ME 2202: Primary Production Processes

INTRODUCTION

Prof. S.K.Sahoo
 Production Process
General concept:
• A sequence of operations designed to increase the value of
an entity. Passenger car, film, software, rice, etc.
Engineering concept:
•It is defined as the interrelated activities to convert raw
input materials into a useful product/service to fulfill a
societal need, involving 7 M’s (Man, Material, Money,
Machine, Method, Market, Meaningful data), output having
acceptable quality and cost.
 Functions of Production/Manufacturing
It is a transformation process.
•Change the properties (physical/chemical) of the work material
•Change the geometry (shape and size) of the work piece.
•Change the appearance of the work piece.
Produce desired quality (dimensional accuracy and surface finish)
at affordable cost.
Value added

Transformation Desired Quality

Product and cost with a
Process
societal need
Machine
Method
Market

Material
Money

Scrap and
Man

Information waste
 System Approach
•Production/manufacturing technology
suggests the methods that enable Refill

creation of a affordable, qualitative

component from raw materials, Value adding
production
necessary to today’s society. processes
Input Output
•Thus production/manufacturing
processes aims to increase value to a Wealth
raw material and creation of wealth.
Demand fluctuations Manufacturing Production rate,
Raw materials, cost and
System quality and delivery
availability
comprising of Profit
Business environment
production
Social need processes Status
Resources and plans
key to wealth
generation
 Complexity in Manufacturing
Materials: 106
metals, ceramics, polymers, composites
Processes: 105
process conditions are ~ ∞
Properties: 102
applications are ~ ∞

Rigidity

Car: ~ 15,000 parts;

Boeing 747 plane: ~6 million parts
Intel core i7 10th generation processor: 67 nm feature size, 298 million
transistors
 Importance of Production or Manufacturing
•Modern manufacturing concept stands on quality & cost i.e. high Q/C
ratio to get comparative advantage.
To decrease the cost -We use mass production
concept which breaks the product into number of

Cost
components and manufacture by special machine
& skilled operator and assembles these parts at
Quality
assembly shop.
To increase quality-
Proper design, considering functional requirement & manufacturing
aspects. When the design takes care of proper manufacturing, it ensure
a better product at an economical cost i.e. we require a optimum
process planning with quality check at proper intermediate points.
Proper Manufacturing Knowledge and Technology: We should
have prior knowledge of process relation & manufacturing concept
before going to design i.e. casting before machining, machining before
hardening , drilling before tapping.
 Pre-manufacturing steps/activities
Realization of Need

Statement of need/problem

Need analysis

Generation of alternative ideas Realizability, Feasibility

Utility, Economic, Safety
No
Evaluation
Yes Design for function
Design development Design for manufacture
No Design for maintenance
Evaluation
Yes
Optimization/
Detail Design Standardization

Production/Manuf.
Optimization/
Detail process plan Standardization
 ME 2202 Primary Production Processes
• Objectives
A. Understand fundamental concepts in materials
processing.
B. To know about various common techniques used in
casting, welding and metal forming.
C. To be acquainted with different influencing factors, and
the methods of controlling, the quality of products, in
particular soundness, microstructure, inclusion levels
and dimensional accuracy.
D. Analyze potential cast/weld/forming defects and failure
mechanisms with reference to specific production
method and industrial problems.
E. Relate theory of elasticity/plasticity to manufacturing.
 TOPICS TO COVER
• Foundry: Introduction to patterns and foundry process, Sand
binders and different additives, Sand testing, and melting furnaces
for ferrous and non-ferrous metals such as cupola, Induction
furnace, Arc furnace & Resistance Furnace. Solidification of
castings, Continuous casting process: Precision investment
casting, centrifugal casting, Die casting, Casting defects.
• Welding and gas cutting: Introduction to gas welding, cutting,
Arc welding and equipment’s. TIG (GTAW) and MIG (GMAW)
welding, resistance welding and thermit welding, Weldability.
• Newer Welding methods like plasma Arc, Laser Beam, Electron
Beam, Ultrasonic, Explosive and friction welding.
• Brazing and soldering, welding defects.
• Destructive and non-destructive testing's of casting and welding.
• Brief introduction to powder metallurgy processes.
 TOPICS (Cont…)

• Plastic deformation of metals: Variables in metal forming

and their optimization. Dependence of stress strain diagram on
Strain rate and temperature. Hot and cold working of metals.
• Forging: Smith Forging, Drop and Press forging, M/c forging.
Forging defects.
• Rolling: Pressure and Forces in rolling, types of rolling mills,
Rolling defects.
• Extrusion: Direct, Indirect, Impact and Hydrostatic extrusion
and their applications. Extrusion of tubes.
• Wire drawing methods and variables in wire-drawing.
Optimum die shape for extrusion and drawing.
• Brief introduction to sheet metal working: Bending, Forming
and Deep drawing.
 ME 2202 Primary Production Processes (Cont…)

