Manufacturing

Processes
BITS Pilani
Pilani Campus

Dr Amrita Priyadarshini
Assistant Professor
Mechanical Engineering
BITS Hyderabad Campus

BITS Pilani
Pilani Campus

Introduction to
Manufacturing Processes

Plan of Lecture
Introduction to the Course
Introduction to the Manufacturing
Introduction to the Manufacturing Processes

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Course Introduction
COURSE DESCRIPTION:
Introduction to Manufacturing processes; Casting processes;
Forming processes; Machining processes; Joining
processes; Unconventional machining processes;
Automation of Manufacturing Processes and Operations;
COURSE OBJECTIVE:
This course is designed to create clear understanding of
various manufacturing processes highlighting the basic
scientific principles with the stress is being on how things
are made. At the end of the course one can appreciate the
reasons why things are made the way they are and the
possibilities of improving upon given methods.
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TEXT BOOK (T):

Serope Kalpakjian, Steven R. Schmid, Manufacturing
Processes for Engineering Materials, Pearson Education
5th Edition, 2011.
REFERENCE BOOKS (R):
Amitabh Ghosh & A. K. Mallik, Manufacturing Science,
Affiliated East-West Press Pvt. Ltd.
P. N. Rao, Manufacturing Technology Vol-I and II, Tata
McGraw-Hill Publications, III Edition, New Delhi.
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Reference Books
1. Richard W. Heine, Carl R. Loper and Philip C.
Rosenthal, Principles of Metal casting, Tata McGrawHill Publication, II Edition, 2004.
2. Richard L. Little, Welding and Welding Technology,
Tata McGraw-Hill Publications, I Edition, New Delhi.

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LECTURE PLAN
Session

Topic

No.

Chapters
from Text
Book

1
2,3

Introduction to Manufacturing processes

Ch 1

Fundamental of the Mechanical Behavior of Materials and Properties of Ch 2 and

Metals

Ch 3

4, 5

Metal Casting Processes and Equipments

Ch 5

6,7

Bulk Deformation Processes

Ch 6

Sheet Metal Forming Processes

Ch 7

Material Removal Processes

Ch 8 and

8
9-13

Ch 9
14-15
16
17-18

Joining Processes

Ch 12

Unconventional Machining Processes

R1: Ch 6

Automation of Manufacturing Processes and Operations

Ch 14
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EVALUATION SCHEME
EC No. Evaluation
Component &
Type of
Examination

Duration

EC-1 Quiz (3)

Weightage Day, Date, Session,Time

15%

EC-2 Mid-Semester Test

(Closed Book)

2 Hours

35%

EC-3 Comprehensive
Exam
(Open Book)

3 Hours

50%

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EVALUATION SCHEME
Component

Weightage

Syllabus (Specify
Chapter Nos. as
per handout)

To be administered online in
during

Quiz 1

5%

Chapter 5

February 1-10, 2015

Quiz 2

5%

Chapter 8

March 1-10, 2015

Quiz 3

5%

Chapter 12

April 1-10, 2015

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What is Manufacturing?
Literal:

Manufacture = Manus (hand) + Factus

(make) Made by hand
Technological: Application of physical and chemical
processes to make parts or products,
including assembly of products.
Economical:
Transformation of materials into items
of greater value by means of processing and/or assembly operations.
CIRP definition: Design + production + assembly
(CIRP = International Academy for Production Eng.)

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Importance of manufacturing
Manufacturing is an important mean to create
material wealth!!!
One job in a manufacturing plant generates about
four other jobs else!!!
Data from the USA:
-

Manufacturing
: ~ 20% of the GNP
Agriculture, mining
: < 5% of the GNP
Construction, public utilities : ~ 5% of the GNP
Service sector
: ~ 70% of the GNP
(GNP = Gross National Product)

Question: What are the figures for India?

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Manufacturing is Important
Technologically
Economically
Historically

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Manufacturing Process
What?

Converting raw materials into useful products

How?

