2012

Manufacturing
Process
Lectures

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Ahver Chaudhary

Manufacturing Process
Why study this subject?
Company producing products need an optimal ways to compete in todays global
marketplace. Knowledge of basic Manufacturing process is essential for Successful
engineering in todays market.
For that Designer and grafter must have basic knowledge of various processes that produce
a part in order to LOWER COST AND REDUCE TIME.
Course Objective:
Understand principles of major Manufacturing Processes
Learn Standard Processes used to produce products.
To select the optimal process for producing products.

Course Outline
Manufacturing Process and its types
Casting
Molds & its types
Heating And Pouring
Fluidity
Solidification
Shrinkage

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Expandable MOLD Casting

Sand Casting
Pattern & cores
Mold making
Shell molding

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Expandable Polystyrene Casting Process

Investing Casting
Permanent Mold Casting
Slush Casting
Die Casting
Hot Chamber and cold chamber Die Casting
Centrifugal force
Casting Quality
Pouring
Cleaning
Product & design Consideration

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Bulk deformation Process

o Rolling
o Rolling Mill

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Thread Rolling
Gear Rolling
Ring Rolling
Roll Piercing
Forging
Open Die & Impression Die Forging
Forging Dies
Hammers & Process
Upsetting & heading Extrusion & its types
Drawing
Joining Process

Welding
o Types
Arc Welding
SMAW
GMAW
GTAW
Resistance Welding
Spot & steam Welding
OXY fuel gas Welding
o Types of Weld joints
o Features Of Weld Joints
o Weld Quality
o Defects
o Inspection & testing Welds
o Brazing
o Soldering
o Sheet Metal Working
o Cutting Operation
o Bending Operation
o Processes
o Rolling Bending & forming

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Mechanical Assembly
Threaded Fastener
Washer
Rivets
Eyelets
Press Fitting
Shrink & Expansion fit
Snap fits
Retaining Fits
Cotter pins
Shaping process for Plastic Extrusion
Subjection Modeling

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o Compression Molding
o Blow Molding
o Thermoforming

Books
ME & tech. by KALPAKJAIN SHMID
Process & Material Of Manufacturing LINDBERG
Material & process in Manuf. DEGRAMO
Fundamentals of Modern Manuf. GROOVER
Manuf. Process PHILIP F. OSTERALD
Design & Tech. by JAMES GARANTT

ENGINEERING
Is a discipline, art, skill, & profession of applying Scientifical, Mathematical, Economic, social
& practical Knowledge in order to design & build
Structures
Machines
Devices
Systems

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Material & process safely realize improvement to lives of people.

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Application of scientific and mathematical principles to practical ends such as design,

manufacturing and operation of efficient and economical structures, machines, process and
systems.
Profession of work performed by an engineer.

Technology
Application of science to provide society and its members with those things that are needed or
desired. It effects our daily lives directly and indirectly in many eays.

Industry
Refers to production of an economic good(either material or service) with an economy as car
industry.

Factory
Its an individual balding (manufacturing plant) where goods are manufactured, supervised by
machine processing and products are formed.

Company
Is a form of business organization that have common purpose and focus & usually and have an
aim of gaining process.

Stock wanders

Board of directors

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President

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Sales & Marketing

Manufacturing

Research & development

1.Product Operation

1.Design engineering

2.Quality Control

2.Customer Services

2.Estimating

3.Industrial
Engineering

2. Production
engineering
3.Prototyping

3.Marketing

3.Exenditure

4.Product Engineering

4.Testing

4. Advertisment

5.Tooling

5.Material Research

Purchasing

1.Purchasing

1.Sales

Finance

1.Accounting
2. Budgeting
3.Planning

Engineering Design Team

Roduct
manager

Sales
MArketing

Purchasing

Industrial
design

Production
Manufacturi
ng
Engineering

Design
engineering
Industrial
Engineering

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Product Manager is Responsible to check whether the product is suitable or not. He co-relates with all to
enhance Quality.

