SUBJECT: MEC131

MANUFACTURING PROCESSES

TIME: 2:30 PM – 5:30 PM

DAYS: MONDAY AND THURSDAY
DEFINITION:
Manufacturing
Derived from the Latin word “manufactus”, manufacturing
means made by hand. It involves making products from raw
sources using different processes, by making use of hand tools,
machinery or even computers. Manufacturing process is that
part of the production process which is directly concerned with
the change of form or dimensions of the part being produced.
CLASSIFICATION OF MANUFACTURING PROCESSES:
 Processes used to change the shape of materials.
 Processes used for machining parts to a fixed
dimension.
 Processes for obtaining a surface finish.
 Processes used for joining parts of the material.
CLASSIFICATION OF MANUFACTURING PROCESSES:
 Processes used to change the shape of materials.
Processes used primarily to change the shape of metals include the following:
• Casting • Roll Forming
• Rolling • Magnetic Forming
• Crushing • Plastic Molding
• Bending • Extruding
• Stretch Forming • Squeezing
• Explosive Forming • Swaging
• Powder Metal Forming • Spinning
• Forging • Torch Cutting
• Drawing • Electroforming
• Piercing • Electrohydraulic Forming
• Shearing
CLASSIFICATION OF MANUFACTURING PROCESSES:
 Processes used for machining parts to a fixed
dimension.
a) In manufacturing any product there are usually a number of operations, which may
be classified as follows:
• Turning • Shaping
• Boring • Sawing
• Milling • Robbing
• Planning • Drilling
• Reaming • Broaching
• Grinding • Routing
CLASSIFICATION OF MANUFACTURING PROCESSES:
 Processes used for machining parts to a fixed
dimension.
b) Non-traditional machining process:
• Ultrasonic • Electrical Discharge • Electro - Arc
• Optical Laser • Electromechanical • Chemical - Milling
• Abrasive Jet Cutting • Electro beam machining • Plasma Arc Machining
CLASSIFICATION OF MANUFACTURING PROCESSES:
 Processes for obtaining a surface finish.
Surface finishing are used to insure a smooth surface, great accuracy, aesthetic
appearance, or protective coating.
Process used are the following:
• Polishing • Abrasive belt grinding • Barrel tumbling
• Electroplating • Honing • Lapping
• Super finishing • Metal spraying • Inorganic Coating
• Parkerizing • Anodizing • Sherardizing
CLASSIFICATION OF MANUFACTURING PROCESSES:
 Processes used for joining parts of the material.
Products requiring the assembly of two or more parts are usually joined by one of the
following process:
• Welding • Brazing
• Pressing • Fastening
• Soldering • Sintering
• Riveting Screw • Adhesive joining
SAFETY IN THE MACHINE SHOP:
 It is very important that safety must come first
before operating any machine tools.
 Remember that safety is an attitude. Always
practice safety working habits in the workplace.
 Always practice safe working procedures at all
times.
GENERAL SAFETY PRECAUTIONS IN THE
MACHINE SHOP:
1. Be sure that all machines have
effective and properly working
guards that are always in place
when machines are operating.
2. Replace guards immediately after
any repairs.
Image courtesy of https://www.machinesafety.co.uk/free-downloads/workshop/
GENERAL SAFETY PRECAUTIONS IN THE
MACHINE SHOP:
3. Do not attempt to oil, clean, adjust or repair
any machine while it is running. Stop the
machine and lock the power switch in the “off”
position.
4. Do not operate any machine unless authorized
to do so.
5. Even after the power is off, do not leave the
machine until it has stopped running.
Someone else may not noticed that it is still in Image courtesy of https://www.shutterstock.com/search/machine+accidents

motion and be injured.

6. Do not try to stop the machine with your
hands or body.
GENERAL SAFETY PRECAUTIONS IN THE
MACHINE SHOP:
7. Always see that work and cutting tools
on any machine are clamped securely
before starting.

