Manufacturing.ppt

1. INTRODUCTION AND
OVERVIEW OF MANUFACTURING
PROCESS
By
Praveen Kumar

2. What is Manufacturing
• Literal: Manufacture :Made by hand
• Technical:
• Economical:

3. Manufacturing Industries
Industry means
• Enterprises or Organizations

4. Manufacturing Industries
 Industries can be classified as:
1. Primary industries - those that exploit natural resources,
e.g., mining, farming, fishing, petroleum
2. Secondary industries - automotive, computers,
electronics
3. Tertiary industries - service sector
e.g., banking, education, communication, hotels

5. Manufacturing Processes
• Two basic types:
1. Processing - transform a work material from
one state of completion to a more advanced
state
2. Assembly - join two or more components to
create a new entity

6. Classification of manufacturing processes

7. Processing Operations
 Three categories of processing operations:
1. Shaping - alter the geometry of the starting work
material
2. Property enhancing - improve physical
properties
• Heat treatment of metals & glass
3. Surface processing –
• Cleaning
• Surface treatments
• Coating and thin film deposition

8. Classification of manufacturing processes

9. Casting Process
1.Expendable Mould and Permanent Pattern
a)Sand Casting
b)Shell Mould Casting
2.Expendable Mould and Pattern
a)Investment Casting
b)Expanded Polystyrene Process
3.Permanent mould
a)Permanent Mould Casting
b)Die Casting
c)Centrifugal casting

10.  Solidification
 Sand Casting
Shaping Processes

11. Open Molds and Closed Molds
(a) open mold,
(b) closed mold

12. AUDI engine block

13. V6 Engine block

14. Shell Molding
Casting process in which the mold is a thin shell of sand
held together by thermosetting resin binder

15. Cylinder heads, Connecting rods ,machine bases, gears, pulleys.

16. Investment Casting
Turbine blade with complex shapes

17. Investment Casting

18. Expanded Polystyrene Process
Engine blocks, cylinder heads, crankshafts, differential carriers, and
transmission cases

19. Permanent Mold Casting
Typical parts include gears, splines, wheels, gear
housings, pipe fittings, fuel injection housings, and
automotive engine pistons

20. Die Casting
• Hot Chamber
hot-chamber machines are primarily used with zinc, tin, and
lead based alloys.

21. Die Casting
• Cold Chamber
Cold-chamber machines are used with
a large composition of aluminium,
magnesium and copper.

22. Centrifugal Casting

23. Classification of manufacturing processes

24. Forming Processes: Deformation
• Bulk Deformation
• Sheet Metal Forming

25. Bulk Deformation Processes
Rolling
Extrusion
Drawing
Forging

26. Figure Shows Some of the steel products made in a rolling mill.
Rolled Products Made of Steel

28. (a) forge hot billet to max diameter
(b) “fuller: tool to mark step-locations
(c) forge right side
(d) reverse part, forge left side
(e) finish (dimension control)
t
Stages in Open die forging

29. Stages in Impression-die (Closed-Die) Forging
Hooks ,Spanners, bolts, Agricultaral equipments

30. Extrusion
Typical use: ductile metals (Cu, Steel, Al, Mg),
Plastics, Rubbers
Common products:
Al frames of white-boards, doors, windows, …
Extrusion

31. Tube drawing

32. Forming Processes: Deformation
• Bulk Deformation
• Sheet Metal Forming

33. Cutting
Deep
Drawing
Sheet Metal Forming Processes
V-Bending

35. Presses
Figure Schematic representation of the
various types of press drive mechanisms.

36. Figure Shows Diagram showing details of a drop hammer
for impression-die forging.
Drop Hammer Details

37. Figure Shows Components of a typical mechanical drive stamping press
Stamping Press

38. Classification of manufacturing processes

39. Forming: Particulate Processing
• Starting materials are powders of metals or
ceramics

40. Classification of manufacturing processes

41. Material Removal Processes -
Machining
• Excess material removed from the
starting piece so to get the desired
geometry
 Examples: machining such as
turning, drilling, and milling; also
grinding and nontraditional
processes
Turning: Machining
of cylindrical parts
Drilling Milling

42. Material Removal Processes -
Machining
• Turning examples
Standard Turning

43. Two Forms of Milling

44. Turning Machine:
Lathe

45. Milling Machine:

46. Classification of manufacturing processes

47. Heat Treatment Processes
• Annealing
• Normalizing
• Quenching & Hardening
• Tempering

48. Classification of manufacturing processes

49. Surface Processing Operations
• Cleaning - chemical and mechanical processes to
remove dirt, oil, and other surface contaminants
• Surface treatments - mechanical working such as
sand blasting, and physical processes like diffusion
• Coating and thin film deposition - coating exterior
surface of the work part. Examples:
 Electroplating
 Physical vapor deposition
 Painting

50. Classification of manufacturing processes

51. Figure 31.1 Basic configuration of an arc welding process.
Permanent Joining Processes:
Welding, Brazing, Soldering, Adhesive Bonding

52. Classification of manufacturing processes

53. Welding
• Heat
• Pressure
 Examples: Metallic Parts & Plastics

54. Types of Welding Processes
• Solid state welding processes
• Liquid state welding processes
• Solid / Liquid state bonding processes

