1

MANUFACTURING
PROCESSES
Asst. Prof. Sadia Riaz
 Course Outline
2

 Title:
 ME-221: Manufacturing Processes
 Books
 Materials and Processes in Manufacturing, Paul Degarmo
 Fundamentals of Modern Manufacturing, Mikell P. Groover
 Grading
Quizzes (3-4) 10%
Assignment+Pres+ Report) 10%
Sessionals (2) 30%
Final 50%
 Tentative Plan
3

Topic Week/
Lecture
Introduction to Manufacturing processes and materials 1-2
Metal Casting 3-4
 Foundry, sand casting, Die casting, permanent mold casting etc.
Forming and Shaping of Plastic and Composite
 Compression/Transfer/Injection molding etc. 5-6
Forming and shaping of metals (Bulk & Sheetmetal)
 Rolling, Forging, Extrusion, Forming, Drawing, etc. 7-9
Metal Cutting
 Lathe, Milling, Shaper, Planner, Drilling, Tools, Grinding, Broaching 10-11
etc.
Joining Processes and Equipments
 Temp/Perm joining, Welding, Soldering, Brazing, tec. 12-15
Quality, Measurement and Inspection
16
 Course Learning Outcomes
4

S.No Outcomes Level of PLO

Learning
1 Describe the manufacturing industry, manufacturing processes and C1 1
properties of materials required for manufacturing

2 Comprehend and distinguish among different machining processes, C2 2

the metal casting, forming and shaping processes

3 Know and choose different assembly processes with respect to the C2 2

industrial / process constraints.
4 Predict the part quality through Measurement and Inspection C3 2

5 Understand the impact of traditional manufacturing techniques on C2 7

environment and the progression towards sustainable
manufacturing.
6 Demonstrate affectively a topic of own interest which deals with the A3 9
latest development in the field of machine tool, manufacturing
processes, research etc.
 Presentation+ Report
(8 Abs Marks)
5

 Any Modern/Recent Manufacturing Process/Research/Innovation/discovery

etc.
 Shaping, machining, forming, casting, RP etc..
 3 Students (according to attendance sheet) each week
 1-2 students (Max 5min / 7mins)
 Presentation
 Introduction
 Basic principle and operation (with figures)
 Advantage/disadvantage w.r.t. its equivalent processes and its uses
 Effect on environment
 Report (Week 15)
 Same topic as presentation
 1 A4 page (Brief, intro, detail, importance, impact, conclusion)
 Course Contents
6

 Metal Casting
 Foundry, sand casting, Die casting, permanent mold casting etc.
 Forming and Shaping of Plastic
 Compression/Transfer/Injection molding etc.
 Forming and shaping of metals
 Rolling, Forging, Extrusion, Forming, Drawing, etc.
 Metal Cutting
 Lathe, Milling, Shaper, Planner, Drilling, Tools, Grinding etc.
 Joining Processes and Equipments
 Temp/Perm joining, Welding, Soldering, Brazing, tec.
 Quality, Measurement and Inspection
 7

INTRODUCTION
Ch. 1
 INTRODUCTION
8

 What is Manufacturing?
 Materials in Manufacturing
 Manufacturing Processes
 Production Systems
 What is Manufacturing?
9

 Manufacture (Latin words)

 manus (hand) and factus (make)
 “made by hand”
 “Made by hand” accurately describes?
 English word “manufacture” was first coined around 1567 A.D.
 Modern manufacturing
 Accomplished by automated and computer-controlled machinery that is
manually supervised
 Can be viewed as
 Technical process
 Economical process
 Manufacturing as a technical process
10

 Application of physical and chemical processes to alter the geometry,

properties, and/or appearance of a given material to make parts or
products
 Manufacturing also includes assembling of multiple parts to make products
 Manufacturing is almost always carried out as a sequence of operations
 Manufacturing as a economic process
11

 Manufacturing is the 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
that have been similarly altered
 Manufacturing / Production
12

 Product quantity vs variety?

 Examples?
 Manufacturing Capability
13

 A manufacturing plant consists of a set of processes

and systems (and people)
 designed to transform a certain limited range of materials
into products of increased value
 Manufacturing capability
 Technical and physical limitations of a manufacturing firm
and its plants
 Manufacturing capability includes:
 Technological processing capability
 Physical product limitations
 Production capacity
 Technological Processing Capability
14

 The available set of manufacturing processes in the plant

 Certain manufacturing processes are suited to certain materials
 By specializing in certain processes, the plant is also specializing in
certain material types
 Also includes the expertise of the plant personnel
 Physical Product Limitations
15

 There are size and weight limitations on the parts or

products that can be made in the plant
 Product size and weight affect:
 Production equipment
 Material handling equipment

 The production and material handling equipment, and plant

size must be planned for products that lie within a certain
size and weight range
 Production Capacity
16

