INTRODUCTION AND 2

OVERVIEW OF COURSE MANUFACTURING Processes

1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Organization of the Course
MANUFACTURING IS IMPORTANT 3

• Technologically
• Economically
• Historically
MANUFACTURING - TECHNOLOGICALLY IMPORTANT 4

• Technology provides the products that help our society and its members live
better
• What do these products have in common?
ƒ They are all manufactured
• Manufacturing is the essential factor that makes technology possible
MANUFACTURING - ECONOMICALLY IMPORTANT 5

U.S. economy:

% of
Sector
GNP
Manufacturing 20%
Manufacturing creates nation
material wealth Agriculture, minerals, etc. 5%

Construction & utilities 5%

GPN =gross national product
Service sector - retail, transportation, 70%
banking, communication, education,
and government
 MANUFACTURING - HISTORICALLY IMPORTANT 6

• To a significant degree, the history of civilization is the history of humans'

ability to make things
WHAT IS MANUFACTURING? 7

Manufacture derives from two Latin words manus (hand) and factus (make);
“made by hand”
• “Made by hand” fabrication methods used when the English word
“manufacture” was first coined around 1567 A.D.
• Most modern manufacturing operations are mechanized and automated
(supervising of human workers)
 MANUFACTURING - TECHNOLOGICAL DEFINITION 8

Application of physical and chemical processes to alter the geometry,

properties, and/or appearance of a starting material to make parts or products
• Manufacturing also includes assembly
• Almost always carried out as a sequence of operations
 MANUFACTURING - Economical DEFINITION 8

the transformation of materials into items of greater

value by means of one or more processing and/or assembly operations,
• The key point is that manufacturing adds value to the starting material
• The product becomes more valuable than the starting material
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EXAMPLE
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OPERATION: CUTTING
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OPERATION: DRAWING
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OPERATION: DEEP DRAWING
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OPERATION: FORGING, HEAT TREATING, CUTTING
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OPERATION: TIG WELDING, FASTENING
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OPERATION: HIGHLY POLISHING
Production Processes - OVERVIEW 16

MECHANICAL TECHNOLOGY or, more precisely, MECHANICAL

PRODUCTION TECHNOLOGY, deals with all processes able to transform
raw materials (or semi-finished products) into end products.
The PRODUCTION ENGINEER, by designing the cycle of transformation from
raw materials into end products, allows a design to be physically made.

Behind each product there is a TECHNOLOGICAL CYCLE, completely

detailed, so that each production step can be performed correctly.

In general, the main guiding issue for cycle selection is ECONOMICAL. Among
several possible production routes, the cheapest way is preferred.
CAR ASSEMBLY 17
TYPES OF PRODUCTION 18

We can divide production into two main groups:

ƒ FLOW production (or continuous p.)

ƒ BATCH production (or discrete p., sometimes the word “manufacturing”
is used for this case only)

Each good is produced using one (sometimes either) of these types.

FLOW PRODUCTION 19

At the end of the process, it is very difficult to recognize the raw materials. No
disassembly is feasible.

In general flow production involves either:

- Mixing, Solving
- Chemical reactions

Typical FLOW productions involve:

ƒ Steel
ƒ Paper
ƒ Cement (for Concrete)
ƒ Chemicals
ƒ Yarn
ƒ ...
ƒ ...
 BATCH PRODUCTION (Manufacturing) 20

Batch product is made of individual parts, assembled together, that can be easily
distinguished (very often in different materials).

In general batch production involves two main phases:

- Part production;
- Assembly.

Therefore, we use batch production for:

ƒ Cars
ƒ Computers
ƒ Household Appliances (washing machines, refrigerators, vacuum cleaners…)
ƒ Clothes, Shoes
ƒ ...
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PART PRODUCTION PHASE

Part Production:
ƒ sequence of OPERATIONS (TRANSFORMATIONS) to change shape,
dimensions, surface finish or other properties of simple (elementary)
parts
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ASSEMBLY PHASE

Assembly:
ƒ Sequence of ACTIONS for grouping, positioning and fixing parts into an
assembly.

n.b.: it’s a hierarchical

sequence, i.e. simple parts
are first assembled into sub-
assemblies, then sub-
assemblies are grouped into
finished product.
 Production Quantity Q 23

The quantity of products Q made by a factory influences the way it works, and so
the procedures are organized
•Annual production quantities can be classified into three ranges:
Production range Annual Quantity Q
Low production 1 to 100 units
Medium production 100 to 10,000 units
High production 10,000 to millions of
 Product Variety P 24

Product variety P refers to different product types or models produced in the plant
•Different products have different features
ƒ They have different geometry, properties, appearance
ƒ They are intended for different markets
ƒ Some have more parts than others
•Number of different product types made each year
•When the number of product types made in the factory is high, this indicates high
product variety
P versus Q in Factory Operations 25
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MORE ABOUT PRODUCT VARIETY

Although P is a quantitative parameter, and it is much less exact than Q

•Soft product variety - small differences between products, e.g., between car
models
•Hard product variety - products differ substantially, e.g., between a small car
and a large truck, with few common parts (if any)
Production Layout
 MATERIALS IN MANUFACTURING 27

Three basic categories:

1. Metals
2. Ceramics
3. Polymers
•Their chemistries are different
•Their mechanical and physical properties are dissimilar
•These differences affect the manufacturing processes that can be used to
produce products from them
IN ADDITION: COMPOSITES 28