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Professional Teams
Competitors

Industries

Companies

Team owners

Investors

Coaches

Managers

Referees, Umpire

Lawyers, judge

Communication

Co-ordination

Rumbles, injuries

Mistakes, Losses

Individual skills

Specialized jobs

Team Skill

people skills

What do Engineers do?

Research
Manufacturing Products
Design products
Manage Departments and Companies

Engineers in Manufacturing
Manufacturing Engineering
Select and co-ordinate specific processes & equipment.

Industrial Engineering
Responsible for manufacturing system design

Material Engineer
Develop and Select Material based on desired material properties and manufacturing process.

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Engineering role in design manufacturing

In Sales & Marketing
Sales Engineer
Application Engineer
Field Service Engineer

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In Research & development

Industrial Engineer
Designer Engineer
Material Engineer
Test Engineer
In Manufacturing
Industrial Engineer
Manufacturing Engineer
Quality Control Engineer

In Processing and operation

Plant Engineer
Project Engineer

Manufacturing Processes
Manufacturing is derived from 2 Latin words
Manus means hand
Factus mean make

Meaning made by hand. The word Manufacture 1st appeared in 1567 and manufacturing in 1683.
In modern sense Manufacturing involves making parts from raw materials by means of various processes,
machinery, operation and well-organized plant activity.

Manufacturing
The process of converting raw materials into products. It includes,
Designing of product
Selection of raw material
& Sequence of processes through which it will be manufactured.
Its a sequence of operation and processes design to create a specific material.
Process of converting Material into Products.
Making a product by changing the shape, size or composition of material.
Manufacturing process alters a materials properties in controlled manners to produce components of products.

In Manufacturing there are many ways to make parts, some are better i.e. economical and to be aware of
them we need to have knowledge of MP.

Factors
Cost
Quantity
Quality
Equipment
Safety
Availability

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Manufacturing process

Includes
Designing
Engineering
Making
Servicing

Processes
A series of action that leads to goal.
Manufacturing involves no. of different types of processing, each of these help move product from an
IDEA to useful item for consumers.

Designing
It involves processes that change IDEA IN MIND to IDEAS ON PAPERs.

Engineering
Act of specifying products and production systems.

Producing
It is a series of processing used to change materials to products.

Servicing
The group of processes used to keep products in working order.

Technologically
Mfg. is application of physical and chemical processes to alter the geometry, properties and appearance of
starting material to make products.
Manufacturing also includes assembly;
Tooling Power
Machinery

Labor
Processed part

Manufacturing Processes

Starting Material

Scrap & waste

Economically
Mfg. is the transformation of materials into items of greater values, by means of 1 or more processing or
assembly operations. Increasing value of materials.

Add-value
The material shape or properties are enhanced by combining it with others.
Manufacturing is one way by which nation creates material wealth.

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U.S economy:
Sector
Manufacturing
Agriculture, minerals, etc.
Construction & utilities
Service Sector-retail, transportation, banking,
Communication, atom, education and Govt.

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% of GNP
20%
5%
5%
70%

Manufacturing
processes

Value
Added $_$

Started material

Material in Processing

Processed part

Mfg. importance Technologically

Tech. application of science to provide society and its members with those things that are needed.
Tech. provides the products and helps our society to live better.

What do these products have in common?

They are all manufactured.

Manufacturing is essential factor that makes technology better.

Historically
Throughout the history, human cultures better at making things, were successful.

Making better tools, make better crafts and weapons

Better crafts let people to live better.
Better weapons allowed then to conquer other cultures in conflict.

To a significant degree, history of man-kind is history of humans ability to make things.