55. Solid State Welding Processes
Steps Solid State:
• Heating the surfaces without causing melting
and applying normal pressure
• Providing relative motion between the two
surfaces and applying light normal pressure
• Applying high pressure without melting

56. Forge Welding
• Surfaces to be joined are heated till they
are red hot and then forced together by
hammering.

57. Friction Welding

58. Friction Stir Welding
• Friction-stir welding joins metal with heat and high
pressure.
 A constantly rotated non consumable cylindrical-shouldered tool
with a profiled nib is transversely fed at a constant rate into a
butt joint between two clamped pieces of butted material
 Frictional heat is generated between the wear-resistant welding
components and the work pieces

59. Explosive Welding
• Very high contact pressure developed by detonating a thin
layer of explosive.
• The detonation imparts high kinetic energy
• No filler material is used and no diffusion takes place.

60. Liquid State Welding
• Arc Welding
• Resistance welding
• Oxyfuel gas welding

61. Arc Welding
• In Electric Arc Welding a sustained arc provides the heat
required for melting the parent as well as filler material.

62. Figure 31.1 Basic configuration of an arc welding process.
Arc Welding
• When the electrode and work piece are in contact, current flows and
when they are separated an arc is generated and the current continues
to flow.
• The arc is generated by the electrons liberated form cathode and
moving towards anode.
• The arc changes electrical energy into heat and light.
Liquid State Welding

63. Shielded Arc Welding
• Consumable Electrode
• Slag
 Proctective Cover
 Slow down Cooling rate
Liquid State Welding

64. Gas Metal Arc Welding
• Gas Metal Arc Welding(GMAW) is also known as MIG welding.
• A Continuous wire if fed into welding gun
Liquid State Welding

65. Submerged Arc Welding
• Submerged Arc Welding (SAW) is only performed by automatic or
semiautomatic methods
• Uses a continuously fed filler metal electrode
• Weld pool is protected from the surrounding atmosphere by a blanket
of granular flux fed at the welding gun
Liquid State Welding

66. Resistance Spot Welding
Resistance welding, showing the
components in spot welding, the
main process in the RW group.

67. Oxyacetylene Welding
Liquid State Welding

69. Classification of manufacturing processes

70. Figure Shows Several techniques for applying filler metal in
brazing: (a) torch and filler rod. Sequence: (1) before, and
(2) after.
Brazing - Soldering: Permanent
Joining Processes – Weak Bonding,
Lower Temperatures

71. Brazing
• The filler metals are generally
copper alloys.
• Cu-Zn and Cu-Ag alloys are used
for brazing

72. Brazing methods
Torch and filler rods
Ring of filler metal at entrance of gap
Foil of filler metal between flat part
surfaces
Brazing

73. Soldering
• The filler material is usually a
lead-tin based alloy

74. Joints in Soldering

75. Classification of manufacturing processes

76. Types of stresses that must be considered in
adhesive bonded joints: (a) tension, (b) shear, (c)
cleavage, and (d) peeling.
Joining Process: Adhesive Bonding

77. Classification of manufacturing processes

78. Mechanical Fastening
Threaded ,Permanent
1. Methods that allow for disassembly
Example: threaded fasteners
2.Methods that create a permanent joint
Example: rivets

79. Threaded Fasteners
• Bolt - externally threaded fastener inserted through
holes and "screwed" into a nut on the opposite side
• Nut - internally threaded fastener having standard
threads that match those on bolts of the same
diameter, pitch, and thread form
• Screw - externally threaded fastener generally Assemble into
blind threaded hole

80. Bolt Specification
A bolt consists of three parts:
• a head
• a shank (optional)
• a thread
T. Thread Diameter
S. Shank Diameter
R. Root Diameter
a b
c
a. Shank length
b. Thread length
c. Nominal length
shank thread
head

81. Nut Specification
Parts:
• a body
• a thread
• a hole
• Diameters
• Height
• Thread Type
• Right handed unless otherwise stated is the norm
• Thread specification
• Will be discussed in the thread specification section
R
T
T Thread Diameter
R Root Diameter
height

82. Types of Bolts
• Carriage bolt
• Usually used to attach a wooden part to
metal.
• Machine bolt
• Used for precision attachment using
threads to secure materials together.
• Tap bolt
• Similar to a machine bolt but the whole
body is threaded.
• Stove bolt
• General purpose fastener used when
precision fit is not necessary.
• Stud bolt
• One end is driven into material & the other
end is left exposed so that other parts can
be fastened to it.

83. Types of Machine Screws
• Machine & cap screws
• Used for precision fit into thread
holes in metal.
• Setscrew
• Typically used for safety reasons
to hold a sleeve, collar or gear on
a shaft to prevent relative motion.
• Thumbscrews
• Used where a screw must be
turned by hand using the thumb
and a finger.

84. Rivets
• Most widely used permanent fastening method
• Typically a pneumatic hammer delivers a succession of blows to
upset the rivet
Types: (a) solid, (b) tubular, (c) semitubular, (d) bifurcated, and (e) compression.
(a) solid, (b) tubular, (c) semitubular, (d) bifurcated, and
(e) compression

85. Rivets used in airplanes.

88. THANKYOU