Mon, 10 Feb, 2014

9:02:10 AM

MCE 4321 Manufacturing Processes

Tentative Lecture Schedule

Topics

Part 1

Introduction to Manufacturing Processes

Part 2

Metal Casting

Part 3

Metal Joining

Dr. Mohammad Ahsan Habib

Part 4

Machining Processes: Fundamentals of cutting

Assistant Professor
E-mail: mahabib@iut-dhaka.edu
Department of Mechanical and Chemical Engineering (MCE)
Room: 405, Level 4, First Academic Building

Part 5

Machining Processes: Cutting tool materials & Cutting fluids

Part 6

Machining Processes: Used to Produce Round and Various Shapes

Part 7

Machining Processes: Abrasive Machining and Finishing Operations

Part 8

Metal Forming & Powder Metallurgy

Part 9

Surface Technology

Part 10

Automation of Manufacturing Processes

Islamic University of Technology (IUT)

Universit Islamique de Technologie
ORGANISATION OF ISLAMIC COOPERATION (OIC)

Dr. Mohammad Ahsan Habib

Mon, 10 Feb, 2014

9:02:05 AM

MCE 4321 Manufacturing Processes

Before Mid Exam

Part No.

After Mid Exam

Part 1
Introduction to Manufacturing Processes

Mon, 10 Feb, 2014

9:02:09 AM

MCE 4321 Manufacturing Processes

Course Information

Products and Manufacturing

Course Teacher:
Dr. Mohammad Ahsan Habib
Room: 405 (First Academic Building)
E-mail: mahabib@iut-dhaka.edu

Product Creation Cycle

Grading Policy:
Attendance:
Class Performance:

Feedback

Material
Selection

Inspection

Process
Selection

Design

10%
15%

4 Quiz or 3 Quiz 1 Assignment + Overall

performance

Mid-term:
Final Exam:

25%
50%

Textbook (reference only):

Kalpakjian and Schmid, Manufacturing
Engineering & Technology, 6th Edition in SI
Units.
Dr. Mohammad Ahsan Habib

Manufacture

Dr. Mohammad Ahsan Habib

Typical product cost

breakdown
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MCE 4321 Manufacturing Processes

Mon, 10 Feb, 2014

9:02:04 AM

MCE 4321 Manufacturing Processes

Manufacturing Need and concept

Mon, 10 Feb, 2014

9:01:21 AM

Value addition by manufacturing

The progress and the prosperity of human civilization are governed and
judged mainly by improvement and maintenance of standard of living
through availability or production of ample and quality goods and
services for mens material welfare ( )in all respects covering
housing, clothing, medicine, education, transport, communication and
also entertainment. It depends on:
Availability of natural resources ()
Exertion of human effort ( ;)both physical and mental
Development and use of power tools and machines (),

Production or manufacturing can be simply defined as value addition processes by

which raw materials of low utility and value due to its inadequate material properties
and poor or irregular size, shape and finish are converted into high utility and valued
products with definite dimensions, forms and finish imparting some functional ability.
A lump of mild steel of irregular shape, dimensions and surface, which had almost no
use and value, has been converted into a useful and valuable product like bolt by a
manufacturing process which imparted suitable features, dimensional accuracy and
surface finish, required for fulfilling some functional requirements.

This can be depicted in a simple form:

: refers to air, water, heat and light, plants and animals and solid and
liquid minerals
: refers to power plants, chemical plants, steel plants, machine tools
etc. which magnify human capability.
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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Mon, 10 Feb, 2014

9:02:03 AM

MCE 4321 Manufacturing Processes

Production Engineering

Dr. Mohammad Ahsan Habib

Mon, 10 Feb, 2014

9:01:23 AM

Production Engineering (Cont. )

Production Engineering covers two domains:

(a) Production or Manufacturing Processes: This refers to science and
technology of manufacturing products effectively, efficiently, economically
and environment-friendly through
Application of any existing manufacturing process and system
Proper selection of input materials, tools, machines and environments.
Improvement of the existing materials and processes
Development of new materials, systems, processes and techniques

(b) Production Management: This is also equally important and essential in

the manufacturing world. It mainly refers to planning, coordination and control
of the entire manufacturing in most profitable way with maximum satisfaction
to the customers by best utilization of the available resources like man,
machine, materials and money.
It may be possible to manufacture a product of given material and desired
configuration by several processes or routes as schematically indicated in
figure.

