Fundamentals of Manufacturing Processes

Materials and Manufacturing Processes

DHEERENDRA KUMAR DWIVEDI

MECHANICAL & INDUSTRIAL ENGINEERING DEPARTMENT

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 Why to talk about it?
• To know their suitability for intended
performance in a given situation
• To get idea about what changes are needed
otherwise
• How to manufacture (give the desired size and
shape)
Typical applications of materials
 Material properties of importance for
manufacturing
• Physical: thermal conductivity, thermal expansion coefficient,
melting point, solidification temperature range
• Chemical: chemical affinity, corrosion, oxidation etc.
• Mechanical: hardness, strength, ductility, creep, fatigue,
fracture resistance
• Dimensional: straightness, flatness, roundness, surface
roughness, length etc.
 Casting
• Melting point
• Solidification temperature range
• Solubility in liquid and solid state
• Reactivity of metal with gases
• Thermal expansion coefficient
• Alloying segregation tendency
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 Forming
• Yield strength
• Ductility
• Work hardenability
• Thermal softening
• Thermal expansion coefficient
• Strengthening mechanism of metal
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 Machining
• Hardness
• Ductility
• Strength
• Thermal conductivity
• Interactions of work metal with tool material

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 Welding
• Melting point
• Solidification temperature range
• Solubility in liquid and solid state
• Reactivity of metal with gases
• Thermal expansion coefficient
• Alloying segregation tendency
• Yield strength and ductility

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 Applicability of Different Manufacturing Processes to
Different Types of Engineering Materials

Basic Primary Deforming Material Joining Property

category of forming processes removal processes changing
material processes [Formative] processes processes
[Additive] [Subtractive] [Consolidation]
Traditi Adva Traditi Adva Traditi Adva Traditi Adva- Traditional
-onal -nced -onal -nced -onal -nced -onal nced
Metals A B* A A A A A A A

Alloys A B* A A A A A A A

Polymers A A B B B A B B C

Ceramics A C C C B A B C C

Composites A C C C B A B B C

A: Widely used; B: Not frequently used; C: Not used; *: Under research stage
Application Range of Manufacturing Processes According to
Melting Temperature of the Material and Batch Size