Image courtesy of https://www.dreamstime.com/royalty-free-stock-

photography-factory-worker-operator-drill-press-retro-image25163507
GENERAL SAFETY PRECAUTIONS IN THE
MACHINE SHOP:
8. Keep the floor clear of metal chips or
curls and waste pieces. Put them in
the container provided for such
things. Scraps are tripping hazards,
and chips or curls may cut through a
shoe and injure the foot.

Image courtesy of https://www.dreamstime.com/stock-images-metal-chips-

image24931734
GENERAL SAFETY PRECAUTIONS IN THE
MACHINE SHOP:
9. All setscrews should be flushed or recessed type. If they are not, move
with caution when near them. Projecting setscrews are very dangerous
because they may catch on sleeves or clothing.

Image courtesy of https://www.hobby-machinist.com/threads/enco- Image courtesy of https:// superlls.com/ index.php? main_page=product

13x40-d1-4-three-jaw-chuck-adjustment.31188/ info&products_id=86169
GENERAL SAFETY PRECAUTIONS IN THE
MACHINE SHOP:
10. Get help for handling long or heavy pieces of material. Follow safe lifting
practices – lift with your leg muscles, not your back.

Image courtesy of https://www.shutterstock.com/image-vector/two-workers-lifting-heavy-wooden-

crate-1597625155
GENERAL SAFETY PRECAUTIONS IN THE
MACHINE SHOP:
11. Do not lean against the machine.

Image courtesy of https://blog.creativesafetysupply.com/dangers-loose-clothing/

GENERAL SAFETY PRECAUTIONS IN THE
MACHINE SHOP:
12. Concentrate on the work and do not
talk unnecessarily while operating the
machine.
13. Don’t talk to others when they are
operating a machine.

Image courtesy of https://safety-work.org/fileadmin/safety-work/articles/IVSS-

Unterweisung_Gefahrstellen_an_Maschinen/ISSA_108_Gefahrstellen.pdf
GENERAL SAFETY PRECAUTIONS IN THE
MACHINE SHOP:
14. Get first aid immediately for any injury.

Image courtesy of https://www.canstockphoto.com/illustration/first-aid.html

CLOTHING AND SAFETY EQUIPMENT:
1. Always wear safety glasses, goggles, or face shields
design for the type of work when operating any
machine.

Image courtesy of https://liggettlawgroup.com/blog/welding-injuries-are-all-too-common/

CLOTHING AND SAFETY EQUIPMENT:
2. Wear clothing suited for the job. Wear shoes with
thick soles – safety shoes if heavy work is being
done.

Image courtesy of https://ose.directory/article/safety-footwear/

CLOTHING AND SAFETY EQUIPMENT:
3. Do not wear rings, watches, bracelets, or other
jewelry that could get caught in moving machinery.

Image courtesy of https://www.seton.com/caution-no-jewelry-loose-clothing-industrial-osha-

machine-hazard-sign-l11450.html
CLOTHING AND SAFETY EQUIPMENT:
4. Do not wear neckties or loose or torn clothing of any
kind.

Image courtesy of https://in.pinterest.com/pin/429882726924059665/

CLOTHING AND SAFETY EQUIPMENT:
5. Wear shirts or jumpers with sleeves cut-off or rolled
above the elbows.

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CLOTHING AND SAFETY EQUIPMENT:
6. Always remove gloves before
turning on or operating any
machine. If material is rough or
sharp and gloves must be worn,
place or handle material with
machine turned off.

Image courtesy of https://www.clipartmax.com/max/m2i8G6i8Z5K9G6i8/

HOUSEKEEPING:
1. Keep floors free of oil, grease, or any other liquid. Clean up
spilled liquids immediately; they are slipping hazards.
2. Aisles should be clear at all times to avoid tripping or other
accidents.
3. Store materials in such a way that they cannot become
tripping hazards.
HOUSEKEEPING:
4. Do not leave tools or work on the table
of a machine even if the machine is not
running. Tools or work may fall off and
cause toe or foot injury.
5. Put tools away when not in use.
6. Place all scrap in scrap boxes.

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image/9284280/worker-working-lathe-machine.html