 The production quantity that can be produced in a given

time period (e.g., month or year)
 Commonly called plant capacity, or production capacity,
 The maximum rate of production that a plant can achieve under
assumed operating conditions
 Operating conditions refer to number of shifts per week, hours per
shift, direct labor manning levels in the plant, and so on
 Usually measured in terms of output units, such as tons of
steel or number of cars produced by the plant
 Materials in Manufacturing
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 Most engineering materials can be classified

into one of three basic categories:
1. Metals
2. Ceramics
3. Polymers
 Materials in Manufacturing
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 Metals
 Usually alloys, which are composed of two or more
elements, at least one of which is metallic
 Ceramics
 compounds containing metallic/semi-metallic and
nonmetallic elements. Typical nonmetallic elements are
oxygen, nitrogen, and carbon
 Polymers
 compounds formed of repeating structural units called
“mers”, whose atoms share electrons to form very large
molecules
Materials in Manufacturing
 In addition to the three basic categories, there
are: Composites
 Non-homogeneous mixtures of the other three basic
types rather than a unique category
 Manufacturing Processes
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 Processing operations
 Transform a work material from one state of completion
to a more advanced state
 Consist of operations that change the geometry,
properties, or appearance of the starting material

 Assembly operations
 Join two or more components in order to create a new
entity
 Processing Operations
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 Shaping operations
 Alter the geometry of the starting work material

 Property-enhancing operations
 Improve physical properties of the material without
changing its shape

 Surface processing operations

 Performed to clean, treat, coat, or deposit
material onto the exterior surface of the work
 Shaping Processes – Four Categories
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 Solidification processes
 starting material is a heated liquid or semi-fluid that solidifies to form
part geometry
 Particulate processing
 Starting material is a powder, and the powders are formed into desired
geometry and then sintered to harden
 Deformation processes
 Starting material is a ductile solid that is deformed

 Material removal processes

 Starting material is a solid (ductile or brittle), from which material is
removed so resulting part has desired geometry
 Solidification Processes
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 Starting material is heated sufficiently to transform it

into a liquid or highly plastic state
 Examples: Casting for metals, molding for plastics
 Particulate Processing
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 Starting materials are powders of metals or ceramics

 Usually involves pressing and sintering, in which powders are
first squeezed in a die cavity and then heated to bond the
individual particles
 Deformation Processes
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 Starting workpart is shaped by application of forces

that exceed the yield strength of the material
 Examples: (a) forging, (b) extrusion
 Material Removal Processes
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 Excess material removed from the starting workpiece so what

remains is the desired geometry
 Examples: machining such as turning, drilling, and milling; also
grinding and nontraditional processes

It is desirable to minimize waste and scrap in part shaping

 Assembly Operations
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 Two or more separate parts are joined to form a new

entity
 Temporary Joining
 screws, bolts, nuts, other threaded fasteners; press
fitting
 Permanent Joining
 Welding, Soldering, Brazing etc.
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 Production Systems
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 The people, equipment, and procedures designed for

the combination of materials and processes that
constitute a firm's manufacturing operations
 30

MECHANICAL PROPERTIES
OF MATERIALS
Self Study for revision of concepts
 Mechanical Properties in
Design and Manufacturing
31

 Mechanical properties determine a material’s

behavior when subjected to mechanical stresses
 Properties include elastic modulus, ductility,
hardness, and various measures of strength
 MECHANICAL PROPERTIES
OF MATERIALS
32

 Stress-Strain Relationships
 Hardness
 Effect of Temperature on Properties
 Fluid Properties
 Stress-Strain Relationships
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 Three types of static stresses to which materials can

be subjected:
1. Tensile - tend to stretch the material
2. Compressive - tend to squeeze it
3. Shear - tend to cause adjacent portions of material to
slide against each other
 Stress-strain curve
 basic relationship that describes mechanical properties for
all three types
 Stress-Strain Relationships
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 Yield point Y can be identified by the

change in slope at the upper end of
the linear region
 Y = a strength property
 Other names for yield point = yield
strength, yield stress, and elastic limit
 The stress corresponds to the
maximum load the object supports is
refer to as the tensile strength TS or
ultimate tensile strength
 Ability of a material to plastically
strain without fracture is called
DUCTILITY

Typical engineering stress-strain plot

in a tensile test of a metal
 Two Regions of Stress-Strain Curve
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 Elastic region
Hooke's Law : e = E ɛ
 Plastic region
 After yielding of the material
 The stress-strain relationship is no longer guided by Hooke's
Law
 As load is increased beyond Y, elongation proceeds at a
much faster rate than before, causing the slope of the curve
to change dramatically
 Necking
36
 True stress-strain curve
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True stress-strain curve for the previous engineering

stress-strain plot
 Strain Hardening in Stress-Strain Curve
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 In the engineering stress-strain curve, the stress was

based on an incorrect area value
 True stress increases continuously in the plastic region
 It means that the metal is becoming stronger as strain
increases
 This is the property called strain hardening