All such manufacturing processes, systems, techniques have to be

Technologically acceptable
Technically feasible
Economically viable
Eco-friendly

Dr. Mohammad Ahsan Habib

Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Mon, 10 Feb, 2014

9:01:24 AM

MCE 4321 Manufacturing Processes

Strategies of increasing profit

Broad classification of Manufacturing Processes

The various process routes may be different in respect of principle, technique,

quality of products and time requirement and cost of manufacture. The best
one is to be selected based on some criteria. Achieving the goal in
manufacturing requires fulfillment of one or more of the following objectives:
reduction of manufacturing time
increase of productivity
reduction of manufacturing cost
increase in profit or profit rate

ii.
iii.

a) Shaping or forming: Manufacturing a solid product of definite size and

shape from a given material taken in three possible states:

b) Removal process: Machining (Traditional or Non-traditional), Grinding etc.

c) Joining process: Welding, brazing, soldering etc.
d) Regenerative manufacturing: Production of solid products in layer by
layer from raw materials in different form:

reducing the overall manufacturing

cost,
increase in revenue, R by increasing
quality and reliability of the products
enhancement of saleable production

Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

All such manufacturing processes can be broadly classified in four

major groups as follows:

in solid state e.g., forging rolling, extrusion, drawing etc.

in liquid or semi-liquid state e.g., casting, injection molding etc.
in powder form e.g., powder metallurgical process.

The most significant and ultimate

objective, i.e., Increase in Profit, ,
can be attained by
i.

Mon, 10 Feb, 2014

9:02:02 AM

Mon, 10 Feb, 2014

9:01:50 AM

liquid e.g., stereo lithography

powder e.g., selective sintering
sheet e.g., LOM (laminated object manufacturing)
wire e.g., FDM. (Fused Deposition Modeling)

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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Mon, 10 Feb, 2014

9:02:01 AM

Manufacturing Process

Engineers in Manufacturing

A sequence of operations and processes designed to create a

specific product
The process of turning materials into a product

Manufacturing Engineer:
Select and coordinate specific processes and equipment
Industrial Engineer:
Responsible for the manufacturing system design
Materials Engineer:
Develop and select materials based on desired material
properties and manufacturing processes

Dr. Mohammad Ahsan Habib

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Dr. Mohammad Ahsan Habib

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MCE 4321 Manufacturing Processes

Mon, 10 Feb, 2014

9:02:00 AM

MCE 4321 Manufacturing Processes

Mon, 10 Feb, 2014

9:01:30 AM

Manufacturing System Designs

Manufacturing System Designs (Cont. )

Job Shop

Flow Shop

Small quantities of products

Large variety of products
Products move through the shop to various machines
General-purpose machines

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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Larger quantities of products

Production line
Special purpose machines

Mon, 10 Feb, 2014

9:01:48 AM

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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Thu, 2 Jan, 2014

9:03:04 AM

Manufacturing System Designs (Cont. )

Manufacturing System Designs (Cont. )

Linked-Cell Shop

Project Shop

Manufacturing and subassembly cells connected to final

assembly
Lean production system
One piece flow system

Dr. Mohammad Ahsan Habib

Product being manufactured cannot be easily moved

during production
Production processes are brought to the product
Examples: Bridges, ships, large airplanes, locomotives, large
machinery

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Dr. Mohammad Ahsan Habib

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MCE 4321 Manufacturing Processes

Mon, 10 Feb, 2014

9:01:32 AM

MCE 4321 Manufacturing Processes

Mon, 10 Feb, 2014

9:01:46 AM

Manufacturing System Designs (Cont. )

Manufacturing System Designs (Cont. )

Continuous Shop

Lean Manufacturing

Large plants
Utilized in the manufacture of liquids, oils, gases, and
powders

100% good units flow from process to process

Integrated quality control (IQC)
All employees are inspectors

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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Mon, 10 Feb, 2014

9:01:45 AM

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Dr. Mohammad Ahsan Habib

MCE 4321 Manufacturing Processes

Manufacturing of Hip Replacement

Mon, 10 Feb, 2014

9:01:39 AM

Automation in Manufacturing
Automated spot welding of automobile
bodies in a mass production line.
Source: Courtesy of Ford Motor
Company.

Components of a total hip

replacement.
Source: Courtesy of Zimmer, Inc.

Dr. Mohammad Ahsan Habib

(a) Manufacturing steps in the production of a roll-formed and

machined total hip replacement stem; (b) Manufacturing steps in
the production of a forged stem. Hip stems can also be produced
by investment casting, metal injection molding, insert injection
molding, and assorted other processes.
Source: Courtesy of Zimmer, Inc.

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Dr. Mohammad Ahsan Habib

Machining a mold cavity for making sunglasses.

(a) Computer model of the sunglass as designed and viewed on the monitor.
(b) Machine the die cavity using a computer numerical-control milling machine
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(c) Final product.