ME206 – Manufacturing Process I

Lecture 1 – Overview of Manufacturing processes

Amber Shrivastava
Department of Mechanical Engineering,
Indian Institute of Technology Bombay

Acknowledgement: Prof. Pradeep Dixit

 Texts/References
• Ghosh A. and Mallick A. K., Manufacturing
Science, Affiliated East West Press, 2001.
• Kalpakijan and Schmidt, Manufacturing
Engineering & Technology, Pearson
Publication
• Mikell P. Groover, Fundamentals of
Modern Manufacturing: Materials,
Processes, and Systems, 2006
• Rao P. N., Manufacturing Technology-
Foundry, Forming and Welding, Tata
McGraw Hill, 1987.
 What is Manufacturing ?
• Application of physical and chemical processes to change the geometry,
properties, and appearance of a starting material to make parts or
products for a given application
• Materials: metal, non-metals, plastic, ceramic, composite
• Manufacturing (Five M’s) : Man, Machine, Materials, Money and
Management
– Controlling these five M’s is the key behind successful
manufacturing
• Manufacturing results in transformation of materials into items of
greater value
– Profit is key objective of any manufacturing industry efficient usage
of resources, reduction in waste, time lag, etc.

3
 Significance of Manufacturing

Manufacturing contribution in India’s GDP :

15% as on March 2020

https://statisticstimes.com/econ
omy/country/india-gdp-
sectorwise.php
 Materials used in today’s manufacturing
• Ferrous metals:
– Carbon steels, alloy steels, stainless
steels, and tool and die steels
• Nonferrous metals and alloys:
– Al, Mg, Cu, Ni, Superalloys, Ti,
– Refractory metals (Mb, Nb, W, Zr,
– low melting alloys (lead, zinc and tin),
and precious metal
• Plastics:
– Thermosets, thermoplastics, and
elastomers
• Ceramics:
– Glass ceramics, glasses, graphite, and
diamond
• Composites:
– Reinforced plastics, metal-matrix and
ceramics-matrix composites
Choosing which material suits best & feasible!

Body mostly of aluminium Cast-iron Al-Si-Mg

Engine blade: Superalloys
alloys
etc Why these materials
and how to work with
them?

Cu-alloys Titanium
Range of Materials & Processes in a Tractor

FIGURE 1.1 Model 8430 tractor, with detailed illustration of its

diesel engine, showing the variety of materials and processes
incorporated. Source: Courtesy of John Deere Company.
 Classification of Manufacturing Processes
• Manufacturing: Five M’s
– Men (women), Machine, Materials, Money and Management
– Define the efficient (profitable) manufacturing system
• Manufacturing processes:
– Shaping processes - alter the geometry of the starting work
material: casting, forming, machining
– Property-enhancing processes - improve physical properties of the
material without changing its shape. Annealing, hardening..
– Surface processing processes - clean, treat, coat, or deposit material
onto the exterior surface of the work. Surface oxidation
• ME206 course will focus on the shaping operations (metal casting,
forming, welding)
• ME338 (Autumn sem) will be on Machining processes

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Classification of manufacturing processes
 Shaping Processes – Main Categories

Deformation process dm~0

Solidification process dm~0

Metal removal processes dm<0 dm>0

Assembly process: Welding

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 Basic manufacturing processes

Metal Casting Powder processing Forging

Heat treatment Welding/Joining Machining/Removal

Plastics – injection moulding Additive/3D printing

 Which processes should be used?

(a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d)
machining, (e) joining two pieces.

• Several processes exist to make the same product

• Selection of the manufacturing processes depends upon many factors:
– Available infrastructure,
– Cost effectiveness (low wastage, high power requirement)
– Operating temperature
– Required mechanical properties of the final product
– Dimensions of the required product
Scales in Manufacturing

Illustration of the range of common sizes of parts

and the capabilities of manufacturing processes
in producing these parts.
Thank you!!