MANUFACTURING PROCESS

EMB 2223

INTRODUCTION TO MANUFACTURING
PROCESS
 What is
Manufacturing?

How do we make these?

 Definition of "Manufacturing"

 "Manufacturing" is a process for

converting ideas and market or customer
needs into artifacts; Includes design,
procurement, test, finance, human resources,
marketing, etc.
 manufacturing is the conversion of raw
materials into useful products
 Main Focus of This Course
 Manufacturing Process

A sequence of operations and processes designed to

create a specific product

The process of turning materials into a

product

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 Products and Manufacturing

Product Creation Cycle

Design → Material Selection → Process
Selection → Manufacture → Inspection →
Feedback
Typical product
cost breakdown
 Manufacturing

Societal pressures, Government

regulations, company plans and policies,
etc
Customer needs

manufacturing Products
Raw
material

People, money, machines and automation

Little "m" manufacturing is all about

 Creating shapes by various means and

assembling these shapes into a useful
product
 A physical product always has a shape
 Function
 Aesthetics
 These shapes are created by a wide variety
of processes
The manufacturing Process
Materials Science, Statics, Dynamics, Mechanics of Materials

Material
Raw Material

Products
Assembly
Transformation
Processes

Machines and Automation

 Production Methods for a Simple Part

Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or
upsetting, (c) extrusion, (d) machining, (e) joining two pieces.
 Fundamentals of manufacturing -
Manufacturing Concepts

 The method chosen depends on the material and the

shape and properties required.

• Formability • Castability
• Machinability • Compactability
• Hardenability • Sinterability
• Weldability
 Why is Manufacturing Important?

 Impact on economy
 Major wealth creation engines
 Gross Domestic Product
 Jobs
 Most decisions made during design are impacted by
production/manufacturing processes
 Critical Decisions/Trade-offs
 function vs cost vs schedule
 Choose materials

 Choose process(es)

 Cost determined by the material and the processes

used to create the shape
Some functional parameters affected
by production processes

 Mechanical properties (Strength, Hardness,

Fatique, Ductility, Resistance to environment)
 Tolerances
 Surface finish
 Resistance to corrosion and abrasion
 Electrical properties
 Thermal Properties
 Appearance/surface finish
Commercially Available Materials

TABLE 40.1
Material Available as
Aluminum P, F, B, T, W, S, I
Copper and brass P, f, B, T, W, s, I
Magnesium P, B, T, w, S, I
Steels and stainless steels P, B, T, W, S, I
Precious metals P, F, B, t, W, I
Zinc P, F, D, W, I
Plastics P, f, B, T, w
Elastomers P, b, T
Ceramics (alumina) p, B, T, s
Glass P, B, T, W, s
Graphite P, B, T, W, s
Note: P, plate or sheet; F, foil; B, bar; T, tubing; W, wire; S,
structural shapes; I, ingots for casting. Lowercase letter
indicates limited availability. Most of these materials are also
available in powder form.
Manufacturing Process Capabilities

Manufacturing
process capabilities
for minimum part
dimensions. Source:
J. A. Schey,
Introduction to
Manufacturing
Processes (2d ed.).
McGraw-Hill, 1987.
 Dimensional Tolerance

Dimensional tolerance capabilities of various manufacturing processes.

 Dimensional Tolerance and Surface Finish
Relationship between relative manufacturing cost and
dimensional tolerance.

Relative production time, as a function of surface finish

produced by various manufacturing processes. Source:
American Machinist.
Examples of General Function/Process
Relationships

 Cast metals tend to be brittle

 Forging adds strength along flow lines
 Machining is cost effective for small lot sizes
 Casting, forging and extrusion have high setup costs
but low production costs
 Heat treatments affect hardness, strength, corrosion
resistance and fatigue properties
 Machining results in lots of scrap (the buy to fly ratio)
Buy to Fly Ratio

The weight of the purchased raw material divided by the

weight of the final part

Process Buy to fly ratio

Machining 1.1 - 50
Hot closed die forging 1.2-1.5
Sheet metal forming 1.1-1.25
Extrusion 1.1-1.3
Permanent mold casting 1.0-1.2
Powder metallurgy 1.0-1.05
 Critical Fact

