Manufacturing process types of manufacturing

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1. Workshop Practice (Theory) :ESC-104 Lecture-1 Presented By: Jagdip Chauhan Assistant Professor Mechanical Engineering Department Guru Jambheswar University of Science & Technology, Hisar

2. What is Manufacturing?

3. Manufacturing: Manu Factus : Latin for ‘made by hand’ Definition: A Well organized method of converting raw material to end product End Product: Value and utility added to output.

4. History of Manufacturing Manufacturing started during 5000 – 4000 BC Wood work, ceramics, stone and metal work Steel Production 600-800 AD Industrial Revolution 1750 AD: Machine tools run by invention of steam engine Mass Production and Interchangeable Parts Computer Controlled Machines 1965 CNC,FMS systems

5. Requirements of a good manufacturing system Product should meet design requirement Economical Process Quality should be built into the system Should be flexible and responsive to new technology High productivity: Best utilization of man, material, machine, capital and available resources.

6. Types of manufacturing process: Primary Manufacturing/Shaping Process Secondary Manufacturing / Machining Process Metal Forming process Joining Processes Surface Finishing Processes that involve the changes in the material properties

7. Primary Manufacturing/Shaping Process: The primary shaping process is used to give the amorphous/raw material a well-defined shape. The primary shaping process involves the casting process, plastic forming technology, powder metallurgy, bending of the metals, forging and gas cutting, and many more.

8. Secondary Manufacturing Process: Secondary processes  further improve the properties, surface quality, dimensional accuracy, tolerance, etc. Advanced  processes  usually (but not necessarily) manufacture desired products in one step .  The process to remove unwanted materials from the jobs using cutting tools is known as machining . The purpose is to give perfect dimensions and desired shape. Machines used for these operations include lathe, milling, drilling, shaper, planner, etc. At the time of machining different multi-point cutting tools, jigs and fixtures, and measuring devices are used. Machining produces a lot of waste metals in the form of chips. These days CNC machining is used for better accuracy and quick machining. Turning, knurling, parting, facing, boring, reaming, slotting, punching, threading, milling, gear cutting are some of the metal removing processes.

9. Metal Forming process: Metal forming is another manufacturing technique used to give the metal desired shape through the application of pressure/stress, forces like compression or tension or shear, or a combination of both. By applying these forces permanent deformation of the metal is achieved. These processes are also known as mechanical working processes. These mechanical working processes are classified into two categories,– hot working processes and cold working processes . The metal forming process does not incorporate metal removal. The metal is deformed and sometimes displaced by the application of forces. Metal forming always includes plastic deformation. In this technique, directly usable articles can be made. Wires, rods, cold drinks bottles, tubes are made by the metal forming process. The hot working process includes forging, hot spinning, rolling, extrusion, hot drawing, etc. Cold Working processes include cold forging, cold rolling, sheet metal working, punching, piercing, squeezing, notching, etc.

10. Joining Processes: Joining is a process we are using in our everyday life frequently. Different sub-assemblies are joined together to get a completely assembled product. In the fabrication process joining is used frequently. In manufacturing or fabrication, two or more metal parts are put together and joined by means of fusion, riveting, screwing, applying pressure, and rubbing. These joining processes are needed to make air-tight joints and semi-permanent or permanent fasteners. These joining techniques are very important in making bigger assemblies. For example, an airplane is assembled by putting together more than a thousand subassemblies. The joining process includes different types of welding, soldering, brazing, riveting and screwing, pressing, nut and bolt joints, etc.

11. Surface Finishing: Surface finishing is a process that is applied to get the desired leveling of the surface and also to obtain the desired smoothness. This process removes a very negligible amount of the materials from the surface and does not involve any effective change in the dimensions. It is not an effective metal removal process It should not be confused with the machining process. Putting some kind of coating over the metal is also a surface finishing process. Various surface finishing processes include honing, lapping, superfinishing, sanding, deburring, electroplating, buffing, painting, anodizing, galvanizing, etc. Sherardizing, Parkerizing, plastic coating, or metal spraying is also known as one kind of surface-finishing process. Surface finishing provides excellent finishing of the metal surface and at the same time gives good protection from environmental contaminants.

12. Processes that involve the changes in the material properties: Different properties of the same metal are desired for different applications. So metal property is needed to be changed in those cases. Material property change may include improved hardness, greater ductility, durability, etc. For some particular uses or operations, suitable properties are needed to be incorporated. Some operations need softer materials, some need harder ones. The properties of the materials change when the total grain size of the materials is regrouped or reorganized. Different grain conditions provide different properties. The grain sizes are changed by the application of different heat treatments. Through heat treatments, the internal structure of the material is changed. And they achieve different improved properties. Common heat treatment methods include –annealing, hardening, case hardening, normalizing, grain refining, tempering and age hardening, etc.

13. I am done Thank You Q&A