IPE 111: Manufacturing Processes-I

Dr. M. Muhshin Aziz KhanAssociate Professor

IPE-111 MANUFACTURING PROCESSES ‑ I3 Hrs/week, 3.00 credits Classification of manufacturing processes;

Machining Processes: types, definition, concepts and applications: Turning, Drilling, Shaping, Milling, Knurling; Thread cutting, Grinding Reaming, Boring, Broaching, etc.;

Forming Processes: Classification, Molding: design of molds, riser, runner, gate spur and core, cost analysis; Casting: casting processes for ferrous and non ferrous metals, sand, die, centrifugal, slush, plaster mould, loam mould, precision investment casting etc., casting defects;

Joining Processes: Classification: soldering, brazing, welding, conventional welding processes, Gas, Arc, TIG, MIG, Termite, resistance, Friction, Electro slag etc;

Syllabus

Reference Books1. Fundamentals of Modern Manufacturing Materials,

Processes, and Systems Mikell P. Groover

Fourth EditionJohn Willy & Sons, Inc.

2. Introduction to Basic manufacturing Processes and Workshop TechnologyRajender SinghNew Age International P. Limited

Definition of Manufacturing

manufacturemanusfactus

Latin words

+

= Made by hand

In modern context: Manufacturing

Involves making or processing a raw material into a finished product, by using various processes, by making use of machines, tools and

even computers

DualityTechnical Activity Economic Activity

Added value

Manufacturing as a Technical Activity

ProcessedPartStarting

material

Scrap and waste

Manufacturing Process

MachineryPowerLaborTools

Manufacturing as an Economic Activity

ProcessedPart

Starting material

Material inProcessing

$Value added $$

Manufacturing Process

$$$

Requirements for a Manufacturing Activity

Manufacturing process and its interaction with the five Ms:

Primary vs. SecondaryManufacturing

Primary processes convert raw materials into standard stock

bauxite ore aluminum petroleum polyester resin wood lumber

Secondary processes convert standard stock into usable parts

aluminum rod fuel valve polyester resin medical tubing lumber furniture

Products are often made by putting many parts together Ball pen: Body, refill, barrel, cap, and refill operating

mechanism. Car: More than 20000 parts are put together Machine Tool: More than 24000 parts are assembled

together.

Manufactured Products

Consumer goods: products purchased directly by consumers

Example: cars, personal computers, TVs, tires, and rackets etc.

Capital goods: products purchased by companies to produce goods and/or provide services.

Example: aircraft, PC, buses.

Secondary Manufacturing Processes

Casting and Molding Forming Separating / Material Removal Conditioning Assembling / Joining Finishing

Secondary Processes Casting and Molding processes hold liquid or semi-liquid

materials in a mold cavity until the material hardens. Very intricated shapes can be manufactured. Range of size of the products manufactured by the

casting process is unlimited.

Forming processes use a shaping device and suitable force, pressure, stress or their combination to cause permanent deformation of a material to give it a required shape and size. No material is removed and wasted, but is only

displaced and deformed.

Separating processes remove unwanted material from a given workpiece to get a desired size, shape and surface finish. Material is removed from unwanted region of the raw

material.

Secondary Processes Conditioning processes use heat, chemical

reactions, or mechanical means to change the properties of a material

Assembly processes join two or more parts or assemblies to produce the required size and shape of the product. Parts can be joined through mechanical,

thermal, or chemical means Joint can be permanent, semi-permanents and

temporary

Finishing processes modify the surface of a material to improve appearance or performance

Manufacturing Work Flow

Custom

Intermittent / Batch

Continuous

Custom manufacturing

Job shop production (low volume of production and variety of work)

Limited number of products built to customer specifications.

Requires highly skilled labor. Least efficient (but most flexible) form of

manufacturing

Batch manufacturing

Parts made in lots of 10 – 1,000 Orders of the product may be repetitive or

nonrepetitive. General-purpose machinery (table saw,

vertical mill) is used, often run by hand Setup times per part decreases as batches

get larger

“Continuous” manufacturing

Same product made repeatedly by dedicated machinery (custom built machine – NOT CUSTOM built product)

Automation becomes more cost-effective Some processes still require batch staging Tooling and setup are large initial expenses

Industries can be classified as primary, secondary, and tertiary.

Primary industries, cultivate and exploit natural resources, such as agriculture and mining.

Secondary industries, take outputs of the primary industries and convert them into consumer and capital goods.

Tertiary industries, constitute the service sector of the economy.

Manufacturing Industries

Manufacturing operations can be divided into two basic types: (1) Processing operations, and (2) Assembly operations.

Processing operations- Transforms a work material from one state of

completion to a more advanced state that is closer to the final desired product.

It adds value by changing the geometry, properties, or appearance of the starting material.

Assembly operation- Joins two or more components to create a new entity,

called an assembly, subassembly, or some other specific terms, e.g., in the joining process, a welded assembly is called a weldment.

Classification of Manufacturing Processes

Fig.: Classification of Manufacturing Processes.

Manufacturing in the Economy

Manufacturing in the Economy The reason for manufacturing's stability is that there is a

synergy between manufacturing and other sectors.

Manufacturing generates most of the economy's productivity and technology,

while other sectors such as services generate the largest share of new employment.

The productivity generated by manufacturing

raises the wages of workers employed in all sectors. boost activity in other sectors.

As these sectors become more successful, they, in turn, create more demand for manufactured goods and its high-paying jobs. http://www.vpmep.org/mfgstats.htm

Contributions to Economic Growth, 1992-1997

Manufacturing also contributes to technological advances, with significant investments in R&D

http://www.vpmep.org/mfgstats.htm