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2015
INTRODUCTION AND
OVERVIEW OF MANUFACTURING Manufacturing is Important
PROCESS-II
[Link] is Manufacturing? Technologically
[Link] in Manufacturing Economically
[Link] Processes
[Link] Systems
Manufacturing - Technologically
Manufacturing - Economically Important
Important
• Technology - the application of science to
provide society and its members with those U.S. economy:
things that are needed or desired
Technology provides the products that help our Sector
% of
GNP
society and its members live better Manufacturing 20%
What do these products have in common? •Manufacturing is Agriculture, minerals, etc. 5%
• They are all manufactured one way by which Construction & utilities 5%
Manufacturing is the essential factor that makes nations create
material wealth
Service sector – retail,
transportation, banking,
70%
technology possible communication, education, and
government
Manufacturing - Technologically Manufacturing - Economically
•Application of physical and chemical processes •Transformation of materials into items of greater
to alter the geometry, properties, and/or value by means of one or more processing and/or
appearance of a starting material to make parts or assembly operations
products
Manufacturing adds value to the material by
Manufacturing also includes assembly changing its shape or properties, or by combining
Almost always carried out as a sequence of
it with other materials
operations Manufacturing
as an economic
Manufacturing process
as a technical
Process:
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Manufacturing Industries - continued
Manufacturing Industries Secondary industries include
• Industry consists of enterprises and manufacturing, construction, and electric
organizations that produce or supply power generation
goods and services
Manufacturing includes several industries
Industries can be classified as: whose products are not covered in this
1. Primary industries - those that cultivate and book; e.g., apparel, beverages,
exploit natural resources, e.g., farming, chemicals, and food processing
mining
2. Secondary industries - take the outputs of
For our purposes, manufacturing means
production of hardware
primary industries and convert them into
consumer and capital goods - • Nuts and bolts, forgings, cars, airplanes, digital
manufacturing is the principal activity computers, plastic parts, and ceramic products
3. Tertiary industries - service sector
Manufacturing Processes
Methods of Manufacture
• Two basic types:
1. Processing operations - transform a work
material from one state of completion to a
more advanced state
• Operations that change the geometry, properties, or
FIGURE 1.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or
upsetting, (c) extrusion, (d) machining, (e) joining two pieces.
appearance of the starting material
2. Assembly operations - join two or more
components to create a new entity
Figure 1.4 Classification of manufacturing processes Processing Operations
• Alters a material’s shape, physical
properties, or appearance in order to add
value
Three categories of processing operations:
1. Shaping operations - alter the geometry of the
starting work material
2. Property-enhancing operations - improve physical
properties without changing shape
3. Surface processing operations - to clean, treat,
coat, or deposit material on exterior surface of the
work
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Shaping Processes – Four Categories Solidification Processes - Casting
1. Solidification processes - starting material is
a heated liquid or semifluid • Starting material is heated sufficiently to
transform it into a liquid or highly plastic
2. Deformation processes - starting material is state
a ductile solid (commonly metal)
Examples: metal casting, plastic molding
3. Particulate processing - starting material
consists of powders •
4. Material removal processes - starting
material is a ductile or brittle solid
Open Molds and Closed Molds
Figure 10.2 Two forms of mold: (a) open mold, simply a
container in the shape of the desired part; and (b) closed
mold, in which the mold geometry is more complex and
Figure 11.1 A large sand casting weighing over 680 kg (1500 lb)
requires a gating system (passageway) leading into the
for an air compressor frame (photo courtesy of Elkhart Foundry).
cavity.
Shell Molding Expanded Polystyrene Process
Casting process in which the mold is a thin shell of sand
held together by thermosetting resin binder
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Investment Casting Permanent Mold Casting
Figure 11.10 Steps in permanent mold casting: (2) cores (if used)
are inserted and mold is closed, (3) molten metal is poured into
the mold, where it solidifies.
Die Casting Centrifugal Casting
Figure 11.14 Cycle in cold-chamber casting: (1) with die
closed and ram withdrawn, molten metal is poured
into the chamber
Forming Processes: Deformation Forming Processes: Deformation
• Starting workpart is shaped by application of
forces that exceed the yield strength of the
material
• Bulk Deformation
Examples: (a) forging, (b) extrusion • Sheet Metal Forming
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Bulk Deformation Processes Rolled Products Made of Steel
Rolling Forging
Drawing
Extrusion
Figure 19.2 Some of the steel products made in a rolling mill.
Sheet Metal Forming Processes Presses
Cutting
Deep
Drawing Figure Schematic representation of the
V-Bending various types of press drive mechanisms.
Types of Press Frame Drop Hammer Details
Figure 17-60 (Left) Inclinable
gap-frame press with sliding
bolster to accommodate two
die sets for rapid change of
tooling. (Courtesy of Niagara
Machine & Tool Works, Buffalo,
NY.)
Figure 17-61 (Right) A 200-ton
(1800-kN) straight-sided press. Figure 19.20 Diagram showing details of a drop hammer
(Courtesy of Rousselle for impression-die forging.
Corporation, West Chicago,
IL.)
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Stamping Press Forming: Particulate Processing
• Starting materials are powders of metals or
ceramics
Usually involves pressing and sintering, in
which powders are first compressed and
then heated to bond the individual particles
Figure 20.32 Components of a typical mechanical drive stamping press
Forming: Material Removal Processes Forming: Material Removal Processes
-Machining -Machining
• Excess material removed from the • Turning examples
starting piece so what remains is the
desired geometry
Examples: machining such as
turning, drilling, and milling; also
grinding and nontraditional Standard Turning Facing
processes
Threading:
Turning: Machining Milling
Drilling
of cylindrical parts
Turning Machine:
Two Forms of Milling Lathe
Figure 21.3 Two forms of milling: (a) peripheral milling, and (b)
face milling.
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Milling Machine: Joining Processes:
Welding, a Permanent Joining Process
Figure 31.1 Basic configuration of an arc welding process.
Arc Welding Gas Metal Arc Welding
A pool of molten metal is formed near electrode tip,
and as electrode is moved along joint, molten
weld pool solidifies in its wake
31.4 Gas metal arc welding (GMAW).
Figure 31.1 Basic configuration of an arc welding process.
Resistance Spot Welding
Oxyacetylene Welding
Resistance welding,
showing the components in
spot welding, the main
process in the RW group.
Figure 31.21 A typical oxyacetylene welding operation (OAW).
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Brazing - Soldering: Permanent
Joining Processes – Weak Bonding, Joining Process: Adhesive Bonding
Lower Temperatures
Figure 32.10 Types of stresses that must be
considered in adhesive bonded joints: (a) tension, (b)
shear, (c) cleavage, and (d) peeling.
Figure 32.4 Several techniques for applying filler metal in brazing:
(a) torch and filler rod. Sequence: (1) before, and (2) after.