhesive bonding
 ASSEMBLY OPERATIONS
Certain mechanical assembly methods are available to fasten two (or more)
parts together in a joint that can be conveniently disassembled.
Screws
Bolts
 ASSEMBLY OPERATIONS
Other mechanical assembly techniques form amore permanent connection;
these include
Rivets
press fitting
expansion fits
 ASSEMBLY OPERATIONS
Special joining and fastening methods are used in the assembly of
electronic products.
Some of the methods are identical too rare adaptations of the preceding
processes, for example, soldering. Electronics assembly is concerned
primarily with the assembly of components such as integrated circuit
packages to printed circuit boards to produce the complex circuits used in
so many of today’s products.