Basics of Manufacturing

WHAT IS MANUFACTURING?
Manufacturing is the application of physical and chemical

processes to alter the geometry, properties, and appearance
of a starting material to make parts or products for a given
application.
Production Engineering I / Erum Khan
PURPOSE OF MANUFACTURING
Manufacturing is the transformation of materials into

items of greater value by means of one or more
processing and/or assembly operations.
PROCESSING OPERATIONS
Three categories of processing operations:
1.
Shape-producing processes - alter the geometry of

the starting work material
2.
Property-enhancing processes - improve physical

properties of the material without changing its shape
3.
Surface processing processes - clean, treat, coat, or

deposit material onto the exterior surface of the work
3
1- SHAPING FOUR MAIN CATEGORIES

a.
b.
Casting (Solidification) Processes - starting material is a

heated liquid that solidifies to form part geometry.
Deformation Processes exploit the ductility or plasticity
of certain materials, mostly metal, and produce the desired
shape by mechanically moving or rearranging the solid.
c.
Material Removal Processes - starting material is a

ductile/brittle solid, from which material is removed. (also
called machining)
d.
Consolidation (Assembly) Processes - two or more

separate parts are joined to form a new entity.
a. CASTING (SOLIDIFICATION) PROCESSES

Starting material is heated sufficiently to transform it
into a liquid or highly plastic state.
Examples: sand casting and die casting for metals,
molding for plastics
a. CASTING (SOLIDIFICATION) PROCESSES

Sand
Casting
Shell Casting
Expendable
Mold
Investment
Casting
Lost Foam
Casting
Casting
Die Casting
Multiple Use
Mold
Permanent
Mold Casting
b. DEFORMATION PROCESSES
Starting workpart is shaped by application of forces
that exceed the yield strength of the material
Examples: forging, extrusion, rolling, sheet metal
forming
b. DEFORMATION PROCESSES
Forging
Hot
Forming
Rolling
Extrusion
Deformation
Processes
Wire
Drawing
Swaging
Cold
Forming
Roll
Forming
Deep
Drawing
c. MATERIAL REMOVAL PROCESSES

Excess material removed from the starting workpiece
so what remains is the desired geometry
Examples: machining such as turning, drilling, and
milling; also grinding and nontraditional processes like
EDM
Turning
Drilling
Milling
c. MATERIAL REMOVAL PROCESSES

Turning
Mechanical
Machining
Milling
Drilling
Material
Removal
Etching
Nontraditional
Machining
Electropolishing
ElectroDischarge
10
Laser Beam
d. ASSEMBLY OPERATIONS
Two or more separate parts are joined to form a

new entity
Types of assembly operations:

Joining processes create a permanent joint.
1.
Examples: welding, brazing, soldering, and adhesive bonding
Mechanical assembly fastening by mechanical

methods
2.
Examples: use of screws, bolts, nuts, other threaded

fasteners; press fitting, expansion fits
11
d. ASSEMBLY OPERATIONS
Oxy-Fuel
Consolidation
Processes
Welding
Arc
Brazing
Laser
Soldering
Discrete
Fasteners
Adhesive
Bonding
Integral
Fasteners
Mechanical
Joining
Press Fit
12
Shrink Fit
2. PROPERTY-ENHANCING PROCESSES
Performed to improve mechanical or physical
properties of the work material
Part shape is not altered, except unintentionally
Examples:
Heat treatment of metals and glasses

Sintering of powdered metals and ceramics
13
3. SURFACE PROCESSING
1.
2.
3.
Cleaning - chemical and mechanical processes to

remove dirt, oil, and other contaminants from the
surface
Surface treatments - mechanical working such as
sand blasting, and physical processes like diffusion
Coating and thin film deposition - coating exterior
surface of the workpart
Several surface processing operations used to
fabricate integrated circuits.
14
ADVANTAGES OF CASTING
Can produce complex shapes with internal cavities or
hollow sections.
Can produce very small and very large parts.
Cast parts range in size from a fraction of a centimeter
and fraction of a gram to over 10 meters or many tons
(100 tons).
Casting process can performed on any metal that can be
heated to the liquid state and that are difficult to process
by other means.
Are economical to use.
1
DISADVANTAGES OF CASTING
Limitation on mechanical properties
Porosity
Poor dimensional accuracy
Poor surface finish.
2
TYPES OF CASTING
Expendable Mold Casting: An expendable mold means

that the mold in which the molten metal solidifies must
be destroyed in order to remove the casting.
These molds are made of sand, plaster, ceramics and

similar materials and have the capability to withstand the
high temperature of molten metals.
Eg. Sand casting
Permanent Mold Casting: A permanent mold is one that

can be used over and over to produce many castings.
It is made of metal that can withstand the high temperature

of the casting operation.
Eg: Die casting
3
MOLD
The mold contains a cavity whose geometry determines
the shape of the cast part.
Types of Mold
Open Mold: the liquid metal is simply poured until it fills the
open cavity.
4
MOLD
Closed Mold: a passageway (gating system) is provided to