• Learning Outcome
1.0 Can explain the fundamental concepts in materials
processing.
2.0 Able to consider the factors influencing, and the methods of
controlling, the quality of products, in particular soundness,
microstructure, inclusion levels and dimensional accuracy.
3.0 Calculate and determine the load, stress, time requirements
for different primary production processes.
4.0 Capable of relating the concept of manufacturing to design
tooling in production instead of using ‘thumb rule’.
5.0 Enable to design the optimum dimension of the product in a
variety of situations where specific properties are required.
6.0 Able to take care of design modifications before the
production of components by casting, forming and/or welding.
 Mapping
Objectives Topics Outcome(s)
A Foundry/Casting 1.0
D
3.0
B Basic welding, cutting 2.0
C and newer welding 4.0
5.0 6.0
Brazing and soldering
B Testing's of casting and welding 1.0
D Powder metallurgy processes. 2.0

A Plastic deformation of metals

1.0
E Forging 3.0
A Rolling 1.0 4.0
E Extrusion 3.0 6.0
A Wire drawing 1.0
B Sheet metal working 5.0
 REFERENCES
1. Manufacturing Technology, P. N. Rao, TMH
2. Manufacturing Engineering and Technology, S. Kalpakjian,
Pearson India, 2012
3. http://nptel.ac.in/courses/webcourse-contents/iit-roorkee/
manufacturing-processes/
4. Manufacturing Science, A. Ghosh and A. K. Mallik, East West
Press.
5. Introduction to Manufacturing Technologies: Principles &
Practice, P.P. Date, Jaico Publication, 2012
6. Mechanical Metallurgy, Dieter, Mc Graw-Hill
7. Fundamentals of metal casting technology, P.C. Mukherjee,
Oxford and IBH.
8. Design of Metal Casting - B. Ravi, PHI.
 Evaluation
1. End Semester (Written examination) : 50 %
2. Mid Semester (Written examination) : 30 %
3. Continuous Teacher’s Assessment : 20 %
a. Three Class Test (Objective type)
b. One Assignment ( To be submitted in .doc file)
c. Class note maintenance (Will be checked periodically)
Course Teacher: Dr. S.K.Sahoo, Professor ME Dept.
Ph. 0661-2462520 e-mail: sksahoo.nit@gmail.com
Room: ME Dept., ME Sciences Building # 105
 CLASSIFICATION OF Production PROCESSES

A. Based on the Importance:

1. BASIC MANUFACTURING PROCESS- it is the process which gives the
initial shape to the raw material prior to the other process be carried
out. Casting and hot forging are the most basic manufacturing
processes. In this process molten metal is poured into a refectory mould
cavity (shape as required) and is allowed to solidify. After solidification
the metal is taken the shape of the mould. Different casting processes
are: sand casting, die casting, centrifugal casting etc. Similarly, by hot
forging we can give initial shape using flat or shaped dies.

