MANUFACTURING PROCESSES I

(Course Code: EMEC214L)

L-T-P STRUCTURE : 3-0-2

CREDITS : 4

Faculty: Dr. Neelanchali Asija Bhalla

 Course outline
➢ Introduction to manufacturing – technological and economic aspects
➢ Introduction to various manufacturing processes
➢Casting process – Types, Defects, Analysis of process, Design
requirements, advantages & limitations, applications.
➢ Welding Process
➢ Metal Forming processes
➢ Powder metallurgy process
➢ Processing of Polymers
➢ Manufacturing of Composite Materials
Important Books..
1. Manufacturing Science A. Ghosh and A.K. Mallik East West
Reference Press
Books 2. Manufacturing, Engineering & Technology - Kalpakjian, S. and
Steven R. Schmid Pearson

1. Materials and Processes of Manufacture- Degarmo, E.P., Black, J.T.,

Kosher, John Wiley & Sons, 2004
2. Modern Manufacturing Processes - Groover
Text Books
EVALUATION SCHEME

Components of Course Evaluation Percentage Distribution

Mid Semester Examination 20%

End Semester Examination 35%

Lab Continuous Evaluation
12%
(lab record-6 / Viva-6)
Assignments 10%
Quizzes 10%
Project (presentation-7/ report-6) 13%
Lecture -01

Introduction to Manufacturing
What is Manufacturing ??
The word manufacture is derived from two Latin words: Manus (hand) and factus
(make), thus implying made by hand. Manufacturing is the application of physical
and chemical processes to alter the shape, geometry, appearance or properties of a
given raw material to a finished part or product.

Value addition by Manufacturing

Manufacturing – Technical and Economic Aspect

TechnicalAspect Economic Aspect

Application of Manufacturing Processes
This includes ;
➢ Application of any existing manufacturing process and system
➢ Proper selection of input materials, tools, machines and environments
➢ Improvement of the existing materials and processes
➢ Development of new materials, systems, processes and techniques

All the manufacturing processes and systems must be;

➢ Technologically feasible and acceptable
➢ Economically feasible and acceptable
 Production Management

Several routes of manufacturing

Objectives to be met;
▪ Reduction of manufacturing cost
▪ Reduction of manufacturing time
▪ Increase in productivity
▪ Increase in profit
▪ Ease of manufacturing
What is the role of engineers in Manufacturing?
What is the difference between Manufacturing processes
and manufacturing systems?
MANUFACTURING SYSTEMS
What is the difference between traditional/ conventional
and non-conventional Manufacturing processes ?
Why there is a need to classify manufacturing processes ?
Various manufacturing processes based upon the approach
to obtain finished product ...

1) Processes in which mass conservation is followed (no

addition nor subtraction of material)

2) Positive Processes/ Joining processes

3) Subtractive manufacturing processes

4) Additive manufacturing processes

Manufacturing Processes based upon the raw materials

I. Manufacturing of metallic products

II. Manufacturing of Ceramic products

III. Composite manufacturing techniques

IV. Manufacturing of Plastic components

 Near Net-shape Manufacturing
• Because not all manufacturing operations produce finished products or products
to desired specifications, additional finishing operations may be necessary.
• For example, a forged part may not have the desired dimensional accuracy; thus
additional operations such as machining may be necessary.
• Likewise, it may be difficult to produce a product using only one manufacturing
process, a part that, by design, has a number of holes in it, necessitating
additional process such as drilling.
• Also, the holes produced by drilling process may not have the proper
roundness, dimensional accuracy, or surface finish, thus necessitating the
need for additional operations, such as honing.
• These additional operations can contribute significantly to the cost of a product
 Net-shape Manufacturing
Consequently, net-shape or near-net-shape manufacturing has become an
important concept in which the part is made also close to the final desired
dimensions, tolerances, and specifications.

Terminology:

Net shape processes - when most of the starting material is used and
no subsequent machining is required to achieve final part geometry

Near net shape processes - when minimum amount of machining is

required
 Design for manufacturability (DFM)

Definitions :
• According to James G. Bralla , (1996) in the broadest sense DFM is
any step, method or system that provides a product design that eases
the task of manufacturing and lower manufacturing cost.
• According to Boothroyd , G (2002) DFMA means the design of
product for ease of manufacturing and assembly
The Advantages of applying DFM during
Product Design

Reduced time to market

Cost reduction

Improved quality
Some DFM Guidelines :
1. Standardize.
2. Design parts that don’t tangle with themselves.
3. Reduce the overall number of components.
4. Reduce the number and types of part.
5. Design with symmetric features
6. Maximize Compliance
7. Eliminate/ minimize post-processing operations
PRODUCT DESIGN FOR SUSTAINABILITY

The three pillars of product design for sustainability are;

1. Environment

2. Economy

3. Technology
PRODUCT DESIGN FOR SUSTAINABILITY

The three R’s of product design are;

1. Recycle

2. Reuse

3. Redesign