MANUFACTURING PROCESSES

KKKM2833

Tutorial

Yousef Almutairi
GA03616

Prof. Dr.ANDANASTUTI MUCHTAR

Dr. NASHRAH HANI BINTI JAMADON
1. Defined the meaning of manufacturing process?

- is the production of goods by combining supplies, ingredients or raw substances using a

formula or recipe

2. What is the dilemma between design and manufacturing in terms of mechanical properties?

- Mechanical properties that are desirable to the designer, such as high strength, usually make
the manufacture of the product more difficult. It is helpful for the manufacturing engineer to
appreciate the design viewpoint and for the designer to be aware of the manufacturing
viewpoint.

3- What are different types of manufacturing processes? 

i) Casting process:

- Die Casting
- Sand Casting
- investment Casting
- Plaster Casting

ii) Forming process:

- Forging.
- Extrusion.
- Rolling.
- Sheet metal working.

iii) Welding process:

- TIG Welding
- Arc Welding 
- MIG Welding 

iv) Material removal process:

 - Milling 
- Drilling 
- Sawing 

4. Name the two basic mold types that distinguish casting processes?

A. Expendable molds.
B. Permanent. 

5. How does solidification of alloys differ from solidification of pure metals?

- Pure metals solidify at a single temperature equal to the melting point. Most alloys
(exceptions are eutectic alloys) start to solidify at the liquidus and complete solidification
occurs at the solidus, where the liquidus is a higher temperature than the solidus.

7. In a wire drawing operation, why must the drawing stress never exceed the yield strength of
the work metal?

- Because if the drawing stress exceeded the yield strength, the metal on the exit side of

the draw die would stretch rather than force metal to be pulled through the die opening.

8. What are the three basic categories of material removal processes?

- The three basic categories of material removal processes are

A. Conventional machining.
B. Abrasive processes.
C. Nontraditional processes.
9. There are two basic types of friction welding. Describe and Distinguish the two types?

- Rotary friction welding (RFW): is a solid-state joining process which works by rotating
one workpiece relative to another while under a compressive axial force.

A. 100% bond at the contact area

B. Scalable to any size weld
C. Ability to join dissimilar materials
D. Minimal joint preparation required

- Linear Friction Welding: is a solid-state process in which one part moves in a linear
motion at high speed and is pressed against another part held stationary. The resulting
friction heats the parts, causing them to forge together.

A. Ability to join dissimilar metals

B. Minimal joint preparation required; resulting in faster production
C. Eco-friendly since no consumables are used
D. Scalable to any size weld

10. Certain changes in joint configuration are usually made to improve the strength of brazed
joints. What are some of these changes?

- In butt joints, the butting surface areas are increased in various ways such as scarfing or
stepping the edges. In brazed or soldered lap joints, the overlap area is made as large as
possible.