History of manufacturing can be divided into 2 subjects;
Invention of material
Processes & development of systems.
6000 years back, casting, hammering, forging and grinding were introduced.
Roman started factories to produce weapons, pottery, glass wares and other products.
A system of manufacturing refers to the way of organizing people & equipment so that production can be
performed efficiently.
Millions of labors dividing the total work into tasks, & having individual workers each become specialist at
performing the task.
Industrial Revolution (1760-1830); change began in England where machines were invented and steam power
replaced winds, water and animal power.
European countries developed steam engine, machine tools, power train and factory system.
Interchangeable parts; production came to be known as American system of manufacturing.(as we change
tools in Lathe machine).
2nd Industrial Revolution; Mass Production, scientific management, assembly lines & electrification of
industries were introduced.
Scientific Management
Motion study

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Aimed at finding best methods to perform given task.

Time study
Establish work standard for job.
Standards
Extensive use of standards in industry.
Use of data collection
Record keeping and cost accountings in factory operations.
Piece rate system
Labor incentive plans, accounting on factory operation.

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(1863-1947) introduced the assembly lines, made possible the mass production of complex consumer products,
as automobiles.
In 1881, the 1st electric power generating station had been built in NY 7 soon electric motors were introduced.
The 20th century was time of more technological advancement than all other centuries combined.

Products
Product means something that is produced. Word production is interchangeably with the word
Manufactured. Manufactured term is used in U.S. while word equipment is used in other countries on
production.
Manufacturing Products
Discrete Products
Individual parts or tolls, having no concern with each other, like gears, bearing balls, Cans, etc.)
Low production
(1-100 units/year)
Medium production
(100-10,000 units/year)
High/Mass production
(over 10,000 units/year)

Continuous products
Items produced by continuous processes as; sheet metal coil (almost), pipes, spool of wire.
Product design
as

Material selection

Manufacturing

Marketing

Manufacturing Goods
Consumer goods
Products purchased directly by consumer, i-e cars
Capital goods
Purchased by other companies, to supply services, as Aircrafts, rail, etc.

Classification of Industries
Primary Industry
Cultivate and exploit natural resources.
As, mining and agriculture.
Secondary Industries
Converts products from primary industries,
As, power generation, construction.
Tertiary Industries
Service-sectors
As, banking, education, govt., legal services, retail-trade, etc.

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MORE INDUSTIAL CLASSIFICATION

Process Industries,
Chemical, petroleum, basic, food, beverage, power
Discrete Industries
Cars. Aircraft, Appliances,etc

Some Manufacturing Industries and their ISCI Codes

Name
Food, beverage, Tobacco
Textile, Apparel, Leather
Wood, wooden products, corks
Paper, publish, portray
Chemical, Coal, petroleum
Ceramics. Glass, Minerals
Basic Metals

ISCI CODE
31
32
33
35
36
37
38

Lecture # 3
Manufacturing Capability
Manufacturing plant consists of processes and systems (& people, of course) designed to transform a
certain limited range of material into products of increased value. It has 3 basic building blocks
1. Materials
2. Processes
3. Systems
Manufacturing capability includes,
1. Technological process capability
2. Physical product Limitation
3. Production Capacity

Technological process capability

DEF. Available set of manufacturing processes at plant.

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Certain manufacturing processes are suited to certain materials and by specializing in certain processes
plant also specializes in certain material.

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Besides physical processes it also includes the expertise of plant personnel.

EXAMPLES: Machine shop cant make steel.
A steel mill cant build cars.

Production

An activity or group of activities carried out to produce a tangible (real/definite) output in the form of
material goods.
TYPES:
1. Batch Production:
The need for batch production arises from the fact that the capacity of any machine/group of
machines is more than the demand rate of product.
2. Continuous production:
When product is in continuous demand in large quantity, demand fluctuation maybe random or
seasonal.
Flow line production has advantage of rapid adjustment of processes variable or small
changes in the product design i.e. Motor cycle parts.
It is a method used to manufacture, produce or process materials without interruptions.
This process is followed most in Oil & gas Industry & in other industries such as float/glass
Industry, where glasses of different thickness are processed in a continuous manner.