By means of various processes, machinery and a well organized

plan
Steps:
design of products
Selection of raw materials
Sequence of processes
Outcome
Adds value
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Application of physical and chemical processes to alter the

geometry, properties, and/or appearance of a starting
material to make parts or products
Manufacturing also includes assembly
Almost always carried out as a sequence of operations

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Transformation of materials into items of greater value by means

of one or more processing and/or assembly operations
Manufacturing adds value to the material by changing its shape
or properties, or by combining it with other materials

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Product design and

Concurrent Engineering
1.
2.
3.
4.
5.

70% to 80% of cost is determined in this phage.

Innovation vs benchmarking
Inputs from market
Theory of product flow
Concurrent engineering

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Product Design Process

Chart showing the various steps

involved in design and manufacturing
a product.

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Concurrent engineering
1. Systematic approach for integration
2. Goal is to minimizing the product design and
engineering changes
3. Direct engineering
4. Essential elements required
5. Analytical model CAD Simulation prototyping
virtual prototyping

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Computer Integrated
Manufacturing
1. CNC
2. Adaptive Control
3. Industrial robots
4. Automated handling
5. Automated and robotic assembly
6. Computer aided process planning
7. GT
8. JIT
9. Cellular Manufacturing
10. FMS
11. Expert systems
12. AI
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Materials in Manufacturing
Metals
- Ferrous: Steel (iron-carbon, 0,02% - 2,11% C)
Cast iron (iron + 2% - 4% C + silicon)
- Nonferrous: copper, aluminium, nickel, alloys
Ceramics: clay, silica, carbides (Al, Si), nitrides (Ti)
Polymers
- Thermoplastic polymers: PVC
- Thermosetting polymers: phenolics, epoxies
- Elastomers: rubber, neoprene, silicone, PU
Composites: more phases, particles/fibres + matrix
glass reinforced plastic, Kevlar.
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Materials in an Automotive
Engine

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Components in Products
Some products are a single
components (nail, bolt, fork,
coat hanger, etc.)

Some products are assemblies

of many components (ball
point pens, automobiles,
washing machines, etc.)

All components are

manufactured.

Manufacturing means, literally,

Made by Hand

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Manufacturing Processes
Two basic types:
1. Processing operations
2. Assembly operations

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Manufacturing Processes
Component
1

Casting
Machini
ng

Component 2

Forming
Component 3

Finish
ed
produ
ct

Classification of
Manufacturing Processes

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Processing Operations
Alters a materials shape, physical properties, or
appearance in order to add value
Three categories of processing operations:
1. Shaping operations
2. Propertyenhancing operations
3. Surface processing operations

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Shaping Processes Four

Categories
1.
2.
3.
4.

Solidification processes
Particulate processing
Deformation processes
Material removal processes

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Solidification Processes/
Casting
These are the only processes where liquid metal in used.
Casting is the oldest known manufacturing process.
It requires preparation of a cavity usually in a refractory
material to resemble closely to the object to be realized.
Molten metal is poured into this refractory mould cavity
and is allowed to solidify.
The object after solidification is removed from the mould.

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Casting

Starting material is heated sufficiently to transform it

into a liquid or highly plastic state
Examples: casting for metals, molding for plastics

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Steps

Melting
Pattern making
Mold making
Pouring
Solidification
Breaking the mold/ cleaning
Final object with desired shape and size

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BITS Pilani, Pilani Campus

Casting

Casting

Manufacturing ProcessCasting

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BITS Pilani, Pilani Campus

Shell moulding

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Expanded Polystyrene Process

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Permanent Mold Casting

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Die Casting

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Centrifugal Casting

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Forming Processes: Deformation

Bulk Deformation
Small surface area to volume (thickness
ratio)
Thickness/ cross section changes Sheet
Metal Forming

Sheet metal forming

Large surface area to volume (thickness ratio)
Thickness constant

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Forming Processes

These are solid state manufacturing processes involving

minimum amount of material wastage and faster
production.
Metal is heated to a temperature which is slightly below
the solidus temperature and then a large force is applied
such that the material flows and take the desired shape.
The desired shape is controlled by means of certain tools
called dies which may be completely or partially closed
during manufacture.
These processes are normally used for large scale
production rates.