2. PRINCIPAL MANUFACTURING PROCESSES: It includes all the

processes which convert the initial blank/shape/cast block to final or
intermediate shape of the product. These processes are backbone or
nucleus of the manufacturing processes. It includes:
 Continue…
•FORMING PROCESSES: In this process the desired shape of the
components are obtained through the plastic deformation of metal. It is
a solid state manufacturing process in which the stress induced is
greater than yield strength but less than the ultimate strength. These
processes are used for mass production and give good mechanical
properties. Example: rolling, forging, extrusion, bending, upsetting,
drawing etc.
•METAL REMOVAL PROCESSES: These processes are used to get desired
shape by removing unwanted materials from the initial blank by a sharp
edge cutting tool. These processes are expensive as more energy is
required and there are lot of wastage. But used widely as it give good
dimensional accuracy and surface finish. Example: Turning, drilling,
boring, shaping, planning, milling, grindings etc.
•FABRICATION PROCESSES: These process involves joining pieces
permanently or temporarily: example welding ( gas welding, arc
wielding), brazing, soldering, riveting. Etc.
 Continue…
3. MAJOR MANUFACTURING PROCESSES: It is the
manufacturing process within principal manufacturing processes that
must be performed earliest or has the importance in the process
sequence. This major process usually used to obtain a critical surface
or area. Critical area or surface can be of two type:
Product critical area: it is the surface which control the
dimension/specification of the component for the good functioning
but not have direct influence on the other component.
Process critical area: These are surface which are used for
reference line/surface or for location other surface (surface that meet
the other component for assembly).
4. Auxiliary process operations:
These process are necessary to accomplished the major process i.e.
heat treatment , straightening , cleaning , finishing etc.
5. Supporting operation :
These process are necessary for successfully completion of product
like, inspection , QC, handling packing, etc.
B. Based on the nature of work:
1. Solidification Processes - Raw material is a hot liquid that
solidifies in a pre-shaped cavity to form part geometry
2. Deformation Processes - starting material is plastically
deformed to get shape
3. Material Removal Processes – Unwanted material is removed
to get desired shape
4. Particulate Processes – Part made by powders
5. Assembly Processes - two or more separate parts are joined to
form a new entity
5. Shaping operations - Alter the geometry of the starting work
material
6. Property-enhancing operations - Improve physical properties
of the material without changing its shape
7. Surface processing operations - Clean, treat, coat, or deposit
material onto the exterior surface of the work
 Summary Processes are…
1.Casting Processes – Sand Casting, Permanent
mold casting, die casting, Centrifugal casting
2.Primary metal working processes – Rolling,
forging, extrusion, wire drawing
3.Joining processes – Welding, brazing, soldering
4.Shearing and Sheet metal forming processes
– Punching, blanking, drawing, bending, forming
5.Machining Processes – Turning, drilling, milling,
grinding
6.Processes for changing physical properties of
the materials – Hardening, Tempering, Annealing,
Surface Hardening.
7.Surface finishing processes – Lapping, honing,
superfinishing
 Solidification Processes
• Starting raw material in a liquid or semisolid form is poured or
forced to flow into a die cavity and allowed to solidify, thus taking
the solid shape of the cavity
• Examples: casting for metals, molding for plastics
 Deformation Processes
• Starting workpart is shaped by application of forces that
exceed the yield strength of the material
• Examples: (a) forging, (b) extrusion
 Material Removal Processes
• Excess material removed from the starting workpiece so
what remains is the desired geometry
• Examples: machining such as turning, drilling, and milling;
also grinding and nontraditional processes

Turning Drilling Milling

 Assembly Operations
• Two or more separate parts are joined to form a new entity
• Types of assembly operations:
1. Permanent joining processes – Create a permanent joint.
• Examples: welding, brazing, adhesive bonding
2. Semi-permanent joining: Riveting, soldering, etc
3. Temporary joining (mechanical assembly) – fastening by
mechanical methods
• Examples: use of screws, bolts, nuts, other threaded
fasteners; press fitting, expansion fits
 Property Enhancing Processes
• Performed to improve mechanical or physical
properties of the work material
• Part shape is not altered, except unintentionally
• Examples:
– Heat treatment of metals and glasses
– Sintering of powdered metals and ceramics
 Surface Processing
1. Cleaning - chemical and mechanical processes to remove
dirt, oil, and other contaminants from the surface
2. Surface treatments - mechanical working such as sand
blasting, and physical processes like diffusion
3. Coating and thin film deposition - coating exterior
surface of the workpart
4. Several surface processing operations used to fabricate
integrated circuits
Overview of processes
 Raw materials

Hot CASTING
Forming
Shaping/Form
ing Machi
ning
SUMMERIZING

Assembly
Fabrication

Finishing
Final
product
 Characteristics of a good production process
• Flexibility Geometric tolerances – flatness,
– Tooling development roundness, cylindricity, straightness,
– Setup time parallelism, perpendicularity, angularity,
true position, etc.
– Cycle time
Surface texture – roughness, waviness, lay
• Quality
Defects- Inclusions, voids, porosity …
– Dimensional – bulk and surface
Microstructure- Grain size, residual stress,
– Properties – bulk and surface
precipitate size, etc.
• Economics Surface integrity- cracks, craters, hardness
– Cycle time changes, heat affected zones, inclusions,
– Materials utilization (low waste) intergranular attacks, pits, plastic
Terminology: deformation, recrystallization, residual
Net shape processes - when most of the stresses, etc.
input material is used and no subsequent
machining is required to get final product
Near net shape processes - when
minimum amount of machining is required
 Selection of a Manufacturing Process

1. Understand Function/Geometry Recognize requisite Properties

Functional requirements of product

Geometry of input raw material and output product
2. Properties Make out required Material(s)
Properties: mechanical, electrical, thermal,
magnetic, optical, deteriorative.

3. Material Identify optimum Processing

Material: structure, composition.

• Processing: changes structure and overall shape

• Material and Geometry compatibility
• Other considerations ( Time, availability, skill, law……..)