3. Mass Production
It is widely used to describe large scale production,
It is used for creating products on large scale in short time, using time saving techniques like
Assembly line & Specialization.
It allows a manufacturer to produce more per work-hour & to lower the labor cost of end process.

Physical Product Limitation

Given a plant with a certain set of process there are size and weight limitation on the parts or products that
can be made in plant.
Product size and weight affects:

Production equipment
Material Handling Equipment

Production material handling equipment and plant size must be planned for products that lie within a certain size and
weight range. Larger heavy parts are moved by crane. Smaller parts can be moved by conveyer belts.

Production Capacity
The max. Quantity that a plant can produce in a given time period under assumed operating conditions.
Operating conditions refers to number of shifts per week, hours per shift direct labor manning level in
plant and so on, usually measured in output units as tons of steel or no. of cars, etc. produced by plant
also called plant capacity.

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Production system

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Consists of people equipment & procedure designed for combination of materials processes that
constitutes a firm & manufacturing materials.
Categories
Production facilities:
It refers to physical equipment & arrangement of equipment in factories.
Manufacturing Support system:
The procedure used by company to manage production & solve the technical problems encountered in
ordering materials.
In general direct labor people (blue collared workers) are responsible for operating manufacturing
equipment & professional staff (white collared worker) is responsible for manufacturing support.

Production Facilities
It consists of factory production equipment and material handling equipment. The equipment comes in
contact with part and assemblies.
It also includes the way Equipment are arranged called Plant layout.
The material is arranged into logical grouping called manufacturing systems as, paper industry.

Low quantity production

In low quantity range is 1-100 units/year., the term job shop is used to describe the type of production
facility.
JOB SHOP:
Make low quantity of specialized & customized products such as space capsule, prototype aircraft &
specialized machinery.

Fixed position Layout

If product is large and heavy and is difficult to move in single location then worker and equipment are
bought near the production place.

Product Layout
Individual components are made in factories in which equipment is arranged according to function type.
The lathes are in one department and the milling is other, it can accommodate great variety of
operation sequence for different part of configuration.

Medium Quantity production

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Quantity range (100-10K units/Year) units actually. When product variety is hard the usual approach is
batch production, after which manufacturing system is changed over to produce next & so on.

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High quality Production

High ranges (10K to million/ units annually) are referred to as Mass production. It is characterized by
high demand rate.
Categories:
Quality production
Flow line Production

Quality Production

Mass production of single part on a single machine or many machines.

Typically involves standard machine with special cooling.

Equipment is dedicated full time to production of one part or production type.

Typically layout used in quantity production is process layout or cellular layout.

Flow line Production

Multiple machines or workstations are arranged into sequence
Product is complex then it requires multiple processing & assembly operations.
Work units are physically moved, through the sequence to complete process.

Workstations are equipped and designed especially for the product to maximize efficiency.

Manufacturing support system

A company must organize itself to design for processes an equipment, plan and control to satisfy product
quality.
Most of their support systems dont directly contact with product. But they plan and control progress
throughout the factory.
Manufacturing support functions are often classified as,

Mfg. support system

QC system
Mfg. process assembly

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Lecture 4

Productivity
Measure of efficiency of (a person, machine, factory, system, etc.) converting inputs into useful products.
Productivity is critical determination of cost.
It can also be termed as energy, material, capital, personnel & resources consumed in any period.

Productivity of an organization is defined as the ratio of outputs produced by the organization & resources
consumed in the process. It is computed by dividing the average output per period by total costs.
Productivity= output/input
Production is total output produced by the organization in given period. There outputs consist of goods
and services that are supplied by the company to its customers.

Production refers to volume, value & quantity of goods and services produced by workers, plant, firm or
economy. It is sum total of results achieved by various factors together.

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Manufacturing Material

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Anything made of matter, consist of one or more substances is material. Wood, cement, hydrogen, air are
all examples.
Term material refers to substances and compounds with certain physical properties that are used as inputs
to production of materials.
In sense materials are parts required to make something else, as building and computers.

