MANUFACTURING PROCESSES

LECTURE 1
BY DR LIAQAT ALI

HOD (DESIGN AND MANUFACTURING)

SCHOOL OF MECHANICAL AND
MANUFACTURING ENGINEERING
MANUFACTURING PROCESSES
 Assignments 10 %
 Quizes 10 %
 OHT1 15%
 OHT2 15%
 Final Exam 50%
MANUFACTURING PROCESSES
 Lectures
 Other sources (slides/handouts)
 Books
 Principles of Metal Manufacturing Processes
 by J.BeDoes,M.J.Bibby

 Fundamentals of Modern Manufacturing

 by Mikell P. Groover

 Advance Manufacturing Processes

 by Kalpajain
MAJOR TOPICS
 Introduction to Advance Manufacturing Processes
 Casting Processes

 Metal Deformation processes

 Sheet Metal Working Processes

 Metal Cutting Theory/Machining Processes

 Automated Machining Processes

 Joining Processes

 Surface Protection and Heat Treatment Processes

 Non-Conventional Machining Process

INTRODUCTION
 What is Manufacturing?
 Historical Development of Materials and
Manufacturing Processes
 Product Design and Concurrent Engineering
INTRODUCTION
 Manufacturing is the term used to describe the making
of products. Until the nineteenth century it was
largely an activity reserved for craftsmen. The
industrial revolution during the second half of the
nineteenth century introduced manufacturing
mechanization.

 The use of machines for spinning and weaving in the

textile industry is generally acknowledged to be the
beginning of modern manufacturing. During this same
time, Bessemer (1855) in England and William Kelly
(1857) in the United States proposed methods for the
mass production of steel. This was followed by the
Hall-Heroult process (1885) for melting aluminum.
These processes provided relatively cheap sources of
the materials required to drive the industrial
revolution.
 INTRODUCTION
 One definition of manufacturing is the conversion of
either raw or semi-finished materials into finished
parts. Such a definition serves to emphasize the
importance of materials in manufacturing operations.
In fact, the choice of material for a given
manufacturing situation may be the limiting
consideration. In general, a material must satisfy two
criteria.

 First, the relevant mechanical, corrosive, electrical or

physical properties of the material must be sufficient
to ensure failure-free performance of the final
product. Second, the material should be easy and
inexpensive to fabricate. Inexperienced engineers
tend to underestimate the importance of this latter
requirement, often leading to frustration and
redesign.
MATERIALS USED IN MANUFACTURING
SELECTING MATERIALS
 Ferrous Metals
 Nonferrous metals and alloys
 Plastics
 Ceramics
 Composite Materials Nanomaterial's, shape-
Memory alloys, metal foams,
SELECTING MATERIALS
 Material Substitution
 Material Properties

 Cost and Availability

 Service Life and Recycling

SELECTING MANUFACTURING PROCESSES

 Part Size and Dimensional Accuracy

 Ultra precision Manufacturing

 Manufacturing and Operational Costs

 Net- Shape Manufacturing

MANUFACTURING OPERATIONS
 Manufacturing operations can be generally
classified into primary and secondary processes.
For metals, primary manufacturing usually
refers to the conversion of ores into metallic
materials. Secondary manufacturing is generally
understood to mean the conversion of the
products from the primary operation into semi-
finished or finished parts. For example, the
fabrication of automobile engine blocks from a
primary melt of iron or aluminum is said to be
secondary manufacturing.
METAL PROCESSING & MANUFACTURING
 Primary Processes
 The vast majority of pig iron produced from iron ores is
processed by blast furnaces
 Steel making by Bessemer steel converter
METAL PROCESSING & MANUFACTURING

BLAST
FURNACE
SCHEMATIC OF A BESSEMER STEEL CONVERTER
OPEN HEARTH STEEL CONVERTER
ELECTRIC ARC FURNACE FOR STEEL PRODUCTION
FLOW DIAGRAM OF THE BAYER PROCESS
(CONVERSION OF BAUXITE INTO ALUMINA)
 The conversion of primary products into secondary
finished or semi-finished components can take place by
one of several alternative routes.
CASTING PROCESSES
 Sand Casting
 Lost Wax Casting

 Die Casting Deep

 Fundamentals of Die Casting Design

FORMING PROCESSES

 Upset forging
 Extrusion
 Thread and gear rolling
 Coining (stamping)
 Wire drawing
 Tube drawing
 Impression-die forging
 Deep drawing
 Bending
 Embossing
 Shearing
SHEET FORMING PROCESSES
 Formability
 Shearing

 Bending

 Stretch forming

 Press working of metals

MACHINING PROCESSES

Mechanical Machining methods

Non-traditional machining
processes
MACHINING PROCESSES

 Mechanical Machining methods

 Conventional Machining
 Single point machining
 (Tunining, Shaping, Planing etc.)
 Multipoint machining
 Drilling, Milling etc.)
 CNC Machining
 CNC Turning
 CNC Milling
NON-TRADITIONAL MACHINING PROCESSES

 Non-traditional machining processes

 Abrasive water jet Machining
 ECM (Electro-chemical machining)
 EDM (Electro-discharge machining)
 EBM (Electron Beam machining)
 LBM (Laser Beam machining)
 Rapid Prototyping
JOINING PROCESSES
 Welding
 Brazing

 Soldering
HEAT TREATMENT OF MATERIALS
 Annealing
 Normalizing

 Tempering

 Quenching
SURFACE TREATMENT
 Diffusional Processes
 Flame Induction Hardening

 Plating Processes

 Thin film coatings

END