  K n
 Brittle Materials
39

 Hard brittle materials (e.g., ceramics) possess

elasticity but little or no plasticity
 Often tested by a bending test (also called flexure
test)
 Brittle materials do not flex
 They deform elastically until fracture
 stress-strain curve (compression)
40
 stress-strain curve (Shear)
41
 Hardness
42

 Resistance to permanent indentation

 Good hardness generally means material is resistant
to scratching and wear
 Most tooling used in manufacturing must be hard for
scratch and wear resistance
 Effect of Temperature on Properties
43

Hot Hardness
 Recrystallization in Metals
44

 Most metals strain harden at room temperature

according to the flow curve (n > 0)
 But if heated to sufficiently high temperature and
deformed, strain hardening does not occur
 Instead, new grains are formed that are free of strain
 The metal behaves as a perfectly plastic material; that is, n
=0
 Recrystallization Temperature
45

 Formation of new strain-free grains is called

recrystallization
 Recrystallization temperature of a given metal is
about one-half its melting point (0.5 Tm)
 Recrystallization and Manufacturing
46

 Recrystallization can be exploited in manufacturing

 Heating a metal to its recrystallization temperature
prior to deformation allows a greater amount of
straining, and lower forces and power are required to
perform the process
 Forming metals at temperatures above
recrystallization temperature is called hot working
47
 Fluid Properties and Manufacturing
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 Fluids flow
 They take the shape of the container
that holds them
 Many manufacturing processes are
accomplished on materials converted
from solid to liquid by heating
 Examples:
 Metals are cast in molten state
 Glass is formed in a heated and highly
fluid state
 Viscosity in Fluids
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 Flow is a defining characteristic of fluids, but the

tendency to flow varies for different fluids
 Viscosity is the resistance to flow that is characteristic
of a given fluid
 Viscosity is a measure of the internal friction
 The more viscous the fluid, the higher the internal friction
and the greater the resistance to flow
 Reciprocal of viscosity is fluidity - the ease with which a fluid
flows
 50

PHYSICAL PROPERTIES
OF MATERIALS
Ch. 4
 Physical Properties in Manufacturing
51

 Physical properties defines the behavior of materials

in response to physical forces other than mechanical.
 volumetric, thermal, electrical & electrochemical properties.
 Important in manufacturing because they often
influence process performance
 Examples:
 In machining, thermal properties of the work material
determine the cutting temperature, which affects how long
tool can be used before failure
 PHYSICAL PROPERTIES
OF MATERIALS
52

 Volumetric and Melting Properties

 Thermal Properties
 Mass Diffusion
 Volumetric and Melting Properties
53

 Properties related to the volume of solids and how

the properties are affected by temperature
 Includes:
 Density

 Thermal expansion
 Melting point
 Density
54

 Important consideration in material selection for a

given application
 Strength is also important
 Both properties are related in strength-to-weight
ratio, which is tensile strength divided by its density
 Useful ratio in comparing materials for structural
applications in aircraft, automobiles, and other products
where weight and energy are of concern
 Thermal Expansion
55

 Density of a material is a function of temperature

 In general, density decreases with increasing temperature
 Volume per unit weight increases with increasing temperature
 Thermal expansion is the name for this effect of temperature on density
 Measured by coefficient of thermal expansion 
 Change in length per degree of temperature, mm/mm/C (in/in/F)
L2 - L1 = L1 (T2 - T1)
 Thermal Expansion in Manufacturing
56

 Thermal expansion is used in shrink fit and expansion fit

assemblies
 Part is heated to increase size or cooled to decrease size to permit
insertion into another part
 When part returns to ambient temperature, a tightly-fitted assembly is
obtained
 Thermal expansion can be a problem in heat treatment and
welding due to thermal stresses that develop in material during
these processes
57
 Melting Characteristics for Elements
58

 Melting point Tm of a pure element = temperature at which it

transforms from solid to liquid state

 The reverse transformation occurs at the same temperature

and is called the freezing point

 Heat of fusion
 heat energy required at Tm to accomplish transformation from solid to
liquid
 Importance of Melting in Manufacturing
59

 Metal casting
 the metal is melted and then poured into a mold cavity
 Metals with lower melting points are generally easier to
cast
 Plastic molding
 melting characteristics of polymers are important in
nearly all polymer shaping processes
 Mass Diffusion
60

 Movement of atoms or molecules within a material or across a

boundary between two materials in contact
 Because of thermal agitation of the atoms in a material (solid,
liquid, or gas), atoms are continuously moving about
 In liquids and gases, where the level of thermal agitation is high, it is a
free-roaming movement
 In metals, atomic motion is facilitated by vacancies and other
imperfections in the crystal structure
(a) model of atoms in two solid blocks in contact:
(b) The concentration gradient dc/dx for metal A is plotted
 Mass Diffusion in Manufacturing
62

 Surface hardening treatments based on diffusion

include carburizing and nitriding
 Diffusion welding - used to join two components by
pressing them together and allowing diffusion to
occur across boundary to create a permanent bond
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THE END