Extrusion
Drop forging

Rolling Process
Wire Drawing

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

BITS Pilani, Pilani Campus

Bulk Deformation Processes

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

BITS Pilani, Pilani Campus

Rolled Products Made of Steel

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Rolling of strip

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Extrusion

Sheet Metal Forming Processes

Cutting

V-Bending

Deep
Drawin
g

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Deep drawing

Material Removal Processes

Excess material removed from the starting piece so what
remains is the desired geometry
Examples: machining such as turning, drilling, and
milling; also grinding and nontraditional processes

Turning: Machining of
cylindrical parts

Drilling

Milling

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Machining
Why?

What?

How?

Machining
Why?
What?
The process in which the desired shape,
size and finish are obtained through
excess material removal from the work
part in the form of small chips using a
cutting tool
How?

Types

Turning

Drilling

Milling

Turning

Drilling

Milling

Machining and Finishing

Processes

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Material Removal Processes

Turning examples

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Two Forms of Milling

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Joining Processes

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Arc Welding
A pool of molten metal is formed near electrode tip, and as
electrode is moved along joint, molten weld pool solidifies in
its wake

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Oxyacetylene Welding

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Gas Metal Arc Welding

GTAW is most commonly used to weld thin sections of stainless steel and nonferrous metals such as aluminum, magnesium, and copper alloys.

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Name

Characteristics

Applications

Atomic hydrogen welding

Two metal electrodes in hydrogen atmosphere

Historical

Bare metal arc welding

Consumable electrode, no flux or shielding gas

Historical

Carbon arc welding

Carbon electrode, historical

Copper, repair (limited)

Flux cored arc welding

Continuous consumable electrode filled with flux

Industry, construction

Gas metal arc welding

[3]

Gas tungsten arc welding

Continuous consumable electrode and shielding gas Industry

[4]

Nonconsumable electrode, slow, high quality welds

Aerospace,Construction(pi
ping),Tool and Die

Plasma arc welding

Nonconsumable electrode, constricted arc

Tubing, instrumentation

Shielded metal arc

welding [5]

Consumable electrode covered in flux, can weld any Construction, outdoors,

metal as long as they have the right electrode
maintenance

Submerged arc welding

Automatic, arc submerged in granular flux

Magnetically Impelled Arc

Butt

both tube ends are electrodes; no protection gas; arc

pipelines and tubes
rotates fast along edge by applied magnetic field

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Resistance Spot Welding

Resistance welding,
showing the components in
spot welding, the main
process in the RW group.

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Brazing - Soldering: Permanent Joining Processes

Weak Bonding, Lower Temperatures

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Joining Process: Adhesive Bonding

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Summary.

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Classification of
Manufacturing Processes

Shape change processes

Machining processes
Joining processes
Unconventional machining processes

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Shape change processes

Casting
Forming
Rolling
Forging
Drawing
Extrusion
Bending
Punching & Blanking

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Machining processes

Turning
Shaping
Planning
Drilling
Boring
Milling

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Joining processes

Soldering
Brazing
Welding
Riveting
Bolting

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Unconventional machining
processes

Abrasive Jet Machining,

Ultrasonic Machining,
Electrochemical Machining,
Electric Discharge Machining,
Electron Beam Machining,
Laser Beam Machining,
Plasma Arc Machining
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Casting Process

Fundamentals of Metal casting and metallurgy

Pattern and Mould
Solidification and its influence on casting quality
Riser and runner design
Casting techniques applied to common metals and alloys
Modern casting processes
Casting defects
Application of casting processes.

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Welding
Fundamentals of Metal welding and metallurgy
Various welding processes and influence of process
parameters on welding.
Welding defect control
Testing of weldments.

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Thank You!

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