LECTURE OBJECTIVES

To develop an understanding of:

Manufacturing Engineering
Basic Manufacturing Processes
Material removal processes/Machining
 Manufacturing Processes

» Manufacturing processes are the steps through which raw materials

are transformed into a final product.
» The manufacturing process begins with the creation of the materials
from which the design is made. These materials are then modified
through manufacturing processes to become the required part.
» Manufacturing processes can include treating (such as heat treating
or coating), machining, or reshaping the material.
» The manufacturing process also includes tests and checks for quality
assurance during or after the manufacturing, and planning the
production process prior to manufacturing.
Classification of Manufacturing Processes
 Manufacturing Processes

Two basic types:

1. Processing operations - transform a work material from
one state of completion to a more advanced state that
change the geometry, properties, or appearance of the
starting material
2. Assembly operations - join two or more components to
create a new entity
Material Removal Processes
 Machining

Machining is a material removal process in which a sharp cutting

tool is used to mechanically cut away material so as to obtain a
finished product of the desired size, shape, and surface quality
• Most common application: to shape metal parts
• Machining is the most versatile and accurate of all manufacturing
processes in its capability to produce a diversity of part
geometries and geometric features
• Casting can also produce a variety of shapes, but it lacks the precision
and accuracy of machining
 Classification of Machining Processes
Traditional/ conventional Non-traditional
1. Mechanical Processes
1. Turning • Water Jet Machining (WJM)
2. Drilling • Abrasive Jet Machining (AJM)
• Abrasive Water Jet Machining (AWJM)
3. Milling • Ultrasonic Machining (USM)
4. Miscellaneous [Shaping and 2. Electrochemical Processes
• Electrochemical Machining (ECM)
Planning, Broaching, Sawing] • Electro Chemical Grinding (ECG)
• Electro Jet Drilling (EJD)
3. Electro-Thermal Processes
• Electro-discharge machining (EDM)
• Laser Jet Machining (LJM)
• Electron Beam Machining (EBM)
4. Chemical Processes
• Chemical Milling (CHM)
• Photochemical Milling (PCM)
 Classification of Machined Parts

1. Rotational - cylindrical or disk‑like shape

2. Non-rotational (also called prismatic) - block‑like or
plate‑like

Fig. Machined parts are classified as: (a) rotational, or (b)

non-rotational, shown here by block and flat parts
.
Raw material
Product
Machining Operations and Part Geometry
Each machining operation produces a characteristic part
geometry due to two factors:

1. Relative motions between the tool and the workpiece

• Generating – part geometry is determined by the feed
trajectory of the cutting tool

2. Shape of the cutting tool

• Forming – part geometry is created by the shape of the
cutting tool
 Generating

Fig. Generating shapes: (a) straight turning, (b) taper turning, (c) contour
turning, (d) plain milling, (e) profile milling
 Forming

Fig. Forming to create shape: (a) form turning, (b) drilling, and (c)
broaching
Combination of Forming and Generating

Fig. Combination of forming and generating to create shape: (a) thread

cutting on a lathe, and (b) slot milling
 Turning
A single point cutting tool removes material from a rotating
workpiece to generate a cylindrical shape
• Performed on a machine tool called a lathe
• Following are the main types of turning
1. Facing 8. Contour turning
2. Taper turning 9. Cutoff
3. Straight turning 10. Knurling
4. Form Turning 11. Finishing
5. Threading/thread cutting
6. Step turning
7. Chemfering
 Turning related operations

Straight Turning
In straight turning, the tool is fed
parallel to the axis of rotation.

Fig. Straight turning

 Turning related operations

Facing
Tool is fed radially inward

Fig. (a) facing

 Turning related operations

Contour Turning
Instead of feeding the tool parallel
to the axis of rotation, tool follows
a contour that is other than
straight, thus creating a contoured
form

Fig. (c) contour turning

 Turning related operations

Chamfering
Cutting edge cuts an angle on the
corner of the cylinder, forming a
"chamfer"

Fig. (e) chamfering

 Turning related operations

Cutoff
Tool is fed radially into rotating work
at some location to cut off end of
part

Fig. (f) cutoff

 Turning related operations

Threading
Pointed form tool is fed linearly across
surface of rotating work part parallel
to axis of rotation at a large feed rate,
thus creating threads

Fig. (g) threading

 Turning related operations

Knurling
Knurling is used to produce
a regularly shaped
roughness/ crosshatched
pattern on the work
surface.
 Turning related operations

Tapper Turning

 An operation performed on a
lathe that feeds a tool at an
angle to the length of the
work piece in order to create
a conical shape.
 Boring
• In fact, boring is an internal turning operation
• Difference between boring and turning:
• Boring is performed on the inside diameter of an
existing hole
• Turning is performed on the outside diameter of an
existing cylinder
Boring machines
• Horizontal or vertical - refers to the orientation of
the axis of rotation of machine spindle
 Lathe Operations

Finishing

 Finishing is done to achieve superior

surface finish up to mirror-like finishing
and very close dimensional precision.