Nonhomogeneous mixtures of the other three basic types rather than a

unique category
MANUFACTURING PROCESSES 29

Two basic types:

1. Processing operations - transform a work material from one state of
completion to a more advanced state
ƒ Operations that change the geometry, properties, or
appearance of the starting material
2. Assembly operations - join two or more components to create a new
entity
MANUFACTURING PROCESSES 30
MANUFACTURING PROCESSES 31
 PROCESSING OPERATIONS 32

Alters a material’s shape, physical properties, or appearance in order to add

value
•Three categories of processing operations:
1. Shaping operations - alter the geometry of the starting work
material
2. Property-enhancing operations - improve physical properties
without changing shape
3. Surface processing operations - to clean, treat, coat, or deposit
material on exterior surface of the work
 SHAPING PROCESSES - FOUR CATEGORIES 33

1. Solidification processes - starting material is a heated liquid or semifluid

2. Particulate processing - starting material consists of powders
3. Deformation processes - starting material is a ductile solid (commonly
metal)
4. Material removal processes - starting material is a ductile or brittle solid
 WASTE IN SHAPING PROCESSES 34

Desirable to minimize waste in part shaping

• Material removal processes are wasteful in unit operations,
• Most casting, molding, and particulate processing operations waste little
material
• Terminology for minimum waste processes:
ƒ Net shape processes - when most of the starting material is
used and no subsequent machining is required
ƒ Near net shape processes - when minimum amount of
machining is required
PROPERTY-ENHANCING PROCESSES 35

Performed to improve mechanical or physical properties of work material

•Examples:
ƒ Heat treatment of metals and glasses
ƒ Sintering of powdered metals and ceramics
•Part shape is not altered, except unintentionally
ƒ Example: unintentional bending of a heat treated part
 SURFACE PROCESSING OPERATIONS 36

• Cleaning - chemical and mechanical processes to remove dirt, oil, and

other contaminants from the surface
• Surface treatments - mechanical working such as sand blasting, and
physical processes like diffusion
• Coating and thin film deposition - coating exterior surface of the
workpart
 ASSEMBLY OPERATIONS 37

Two or more separate parts are joined to form a new entity

• Types of assembly operations:
1. Joining processes - create a permanent joint
ƒ Welding, brazing, soldering, and adhesive bonding
2. Mechanical assembly - fastening by mechanical methods
ƒ Threaded fasteners (screws, bolts and nuts); press fitting,
expansion fits
New trends in Manufacturing: INDUSTRY 4.0
New trends in Manufacturing: LEAN PRODUCTION-Six Sigma
New trends in Manufacturing: ENVIRONMENTALLY (GREEN) MANUFACTURING
New trends in Manufacturing: NANOTECHNOLOGY
 COURSE PROGRAMME 38

Subjects overview

ƒ 1. Introduction: Importance of development of production technology. Process capabilities, shapes

and tolerances characteristic of each process. Process classification. Workability of materials
according to processes. Effect of required accuracy on production cost and time. Models of
technological processes. Physical and empirical models.
ƒ 2. Casting: Foundry work cycle design. Definition of cast part from end product shape, of foundry
equipment from cast pat shape. Design and dimensioning of feeding system. Design and
dimensioning of feeders. Exercises on foundry cycle design .

ƒ 3. Forming: Basics on theory of plasticity. Rolling: overview, types of mills, economics, tooling. Tube
rolling. Rolling defects. Wire, rod and tube drawing. Direct and reverse extrusion: overview, forces,
extrusion defects, economics, tooling. Bulk forming : basics, economics, machines, tooling. Sheet
metal forming: blanking, bending, deep-drawing.

ƒ 4. Machining: Models of machining . Chip formation modeling problems.

Cutting forces: prediction and experimental evaluation. Machining parameter optimization.
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SOLIDIFICATION PROCESSES

Starting material is heated sufficiently to transform it into a liquid or highly

plastic state
•Examples: metal casting, plastic molding
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SOLIDIFICATION PROCESSES
PARTICULATE PROCESSING 42

Starting materials are powders of metals or ceramics

• Usually involves pressing and sintering, in which powders are first
compressed and then heated to bond the individual particles
DEFORMATION PROCESSES 43

Starting workpart is shaped by application of forces that exceed the yield

strength of the material
•Examples: (a) forging, (b) extrusion
DEFORMATION PROCESSES 44
DEFORMATION PROCESSES 45
 MATERIAL REMOVAL PROCESSES 46

Excess material removed from the starting piece so what remains is the desired
geometry
•Examples: machining such as turning, drilling, and milling; also grinding and
nontraditional processes
AIMS of THE COURSE 47

• To form a production engineer, specialized in the

traditional production processes

• By means of:
ƒ General description of the conventional processes
ƒ By modeling the production processes, that means
by controlling their main aspects: costs, tolerances,
time
TEXTBOOKS 49

Recommended:
• Course slides
• Kalpakjian, “Manufacturing engineering and technology”, Prentice Hall
• Groover, “Fundamentals of Modern Manufacturing”, Wiley

• Kaganas, Basic manufacturing Processes, McGraw-Hill.

• Jensen, Engineering Drawing and Design, McGraw. Hill.

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AVAILABLE ON-LINE

WORK IN PROGRESS

Google Classroom
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EXAM PROCEDURE

• Standard procedure: Closed book exam

• No make up exams

• Project
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