Raw material

A material can be anything a finished product or un-processed raw material. Raw materials are first
extracted/harvested from the earth and are divided into a form that can be easily transported or stored and
then processed to produce semi-finished raw material.
These can be input to a new cycle of production & finishing processes to create finished materials, ready
for distribution, construction & consumption.

Materials in Manufacturing
Selecting material

What make suitable for production.

Choose material with applicable properties

Aesthetic Properties are important too. It includes color, surface, texture &
pattern.

Material Selection

Recycling
Methods of manufacturing on Construction
Cost of materials
Short & Terms Available
Engineering Materials,
Metals, Polymers, Ceramics, Composite, glasses, etc.

Properties

Avaliability of
Products

Properties
Required

Material
Handling &
manufcturing
cost

Construction &
manufacturing
Process

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Mechanical:
Strength, Toughness, Ductility, hardness, Elasticity, Fatigue.

Physical:
Density, Specific heat, thermal expansion, thermal conductivity, melting point, electric and magnetic
properties.
Chemical:
Oxidation, Corrosion, Toxicity, flammability, rusting.

Mechanical Properties
Strength
Measure of how good material is at resisting and being deformed when acted upon by a force.
Tensile Strength
Ability of material to with stand pulling force or tension force.
Compressive Strength
Ability of material to withstand squeezing force or compressive force.
Torsional properties
Ability to withstand twisting force or torsion
Stiffness
Property to resist a bending deformation
Ductility
Property of material that allows it to be elongated or stretched fairly strong in tension. They
always stretch before breaking.
Brittleness
Material which fractures due to little force or deformation. They break under tension.
Hardness
Measure of materials ability to withstand being stretched, cut or elevated.
Toughness
Measure of how much energy is required to break a material.
Fatigue
Various components & structures such as tools, gears, discs, are subjected to under cyclic load
cause fatigue failure.

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Lecture 5
More Mechanical Properties

Thermal Conductivity
it relates to how heat travels or conducted through material.

Thermal Expansion
most metals get expands on heating and contracts on cooling.

Electric Properties
Ability to conduct electricity

Magnetic Properties
they can be attracted by magnet or are magnet themselves.

Optical Properties

Reflection
Light bounces back off.

Radiation/Absorption
Color of the metal affects the ability to absorb heat, i.e. black absorbs more heat.

Density
It is the ratio of mass to volume.

A stupid chart! Seriously cant understand y was it taught! But here it is!

Heat Treament

Annealing
Alloying
Reinforcement
Lamination

Property
Modifictaion

Behavior of
manufacturing
properties of
Materials

Engineering Materials
Metals

Ferrous
Steel, Stainless Steel, Tools and die made of steel, Cast iron, etc.

Non-ferrous
Aluminum, copper, titanium, tungsten & others

Amorphous
Shapeless metals.

Plastics

Thermoplastics

Acrylics- watch glasses

ABS
PVC
Nylons

Thermostes

Once Deformed can't be re-shaped

Epoxies
Phenolics
Polyamids

Elastomers

High Elastic Ranges

Rubbers
Silicos

A plastic is any of a wide range of synthetic/semi-synthetic organic solid used in manufacturing of

industrial materials.
Plastics are typically polymers of high molecular masses and may contain other substances to
performance and/or reduce production cost.
MONOMERS of plastics are either natural or synthetic organic compounds.
Word Plastic is derived from 2 Greek words:

PLASTIKOS - capable of being shaped/Molded

PLASTOS molded.

This name refers to their Malleability or plasticity during manufacturing. This allows them to be
CASTED, PRESSED or EXTRUDED into variety of shapes as films, fibers, plates, tubes, bottles,
boxes and much more.

Malleability:
Material's ability to form a thin sheet by hammering or rolling.
ICI:
Imperial Chemical Industry;
BUISNESS Make Polyesters, Soda-ash, Paints, Chemical manufacturing and sell a wide range of
industrial consumer products.