 You cannot design any hardware without taking into

account the production process used to make that
product
 Manufacturing considerations must be included in
the design as early as possible
 What is Manufacturing - Dimensions

 Product Creative Characteristics (How new products

differ from previous ones)
 Product Size (physical dimension)
 Product Complexity/Sophistication
 Scale
 Material Flow
 Degree of Automation
 Product Creative Characteristics

 How new products differ from previous ones

 Selection design (Lego houses)
 Configuration design (automobiles)
 Parametric design (portable generators)
 Redesign (New VCR)
 Original design (the original VCR, the Space
Shuttle)
Product Size (physical dimension)

 An individual device on a computer chip

 A computer chip
 A television
 An automobile
 A Navy cruiser
Number of parts/amount of
electronics/intelligence

 A nail
 A TV
 A car or truck
 A 777 aircraft
 A satellite
 Mars sojourner
 A CPU chip (5 million
components)
 Scale

 Number of people and disciplines involved

 Artisan
 Garage machine shop
 General Motors, Arlington Plant
 Boeing Commercial Aircraft
 Engineering firms who make bridges, chemical
plants or dams
 Material Flow

 How the work is organized on the shop floor

 Discrete parts (traditional job shop)
 Cellular (New machine shops)
 Semicontinuous
 Continuous flow (bottle making)
 Process (chemical industry and oil refineries)
 Degree of Automation

 How much automation exists on the shop floor

 Manual
 Machine assisted
 Computer controlled - islands of automation
 Computer integrated manufacturing
Basic Manufacturing Processes

Casting and Foundry

Forming or Metalworking
Machining
Joining and Assembly
Rapid Prototyping
Other
 Casting and Foundry Processes

In one step raw materials are transformed

into a desirable shape
Parts require finishing processes
Excess material is recyclable

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 Basic Casting Process

A mold is created – A cavity that holds the molten

material in a desired shape until it is solidified
Multiple-use mold
Single-use molds
Material is heated to a specified temperature
Molten material is poured into a mold cavity
Molten material solidifies into the shape of the cavity
Casting or mold is removed
Casting is cleaned, finished, and inspected
 Forming and Metalworking Processes

Utilizes material that has been cast

Modify the shape, size, and physical
properties of the material
Hot and cold forming

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 Forming and Metalworking Processes

Rolling – Material passes through a series of

rollers, reducing its thickness with each pass

Forging – Material is shaped by the controlled

application of force (blacksmith)
 Forming and Metalworking Processes
Extrusion – Material is compressed and forced
through a die to produce a uniformed cross section

Wire, rod, and tube drawing – Material is pulled

through a die to produce a uniformed cross section

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 Forming and Metalworking Processes

Cold forming and forging – Slugs of material

are squeezed into dies
 Machining Processes

Controlled removal of material from a part to

create a specific shape or surface finish
Cutting element is used
Movement must exist between the part and
cutting element

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Machining Processes

Turning Processes
Operations that create cylindrical parts
Work piece rotates as cutting tool is fed into
the work

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Machining Processes
Turning Processes
Lathes and turning centers
Processes include: Straight, taper, contour
turning, facing, forming, necking, parting,
boring, threading, and knurling

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Machining Processes
Milling Processes
Operations that create flat or curved
surfaces by progressively removing
material
Cutting tools rotate as the work piece is
secured and fed into the tool
 Machining Processes

Milling Processes
Mills – Vertical and horizontal
Processes include: Surfacing, shaping,
forming, slotting, T-slotting, angle, straddle,
dovetailing, and slab milling
 Machining Processes
Drilling Processes
Operations that create holes
Cutting tools rotate and are fed into
nonmoving secured work pieces
 Machining Processes
Drilling Processes
Drilling and boring machines
Processes include: Drilling, counter drilling,
step drilling, boring, counter boring,
countersinking, reaming, spot facing, and
tapping
 Machining Processes
Abrasive Machining Processes
Operations in which small particles of materials
(abrasives) remove small chips of material upon
contact
Drum, disc, and belt sanders; surface, vertical
and horizontal spindle; disc grinders; media
blaster; tumblers
 Machining Processes
Thermal and Chemical Processes
Operations that cut and shape materials
through chemical means
No mechanical force is used
Electrical discharge, electrochemical,
chemical, laser, electron beam, flame
cutting, and plasma-arc cutting
Processes include: Grinding, sawing,
cutting, machining, milling, blanking, and
etching
 Sheet Metal Working
Shearing Processes
Operations that break unwanted material away from the
part
A material is placed between a stationary and movable
surface. The movable surface (blade, die, or punch)
applies a force to the part that shears away the
unwanted material.
Sheet Metal Working
Shearing Processes
Automated hole punch, squaring shear, and
rotary cutter
Processes include: Shearing, blanking, cutoff,
and parting; punching, perforating, and slotting;
notching, lacing, and trimming
 Heat Treating Processes

