Introduction to Manufacturing

Technology
(Overview of Manufacturing technologies)

Instructor: HAILE
 Overview of the manufacturing
• Manufacturing processes can be broadly
divided into two groups:
a) primary manufacturing processes : Provide
basic shape and size
b) secondary manufacturing processes :
Provide final shape and size with tighter
control on dimension, surface characteristics
 Overview manufacturing
Manufacturing systems approaches.

• Basic manufacturing processes. (Casting, Forming process,

Fabrication process, Material removal process)
• Advanced Machining processes (ECM, EDM, EBM, LBM, AJM, USM
processes)
• Micro-manufacturing processes (Etching, Deposition, Lithography,
Replication and molding, Dip-pen lithography, Compression molding,
Nano-imprint lithography)
 Manufacturing Systems Approach
Definition of Manufacturing Technology:

•Manufacturing technology provides the tools that

enable production of all manufactured goods. 
These master tools of industry magnify the effort of
individual workers and give an industrial nation the
power to turn raw materials into the affordable,
quality goods essential to today’s society. 
•Thus manufacturing process really represents
adding value to a raw material and creation of
wealth.
Casting Processes
• These are the only processes where
liquid metal in used.
• Casting is the oldest known
manufacturing process.
• It requires preparation of a cavity usually
in a refractory material to resemble
closely to the object to be realized.
• Molten metal is poured into this
refractory mould cavity and is allowed to
solidify.
• The object after solidification is removed
from the mould.
 Forming Processes
• These are solid state manufacturing processes involving minimum amount of
material wastage and faster production.
• Metal is heated to a temperature which is slightly below the solidus temperature
and then a large force is applied such that the material flows and take the desired
shape.
• The desired shape is controlled by means of certain tools called dies which may be
completely or partially closed during manufacture.
• These processes are normally used for large scale production rates.

Extrusion
Drop forging

Rolling Process

Wire Drawing
 Fabrication processes
• These are secondary manufacturing processes where the starting raw
materials are processed by any of the previous methods.
•It essentially involves joining pieces either temporarily or permanently so
that they would perform the necessary function.
•The joining can be achieved by both heat and pressure and / or a joining
material.
Gas Welding
Resistance Welding

Arc Welding
 Material Removal Processes
• These are also secondary manufacturing processes where the additional
unwanted material is removed in the form of chips from the blank material by a
harder tool so that a final desired shape can be obtained.
• Material removal is the most expensive manufacturing process because more
energy is consumed, and also a lot of waste material is generated in the process.

Turning Shaping
Grinding

Milling Drilling
Sawing
 History of Machining
• Mankind used bones, sticks and stones as
hand tools since the earliest times

The most ancient Paleolithic stone tool During the Upper Paleolithic further
industry the Oldowan was developed by technological advances were made such
the earliest members of the genus Homo as the invention of Nets, bolas, the spear
such as Homo habilis around 2.6 million thrower the bow and arrow.
years ago. and contained tools such as
choppers, burins and awls.
 History of Machining
Hand held tools from Bronze Age
developed around 1 million years back.

Upto almost the seventeenth century all

tools were either hand operated or done
so by other very elementary methods.

Introduction of water, steam and later

electricity as useful sources of energy
led to the concept of power driven Ceremonial giant dirk of the
machine tools. Plougrescant-Ommerschans type, Bronze Age weaponry
Plougrescant, France, 1500-1300BC. and ornaments

John Wilkinson in 1774 first constructed a precision

machine for boring engine cylinders, powered by steam.
 History of Machining

• 23 years later, Henry Maudslay made a further advancement in machining

when he devised screw cutting engine lathes.
• James Nasmyth invented the second basic machining tool for shaping and
planing.
First Universal Milling machine was built by J.R. Brown in
1862.

In the late nineteenth century, the grinding machine was

introduced. An advanced form of this process is the lapping
process used to produce a high quality surface finish and a
very tight tolerance
 History of Machining

• In the later part of 19th and 20th Centuries the machine tools became
increasingly electrically powered.
• The basic machine tools had further refinements; for instance multiple
point cutters for milling machines were introduced.
• The whole machining paradigm was however still related to an operators
judgment who by looking at a part and using his skills would set up an
operation sequence and use this for machining the work piece. Accuracy of
such a product would depend solely on the operator.
• The introduction of NC (numerical control) in 1953 lead to computer
numeric control and direct numeric control.
• Present capabilities of these tooling systems have enormously increased
due to development in electronic controls and computers and present
capabilities enable complex shapes to be produced with finishing accuracy
close to a + 1 Micron.
 History of Machining
• In modern machining practices, harder, stronger, and tougher
materials that are more difficult to cut are used. So, processes
should be independent of material properties of the work piece.
• Non conventional machining practices came very handy as an
alternative to the conventional domain which could handle shape
complexity, surface integrity and miniaturization requirements.
• Hybrid machining made use of the combined enhanced
advantages of two or more participating processes.
• Micromachining had emerged because of this change of
capabilities.
• Recent applications of micromachining include silicon/ glass
micromachining, excimer lasers and photolithography.
 History of Machining
• Machines such as precision grinders may be capable of producing an
accuracy level of + 1 microns that can be measured using laser instruments
and optical fibers.
• Future trends in micromachining include laser and electron beam
lithography and super high precision grinding, lapping and polishing
machines. For measurements high precision laser beam based scanners are
used for measuring surface finish etc.
• Nano-machining is a very recent trend in these processes wherein atoms
and molecules can be removed instead of chips in conventional machines.
• Nano-machining was introduced by Tanigushi to cover the miniaturization
of components and tolerances in the range from submicron level to that of
an individual atom or molecule between 100nm and 0.1 nm.
Abrasive Machining Categories
• The Metal abrasion action is adopted during
grinding, honing and super finishing processes that
employ either a solid grinding wheel or sticks in the
form of bonded abrasive.

• Furthermore in lapping, polishing, and buffing, loose

abrasives are used as tools in a liquid medium.
Classification of all Material Removal
Processes

Area of
interest
 Non Traditional Machining
• Traditional machining is mostly based on removal of materials
using tools that are harder than the materials themselves.
• New and novel materials because of their greatly improved
chemical, mechanical and thermal properties are sometimes
impossible to machine using traditional machining processes.
• Traditional machining methods are often ineffective in machining
hard materials like ceramics and composites or machining under
very tight tolerances as in micromachined components.
• New processes and methods play a considerable role in machining
for aircraft manufacture, automobile industry, tool and die
industry mold making etc.
• They are classified under the domain of non traditional processes.
 Classification of Non Traditional Machining

Single action non traditional Machining processes:

For these processes only one machining action is used for material removal. These
can be classified according to the source of energy used to generate such a
machining action: mechanical, thermal, chemical and electrochemical.