POLYMER OF ABS Acrylonitrile-butadiene-styrene

Ceramics:
Oxides, Nitrides, Carbides, Glass, glass ceramics, Graphite/Diamond.

Composites:
Reinforced Plastics, Metal-matrix, Ceramic-matrix, Laminates.

Explanation and Examples of materials,

METALS
Metal is a chemical element that is good conductor of electricity and heat.
It forms CATIONS and ANIONS.
They form ionic bonds with non-metals.
They generally have properties like;

Ductility
Malleability
High electrical and thermal conductivity
have BFF, FCC, HCP
Opaqueness and Reflectivity
Bonding depends upon chemical properties.

Categories of metals:
Ferrous

Mild Steel
Contains 0.1% to 03% Carbon
it is used in sheets, strips, round bars, pipes, channels, etc.

Medium Carbon Steel

Contains 0.3% to 07% Carbon
(Connecting rods, Keys, Gear Wheels)

High Steel Carbon

0.7% to 1.3% Carbon
(twist drills, Cutter blade, Spring and cold chisel)

Stainless Steel
Contains iron-chromium alloys and chromium contents between 13-27%.

(watch back, pens, pipes fitting, cutlery & sink)

Grey Cast Iron

Iron 94%, - carbon 3%- silicon 2%, & traces of Magnesium, Sulfur and phosphorus.
(Cylinders head, blocks, man-hole covers, & base of pillar drills.)

Non-Ferrous

Aluminum
Soft- Ductile- light- has low tensile strength and resists corrosion.
Aluminum Alloys
They are made to Impart hardness and strength & to produce other properties
They are made by adding Aluminum and Cu-Mg-Cr-S-tin etc.
(Drink cans, Door handles, rivets and ladders)
Copper
it is 3rd most important pure metal- fairly ductile & moderately strong.
Good conductor of electricity and conductor of Heat.
(Soldering tips, Car radiators, Decorative ornaments, copper wires, name plates & soldering iron bit.)
Brass
Copper-zinc alloy
It has good electric conductivity and anti-corrosion properties.
(Screws- nuts and bolts- door handles- keys- light fittings and musical instruments.

Other Examples are

Magnesium and its Alloys
Copper and its Alloys
Nickel and its Alloys
Titanium and its Alloys
Zinc and its Alloys
Lead and tin.
Alloys:
Mixture of 2 or more metals (or with at least one being metal).
CERAMICS:
A ceramic material is a mixture of inorganic compounds consisting of metals, semi-metals, & one or more
non-metals.
Word Ceramics comes from KERAMOS which is potters clay or wave made from fired clay.
Typical non-metallic elements used in it are; O-N-C, etc.
General Properties

High Hardness
Stiffness
Electrically and thermally insulators
Brittleness
Chemically inert

Important Examples are;

Silica

Alumina
Hydrous
Aluminum silicate (KAOLINITE)
Clay
Makes pottery, tiles and Silica(basics of glass material)
Clay production produces bricks, clay pipes and building tiles, etc.
Carbides
Cutting tools, etc.
Nitrides
cutting /grinding tools and Abrasive.
Concrete
itself is a composite material but its components are ceramics
Glass
bottles, glasses and lens
White wares
Molds- pottery- porcelain tableware and stoneware
Glass Fiber

Abrasive
Aluminum oxide+ Silicon oxide
Magnetic ceramics
Bio-ceramics
Cutting tools material

Refractory Ceramics
Highly capable of bearing high temperature- is used in Furnace walls, crucibles and, olds.

Abrasive
An Abrasive is a material often a mineral that is used to shape of finish a work-piece through rubbing
which leads to parts of work-piece worn away.
While finishing a material often means polishing it to gain a smooth reflective surface.
Abrasive machining is a machine process where material is removed from a work-piece using a multitude
of small abrasive particles, common examples include: honing, grinding and polishing.
HONING: is a metal working process name. Polishing of Linear (inside surface of piston).
Abrasive processes are usually expansive but capable of higher tolerance and better surface finishing than
other machining processes.

