Course Manufacturing

Technology

Course Overview

Conventional Machining Processes

Material Removal Process
Casting
Forging
Welding
Non Conventional Machining Process
Abrasive Machining Process

Manufacturing - Basics

Manufacturing is the use of machines, tools and labor to produce goods

for use or sale. Raw materials are transformed into finished goods on a
large scale. Such finished goods may be used for manufacturing other,
more complex products, such as aircraft, household
appliances or automobiles, or sold to wholesalers, who in turn sell them
to retailers, who then sell them to end users the "consumers".

Key Words to know!

Just in Time Production

Lean Manufacturing
Kanban
Toyota Manufacturing Leaders!

Conventional Machining Processes

Rolling
Drawing
Extrusion
Blanking
Fine Blanking
Deep Drawing

Rolling

Rolling, is a continuous bending operation in which a long strip of sheet

metal (typically coiled steel) is passed through sets of rolls mounted on
consecutive stands, each set performing only an incremental part of the
bend, until the desired cross-section profile is obtained. Rolling is ideal for
producing constant-profile parts with long lengths and in large quantities.

Drawing

Drawing is a metalworking process which uses tensile forces to stretch

metal. It is broken up into two types: sheet metal drawing and wire, bar,
and tube drawing. The specific definition for sheet metal drawing is that it
involves plastic deformation over a curved axis. For wire, bar, and tube
drawing the starting stock is drawn through a die to reduce its diameter
and increase its length.

Extrusion

Extrusion is a process used to create objects of a fixed crosssectional profile. A material is pushed or drawn through a die of the
desired cross-section. The two main advantages of this process over other
manufacturing processes are its ability to create very complex crosssections and work materials that are brittle, because the material only
encounters compressive and shear stresses. It also forms finished parts
with an excellent surface finish.

Blanking and piercing

Blanking and piercing are shearing processes in which a punch and die are
used to modify webs. The tooling and processes are the same between
the two, only the terminology is different: in blanking the punched out
piece is used and called a blank; in piercing the punched out piece is scrap

Fine Blanking

Fine blanking is a specialized form of blanking where there is no fracture

zone when shearing. This is achieved by compressing the whole part and
then an upper and lower punch extract the blank.[5] This allows the
process to hold very tight tolerances, and perhaps eliminate secondary
operations.
Materials that can be fine blanked include aluminium, brass, copper,
and carbon, alloy and stainless steels.

Fine Blanking

Deep Drawing

Deep drawing is a sheet metal forming process in which a sheet metal

blank is radially drawn into a forming die by the mechanical action of a
punch.[1] It is thus a shape transformation process with material retention.
The process is considered "deep" drawing when the depth of the drawn
part exceeds its diameter.

Material Removal Process

Turning

Turning - Few Key terms

Facing
Parting
Roughing
Drilling
Boring
Knurling
Threading
Reaming

Casting

In metalworking, casting involves pouring a liquid metal into a mold,

which contains a hollow cavity of the desired shape, and then is allowed to
solidify. The solidified part is also known as a casting, which is ejected or
broken out of the mold to complete the process.

Casting Pictorial Representation

Forging

Forging is a manufacturing process involving the shaping of metal using

localized compressive forces. Forging is often classified according to the
temperature at which it is performed: '"cold," "warm," or "hot" forging.
Common forging processes include: roll forging, swaging, cogging, opendie forging, impression-die forging, press forging, automatic hot forging
and upsetting.
Open Die Forging -Open-die forging is also known as smith forging.[6] In
open-die forging, a hammer strikes and deforms the workpiece, which is
placed on a stationary anvil.
Cogging is successive deformation of a bar along its length using an opendie drop forge. It is commonly used to work a piece of raw material to the
proper thickness. Once the proper thickness is achieved the proper width
is achieved via edging.

Forging Contd..

Edging is the process of concentrating material using a concave shaped

open die. The process is called edging, because it is usually carried out on
the ends of the workpiece. Fullering is a similar process that thins out
sections of the forging using a convex shaped die. These processes
prepare the workpieces for further forging processes.

Fullering

Edging

Welding

Welding is a fabrication or sculptural process that joins materials,

usually metals or thermoplastics, by causing coalescence. This is often
done by melting the workpieces and adding a filler material to form a pool
of molten material (the weld pool) that cools to become a strong joint,
with pressure sometimes used in conjunction with heat, or by itself, to
produce the weld. This is in contrast with soldering and brazing, which
involve melting a lower-melting-point material between the workpieces to
form a bond between them, without melting the workpieces.

Please check the link- it would be useful :

http://en.wikipedia.org/wiki/List_of_welding_processes

Schematic Diagram

Arc Welding

Resistance Welding

TIG Welding

Non Conventional Machining Process

Abrasive Machining Process

Abrasive machining is a machining process where material is removed

from a workpiece using a multitude of small abrasive particles. Common
examples include grinding, honing, and polishing. Abrasive processes are
usually expensive, but capable of tighter tolerances and better surface
finish than other machining processes.
Mechanics of abrasive machining
Abrasive machining works by forcing the abrasive particles, or grains, into
the surface of the workpiece so that each particle cuts away a small bit of
material. Abrasive machining is similar to conventional machining, such as
milling or turning, because each of the abrasive particles acts like a
miniature cutting tool.

Few key words to be remembered!

Fixed (bonded) abrasive processes
Grinding
Honing, superfinishing
Tape finishing, abrasive belt machining
Buffing, brushing
Abrasive sawing, Diamond wire cutting, Wire saw
Sanding
Loose abrasive processes
Polishing
Lapping
Abrasive flow machining (AFM)
Hydro-erosive grinding
Water-jet cutting
Abrasive blasting
Mass finishing, tumbling

Abrasive Water jet Machining

A water jet cutter, also known as a waterjet,[1] is a tool capable of slicing

into metal or other materials (such as granite) using a jet of water at high
velocity and pressure, or a mixture of water and an abrasive substance.

1 High Pressure Water inlet

2- Jewel Ruby or Diamond
3- Abrasive
4-Mixing Tube
5-Guard
6-Cutting water Jet
7-Cut Material

Abrasives
Conventional
Aluminum oxide (Corundum)
Silicon carbide
Emery
Pumice
Sand
Steel abrasive
Superabrasives
Diamond
Cubic Boron Nitride (CBN), Borazon

References
Kalpakjian, Serope; Steven R. Schmid
(2003). Manufacturing Processes for
Engineering Materials. Pearson Education.
www.google.com
en.wikipedia.org
Notes taken down during classrooms!