Controlled heating and cooling of a material to

alter its properties while maintaining its shape
Properties include: Strength, toughness,
machinability, wear resistance, and corrosion
resistance
90% of heat treating is preformed on steel and
other ferrous metals
 Heat Treating Processes

To aid in the manufacturing process, materials

can be treated to be weak and ductile and
then can be re-treated to provide high
strength.
Can also occur incidentally during the
manufacturing process
 Joining and Assembly Processes

Can you think of a product with only one

part?
Most products consist of multiple parts that
are assembled to form a finished product.
Typical assembly processes include:
Mechanical fastening; soldering and
brazing, welding; adhesive bonding
 Joining and Assembly Processes
Mechanical Fastening
Use physical force to hold parts together
Mechanical fasteners or part design
Screws, bolts, nails, rivets, cotter pins,
retaining clips, and edge design

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 Joining and Assembly Processes

Welding
Operations that use heat, pressure, or both
to permanently join parts
Gas, arc, stud, spot, forge, roll laminating,
resistance, and induction welding

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 Joining and Assembly Processes

Adhesive bonding
Bonding of adjoining surfaces by filling the gap
between each surface with a bonding material
Glue, cement, thermoplastic, thermosetting, and
elastomers

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 Joining and Assembly Processes

Soldering and Brazing

Operation in which metal surfaces are bonded
together by an alloy
Heated molten alloy flows between the adjoining
surfaces
When the heat is removed, the molten metal
solidifies and the metal surfaces are bonded

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 Rapid Prototyping

Additive process
Parts are produced directly from software
applications
Common rapid prototyping systems include:
stereolithography (SLA), selective laser
sintering (SLS), fused deposition modeling
(FDM), laminated object manufacturing
(LOM), digital light processing (DLP)
 Rapid Prototyping

Finished parts can be field tested depending

upon building material
Created parts can be used to create a mold
Modifications to design can be implemented
quickly
 Other Manufacturing Processes

Testing
Transportation
Material handling
Packaging

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 Material-Specific
Manufacturing Processes
Plastic Processes
Ceramic Processes

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 Plastics Manufacturing Processes
Extrusion
A rotating screw forces plastic through a
heating chamber and then through a
heated die
Produces long plastic parts with uniform
cross sections
 Plastics Manufacturing Processes
Injection Molding
Heated plastic is forced by a movable plunger
through a nozzle and then into a mold. The material
fills the mold and then is cooled.
Most widely used high-volume production process
 Plastics Manufacturing Processes
Casting
Plastic is melted and poured into a mold –
No pressure or fillers are required.
Rotational Molding
A closed mold is filled with a
predetermined amount of plastic. The
mold is heated, rotated, and then cooled
to create a hollow plastic object with
uniform wall thickness.
Plastics Manufacturing Processes
Blow Molding

A solid bottom hollow tube is placed

between two mold halves and heated.
The heated tube is then expanded into
the sides of the mold with compressed
air.
 Plastics Manufacturing Processes
Thermoforming
Plastic sheets are heated over an open
mold to a working temperature. Once
workable, a vacuum is applied to the mold,
forcing the plastic sheet to take the shape
of the mold.
Reaction Molding
Liquid reactants are mixed and then
pressurized into a mold.
No heat is needed. Curing time is typically
less than 1 minute.
 Ceramic Manufacturing Processes

Two distinct classes of materials and

processes exist.
Glass is heated to a molten state, shaped
by viscous flow, and then cooled to
produce a solid.

Crystalline Ceramics
Material is shaped and then heated
to produce a permanent solid.