Introduction to Manufacturing Processes

Products and Manufacturing

Product Creation Cycle
Design Material Selection Process Selection Manufacture Inspection Feedback Typical product cost breakdown

Manufacturing Process
A sequence of operations and processes designed to create a specific product The process of turning materials into a product

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Engineers in Manufacturing
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

Manufacturing System Designs

Job Shop
Small quantities of products Large variety of products Products move through the shop to various machines General-purpose machines

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Manufacturing System Designs

Flow Shop
Larger quantities of products Production line Special purpose machines

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Manufacturing System Designs

Linked-Cell Shop
Manufacturing and subassembly cells connected to final assembly Lean production system One piece flow system

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Manufacturing System Designs

Project Shop
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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Manufacturing System Designs

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

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Manufacturing System Designs

Lean Manufacturing
100% good units flow from process to process Integrated quality control (IQC) All employees are inspectors

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Basic Manufacturing Processes

Casting and Foundry Forming or Metalworking Machining Joining and Assembly Rapid Prototyping Other

Casting and Foundry Processes

In one step raw materials are transformed into a desirable shape Parts require finishing processes

Excess material is recyclable

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Basic Casting Process

A mold is created A cavity that holds the molten material in a desired shape until it is solidified Multiple-use mold Single-use molds

Material is heated to a specified temperature

Molten material is poured into a mold cavity Molten material solidifies into the shape of the cavity Casting or mold is removed Casting is cleaned, finished, and inspected

Forming and Metalworking Processes

Utilizes material that has been cast
Modify the shape, size, and physical properties of the material Hot and cold forming

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Forming and Metalworking Processes

Rolling Material passes through a series of
rollers, reducing its thickness with each pass

Forging Material is shaped by the controlled

application of force (blacksmith)

Forming and Metalworking Processes

Extrusion Material is compressed and forced
through a die to produce a uniformed cross section

Wire, rod, and tube drawing Material is pulled

through a die to produce a uniformed cross section

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Forming and Metalworking Processes

Cold forming and forging Slugs of material
are squeezed into dies

Machining Processes
Controlled removal of material from a part to create a specific shape or surface finish

Cutting element is used

Movement must exist between the part and cutting element

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Machining Processes
Turning Processes
Operations that create cylindrical parts Work piece rotates as cutting tool is fed into the work

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Machining Processes
Turning Processes
Lathes and turning centers Processes include: Straight, taper, contour turning, facing, forming, necking, parting, boring, threading, and knurling

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Machining Processes
Milling Processes
Operations that create flat or curved surfaces by progressively removing material Cutting tools rotate as the work piece is secured and fed into the tool

Machining Processes
Milling Processes
Mills Vertical and horizontal Processes include: Surfacing, shaping, forming, slotting, T-slotting, angle, straddle, dovetailing, and slab milling

Machining Processes
Drilling Processes
Operations that create holes Cutting tools rotate and are fed into nonmoving secured work pieces

Machining Processes
Drilling Processes
Drilling and boring machines Processes include: Drilling, counter drilling, step drilling, boring, counter boring, countersinking, reaming, spot facing, and tapping

Machining Processes
Shearing Processes
Operations that break unwanted material away from the part
A material is placed between a stationary and movable surface. The movable surface (blade, die, or punch) applies a force to the part that shears away the unwanted material.

Machining Processes
Shearing Processes
Automated hole punch, squaring shear, and rotary cutter
Processes include: Shearing, blanking, cutoff, and parting; punching, perforating, and slotting; notching, lacing, and trimming

Machining Processes
Abrasive Machining Processes
Operations in which small particles of materials (abrasives) remove small chips of material upon contact Drum, disc, and belt sanders; surface, vertical and horizontal spindle; disc grinders; media blaster; tumblers

Machining Processes
Thermal and Chemical Processes
Operations that cut and shape materials through chemical means

No mechanical force is used

Electrical discharge, electrochemical, chemical, laser, electron beam, flame cutting, and plasma-arc cutting Processes include: Grinding, sawing, cutting, machining, milling, blanking, and etching

Heat Treating Processes

Controlled heating and cooling of a material to alter its properties while maintaining its shape

Properties include: Strength, toughness, machinability, wear resistance, and corrosion resistance 90% of heat treating is preformed on steel and other ferrous metals

Heat Treating Processes

To aid in the manufacturing process, materials can be treated to be weak and ductile and then can be re-treated to provide high strength. Can also occur incidentally during the manufacturing process

Joining and Assembly Processes

Can you think of a product with only one part? Most products consist of multiple parts that are assembled to form a finished product.

Typical assembly processes include: Mechanical fastening; soldering and brazing, welding; adhesive bonding

Joining and Assembly Processes

Mechanical Fastening
Use physical force to hold parts together Mechanical fasteners or part design Screws, bolts, nails, rivets, cotter pins, retaining clips, and edge design

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Joining and Assembly Processes

Welding
Operations that use heat, pressure, or both to permanently join parts

Gas, arc, stud, spot, forge, roll laminating, resistance, and induction welding

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Joining and Assembly Processes

Adhesive bonding
Bonding of adjoining surfaces by filling the gap between each surface with a bonding material Glue, cement, thermoplastic, thermosetting, and elastomers

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Joining and Assembly Processes

Soldering and Brazing
Operation in which metal surfaces are bonded together by an alloy Heated molten alloy flows between the adjoining surfaces

When the heat is removed, the molten metal solidifies and the metal surfaces are bonded

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Rapid Prototyping
Additive process
Parts are produced directly from software applications Common rapid prototyping systems include: stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), laminated object manufacturing (LOM), digital light processing (DLP)

Rapid Prototyping
Finished parts can be field tested depending upon building material Created parts can be used to create a mold

Modifications to design can be implemented quickly

Other Manufacturing Processes

Testing

Transportation
Material handling

Packaging

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Material-Specific Manufacturing Processes

Plastic Processes Ceramic Processes

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Plastics Manufacturing Processes

Extrusion
A rotating screw forces plastic through a heating chamber and then through a heated die Produces long plastic parts with uniform cross sections

Plastics Manufacturing Processes

Injection Molding
Heated plastic is forced by a movable plunger through a nozzle and then into a mold. The material fills the mold and then is cooled. Most widely used high-volume production process

Plastics Manufacturing Processes

Casting
Plastic is melted and poured into a mold No pressure or fillers are required.

Rotational Molding
A closed mold is filled with a predetermined amount of plastic. The mold is heated, rotated, and then cooled to create a hollow plastic object with uniform wall thickness.

Plastics Manufacturing Processes

Blow Molding
A solid bottom hollow tube is placed between two mold halves and heated. The heated tube is then expanded into the sides of the mold with compressed air.

Plastics Manufacturing Processes

Thermoforming
Plastic sheets are heated over an open mold to a working temperature. Once workable, a vacuum is applied to the mold, forcing the plastic sheet to take the shape of the mold.

Reaction Molding
Liquid reactants are mixed and then pressurized into a mold.
No heat is needed. Curing time is typically less than 1 minute.

Ceramic Manufacturing Processes

Two distinct classes of materials and processes exist.
Glass is heated to a molten state, shaped by viscous flow, and then cooled to produce a solid.

Crystalline Ceramics
Material is shaped and then heated to produce a permanent solid.

Manufacturing Importance
Typical product cost breakdown