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Manufacturing Methods: An Introduction

The course provides an introduction to various manufacturing techniques including casting, deformation processes, sheet metal working, and powder metallurgy. It aims to teach students how to determine key parameters for processes like rolling, forging, extrusion, and drawing based on given information. The document also discusses manufacturing operations like solidification, particulate processing, deformation, material removal, and surface processing. It defines manufacturing and production and explains how manufacturing supports lean production and six sigma quality improvement programs.

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Rafique
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92 views

Manufacturing Methods: An Introduction

The course provides an introduction to various manufacturing techniques including casting, deformation processes, sheet metal working, and powder metallurgy. It aims to teach students how to determine key parameters for processes like rolling, forging, extrusion, and drawing based on given information. The document also discusses manufacturing operations like solidification, particulate processing, deformation, material removal, and surface processing. It defines manufacturing and production and explains how manufacturing supports lean production and six sigma quality improvement programs.

Uploaded by

Rafique
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Manufacturing Methods: An Introduction

ME 821: MANUFACTURING METHODS (3-1-0)


Theory – 100 Sessional – 75 Time: 3Hours
Course Overview
Manufacturing is one of the important courses in mechanical
engineering because it involves conversion of raw materials into
useful engineering products. Hence, manufacturing is basically a
value addition process a process of addition of value to materials.

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Manufacturing Methods: An Introduction

Course Overview
The course is designed to offer knowledge on various
manufacturing techniques viz., casting, deformation processes, sheet
metal working and powder metallurgy. In addition, other processes
viz., surface finishing methods, threads and gear manufacturing will
also be discussed.

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Manufacturing Methods: An Introduction

ME 821: MANUFACTURING METHODS (3-1-0)


Theory – 100 Sessional – 75 Time: 3Hours
Course Outcomes: After completion of the course students will be able to:

CO-1: Given roll diameter, reduction required and coefficient of


friction in cold working, students will be able to determine the
maximum draft possible, number of stages (passes) required
and rolling torque and power.
CO-2: For a given material (defined by a flow curve) and
reduction, student will be able to determine the forging force
required in forging operation.
CO-3: For a given reduction and given material (defined by a
flow curve), students will be able to determine the ram pressure
(force) using Johnson equation in a extrusion process.

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Manufacturing Methods: An Introduction

ME 821: MANUFACTURING METHODS (3-1-0)


Theory – 100 Sessional – 75 Time: 3Hours

CO-4: For a given reduction and given material (defined by a


flow curve), students will be able to determine the drawing
force in a wire drawing operation.
CO-5: For a given vertical or bottom gating mould, students
will be able to design riser and determine mould filling time
and total solidification time.
CO-6: For a blanking or drawing operation, students will be
able to design blanking, drawing die and punch.

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Manufacturing Methods: An Introduction

MANUFACTURING is derived from two Latin words


Manus (hand) and
Factus (make);
the combination means made by hand.
Manufacturing may be defined two ways,
 technologic and
 economic.

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Manufacturing Methods: An Introduction

Manufacturing or Production?
Generally, production has a broader meaning than manufacturing.
‘‘Crude oil production”

A manufacturing process is a designed procedure with the intention of


increasing the value of that material.

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Manufacturing Methods: An Introduction

Manufacturing operations can be divided into two basic types:

(1) Processing operations and


(2) Assembly operations

A processing operation transforms a work material from one state of


completion to a more advanced state that is closer to the final desired
product.
It adds value by changing the geometry, properties, or appearance of the
starting material.
An assembly operation joins two or more components to create a
new entity, called an assembly, subassembly, or some other term
that refers to the joining process (e.g., a welded assembly is called a
weldment)

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Manufacturing Methods: An Introduction

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Manufacturing Methods: An Introduction
Solidification processes

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Manufacturing Methods: An Introduction

Particulate processing

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Manufacturing Methods: An Introduction

Deformation processes

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Manufacturing Methods: An Introduction

Material removal processes

Near net shape processes?

Require minimum machining to produce the final shape

Property-Enhancing Processes

Surface Processing

(1) cleaning,
(2) surface treatments, and
(3) coating and thin film deposition processes

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Manufacturing Methods: An Introduction

Cleaning includes both chemical and mechanical processes to remove dirt,


oil, and other contaminants from the surface.
Surface treatments include mechanical working such as shot peening and
sand blasting, and physical processes such as diffusion and ion
implantation.
Coating and thin film deposition processes apply a coating of material to
the exterior surface of the work part. Examples:
→ electroplating,
→ anodizing of aluminium,
→ organic coating (call it painting), and
→ porcelain enamelling

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Manufacturing Methods: An Introduction

MANUFACTURING SUPPORT SYSTEMS

To operate its facilities efficiently


→ design the processes and equipment,
→ plan and control the production orders, and
→ maintain product quality requirements.
SUPPORT SYSTEMS are:
# Manufacturing engineering
Decides what processes should be used to make the parts and
assemble the products. This department is also involved in designing
and ordering the machine tools and other equipment

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Manufacturing Methods: An Introduction
# Production planning and control
This department is responsible for solving the logistics problem in
manufacturing—ordering materials and purchased parts, scheduling
production, and making sure that the operating departments have the
necessary capacity to meet the production schedules.

# Quality control
Designing and building products that conform to specifications and
satisfy or exceed customer expectations

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Manufacturing Methods: An Introduction
LEAN PRODUCTION AND SIX SIGMA
These are two programs aimed at improving efficiency and quality in
manufacturing. They address the demands by customers for the products
they buy to be both low in cost and high in quality.

Lean Production
Lean production can be defined simply as ‘‘doing more work with fewer
resources.’’
It means that fewer workers and less equipment are used to accomplish
more production in less time, and yet achieve higher quality in the final
product. The underlying objective of lean production is the elimination
of waste.

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Manufacturing Methods: An Introduction

SIX SIGMA
Six Sigma was started in the 1980s at Motorola Corporation in the
United States.
The objective was to reduce variability in the company’s processes and
products to increase customer satisfaction. Six Sigma can be defined as
‘‘a quality-focused program that utilizes worker teams to accomplish
projects aimed at improving an organization’s operational performance.”

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