permit the molten metal to flow from outside the mold into
the cavity. (closed mold is the most important category in
production casting).
5
TYPES OF CASTING
Net Shape Manufacturing: Some casting processes are

capable of producing parts to net shape. No further
manufacturing operations are required to achieve the
required geometry and dimensions of the parts.
Near Net Shape Manufacturing : Casting process for which

additional shape processing is required (usually
machining) in order to achieve accurate dimensions and
details.
6
CASTING PROCESS
In casting process, a material is first melted, heated

to proper temperature, and sometimes treated to
modified its chemical composition.
The molten material is then poured into a cavity or

mold that holds it in the desired shape during cooldown and solidification.
In a single step, simple or complex shapes can be

made.
Steel and aluminium are the metals most commonly

used.
1
BASIC REQUIREMENTS OF CASTING PROCESSES

1. Mold Cavity
Have desired shape and size, with due allowance for

shrinkage of the solidifying material.
Any geometrical feature desired in the finished casting

must be present in the cavity.
Mold material should withstand the high temperatures

and not contaminate the molten material.
2

1. Mold Cavity
Single use mold sand

Cheap
Smaller quantities (Low volume production)
Higher melting temperature materials
Multiple use mold metal, graphite

Costly
High volume / mass production
3

2. Melting Process
Capable of providing molten material at the proper

temperature, in the desired quantity, with acceptable
quality, and at a reasonable cost.
4

3. Pouring Technique
Devised to introduce the molten material

into the mold.
Provision should be made for the escape

of all air and gases present in the cavity
prior to pouring, as well as generated by
the introduction of hot metal.
Molten material must be free to fill the

cavity.
5

4. Solidification Process
Should be properly designed and controlled.
Castings should be designed so that solidification and

solidification shrinkage can occur without producing internal
porosity or voids.
Avoid mold excessive restraint to shrinkage, it may cause

crack in casting.
6

5. Mold Removal
Part should be easy to remove form the mold.
Single use mold have no difficulty as molds are broken /

destroyed after each casting.
Multiple use molds have problem when complex shapes are
being casted.
7

6. Cleaning, Finishing & Inspection Operations
These operations are required after casting removal form the

mold.
Extra material is usually attached where the metal entered the

cavity, along mold parting lines and mold material may adhere
to the casting surfaces. All of these must be removed from the
finished casting.
8

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WHAT IS MANUFACTURING?

Manufacturing is the application of physical and chemical

Production Engineering I / Erum Khan

Manufacturing is the transformation of materials into

Production Engineering I / Erum Khan

Three categories of processing operations:

Shape-producing processes - alter the geometry of

Property-enhancing processes - improve physical

Surface processing processes - clean, treat, coat, or

Production Engineering I / Erum Khan

1- SHAPING FOUR MAIN CATEGORIES

Casting (Solidification) Processes - starting material is a

Material Removal Processes - starting material is a

Consolidation (Assembly) Processes - two or more

a. CASTING (SOLIDIFICATION) PROCESSES

Production Engineering I / Erum Khan

a. CASTING (SOLIDIFICATION) PROCESSES

Production Engineering I / Erum Khan

Production Engineering I / Erum Khan

c. MATERIAL REMOVAL PROCESSES

c. MATERIAL REMOVAL PROCESSES

Two or more separate parts are joined to form a

Types of assembly operations:

Examples: welding, brazing, soldering, and adhesive bonding

Mechanical assembly fastening by mechanical

Examples: use of screws, bolts, nuts, other threaded

Production Engineering I / Erum Khan

Heat treatment of metals and glasses

Production Engineering I / Erum Khan

Cleaning - chemical and mechanical processes to

Production Engineering I / Erum Khan

Expendable Mold Casting: An expendable mold means

These molds are made of sand, plaster, ceramics and

Permanent Mold Casting: A permanent mold is one that

It is made of metal that can withstand the high temperature

Closed Mold: a passageway (gating system) is provided to

Net Shape Manufacturing: Some casting processes are

Near Net Shape Manufacturing : Casting process for which

In casting process, a material is first melted, heated

The molten material is then poured into a cavity or

In a single step, simple or complex shapes can be

Steel and aluminium are the metals most commonly

BASIC REQUIREMENTS OF CASTING PROCESSES

Have desired shape and size, with due allowance for

Any geometrical feature desired in the finished casting

Mold material should withstand the high temperatures

BASIC REQUIREMENTS OF CASTING PROCESSES

Single use mold sand

Multiple use mold metal, graphite

BASIC REQUIREMENTS OF CASTING PROCESSES

Capable of providing molten material at the proper

BASIC REQUIREMENTS OF CASTING PROCESSES

Devised to introduce the molten material

Provision should be made for the escape

Molten material must be free to fill the

BASIC REQUIREMENTS OF CASTING PROCESSES

Should be properly designed and controlled.

Castings should be designed so that solidification and

Avoid mold excessive restraint to shrinkage, it may cause