Types of Ceramics
Traditional Ceramics
Silica used for clay, common abrasive material and cement are its examples.

New ceramics
Non-silicates such as oxides and carbides.

Glass
Based primarily on silica and have own crystalline structure.

Glass Ceramics
Glass transformed into largely crystalline structures by heat treatment.

On bases of processing Types are:

Crystalline ceramics
includes traditional and modern ceramics both.
Amorphous Ceramics

POLYMERS:
These are the compounds formed by repeating structures called MERS, whose atoms share electrons to
form very large molecules by covalent bond.
Elements in Polymers are usually C + H, O, N & Cl.
General Properties
Low densities
High electric resistivity
Low thermal conductivity
Strength and stiffness vary widely.
Categories

Thermoplastics
Thermosetting
Elastomers

Composites:
Materials consisting of two or more phases that are processed separately and are the bonded together to
achieve properties superior to constituents.
PHASES:
Homogenous mass of material, such as grains of identical unit cell structure in solid materials.
MATRIX:
Usual structure consists of particles or fibers of 1 phase mixed in 2nd, called MATRIX.
Synthetically we can produce, composite of greater value epoxy, Kevlar composite etc.,
General Properties

Strength to weight ratio

(Ratio of stiffness to weight)
Fatigue properties & roughness
Corrosion dont occurs
Better appearance and control of surface appearance.

Properties depends upon:

Components
Physical shape of components
The way components are combined to form final material.

Aerospace industry is one of the biggest users of composites. Other uses are car bodies, boat hulls, tennis rackets &
carbide tools too.

Disadvantages:

Anisotropic properties (change with direction)

Attacked by chemicals and solvents
Expensive (but decrease as volume increase)
Manufacturing methods are costly.

OTHER COMPOSITES
Venn diagram showing 3 basic
material type and their composites.

Metal-polymer
Ceramics

Metal ceramic
composite
Metals

Ceramics

Polymers

Ceramic
polymer
Composites

Manufacturing Process
It has two types:
Processing Operations;
Transforms a work material from one state of completion to a more advanced state.
It changes the geometrical properties and appearance of starting material.
Assembly Operations;
Just join 2 or more components to form a new entity.

Classification of Manufacturing process;

Solidification Processes
Particulate Processing

Shaping Process

Deformation Processes

Processing
Operations

Property
Enhancing
processes

Material Removal
Heat Treatment

Surface
processing
opertaions
Manufacturing
processes

Cleaning and surface

treatment
Coating and deposition
processes
Welding

Permanent
Joining
processes
Assembly
Operations

Brzing & Soldering

Adhesive bonding

Mehcanical
Fastening

Threaded Fasteners
Permanent Fastening
Methods

Processing Operations;
Alters materials shape, physical properties or appearances in order to add value.

Categories

Shaping Operations

Property enhancing operations

Alters geometry of starting material.

Improves physical properties without changing shape.

Surface processing operations

To clean, treat, coat, or deposit material on exterior surface of the work-piece.

Shaping Operations

Solidification processes
Starting material is a heated liquid or semi-liquid.
Particulate processing
Starting material consists of powder form.
Deformation processes
Starting material is a ductile solid (commonly metals)
Material removal processes
Starting material is ductile or brittle solid.

Casting, Forging and machining processes are shaping processes.

Deform material;

Casting
Rolling/ forging
Extrusion/ Drawing
Metal sheet forming
Powder metal processes

Solidification processes
Starting material is sufficiently heated to transform it into a liquid or highly plastic state, i.e.,
Metal Casting, Plastics Molding etc.

Particulate processing
Starting materials are powder of metals or ceramics.
The common techniques involves, Pressing and Sintering (powder into solid)

In which Powder are first squeezed into die cavity under high pressure and then heated to bond the
individual particles together.