Introduction to Manufacturing Processes

Product Creation Cycle Design Material Selection Process Selection Manufacture Inspection Feedback Typical product cost breakdownProducts and Manufacturing

Manufacturing ProcessA sequence of operations and processes designed to create a specific productThe process of turning materials into a productiStockphoto.com iStockphoto.com iStockphoto.com

Engineers in ManufacturingManufacturing Engineer Select and coordinate specific processes and equipment Industrial Engineer Responsible for the manufacturing system designMaterials Engineer Develop and select materials based on desired material properties and manufacturing processes

Manufacturing System DesignsSmall quantities of products Large variety of productsProducts move through the shop to various machinesGeneral-purpose machinesJob ShopiStockphoto.com iStockphoto.com

Manufacturing System DesignsFlow ShopLarger quantities of productsProduction lineSpecial purpose machines iStockphoto.com iStockphoto.com

Manufacturing System DesignsLinked-Cell ShopManufacturing and subassembly cells connected to final assemblyLean production systemOne piece flow systemiStockphoto.com iStockphoto.com

Manufacturing System DesignsProject ShopProduct being manufactured cannot be easily moved during productionProduction processes are brought to the productExamples: Bridges, ships, large airplanes, locomotives, large machineryiStockphoto.com iStockphoto.com

Manufacturing System DesignsContinuous ProcessLarge plantsUtilized in the manufacture of liquids, oils, gases, and powders iStockphoto.com iStockphoto.com

Manufacturing System DesignsLean Manufacturing100% good units flow from process to process Integrated quality control (IQC)All employees are inspectorsiStockphoto.com iStockphoto.com

Basic Manufacturing ProcessesCasting and Foundry Forming or MetalworkingMachiningJoining and AssemblyRapid PrototypingOther

Casting and Foundry ProcessesIn one step raw materials are transformed into a desirable shapeParts require finishing processesExcess material is recyclableiStockphoto.com

Basic Casting ProcessA mold is created A cavity that holds the molten material in a desired shape until it is solidified Multiple-use mold Single-use moldsMaterial is heated to a specified temperatureMolten material is poured into a mold cavityMolten material solidifies into the shape of the cavityCasting or mold is removedCasting is cleaned, finished, and inspected

Utilizes material that has been castModify the shape, size, and physical properties of the materialHot and cold formingForming and Metalworking ProcessesiStockphoto.com iStockphoto.com

Forming and Metalworking ProcessesRolling Material passes through a series of rollers, reducing its thickness with each pass Forging Material is shaped by the controlled application of force (blacksmith)

Wire, rod, and tube drawing Material is pulled through a die to produce a uniformed cross sectionExtrusion Material is compressed and forced through a die to produce a uniformed cross sectionForming and Metalworking ProcessesiStockphoto.com

Cold forming and forging Slugs of material are squeezed into diesForming and Metalworking Processes

Machining ProcessesControlled removal of material from a part to create a specific shape or surface finishCutting element is used Movement must exist between the part and cutting elementiStockphoto.com

Turning ProcessesOperations that create cylindrical parts Work piece rotates as cutting tool is fed into the workMachining ProcessesiStockphoto.com iStockphoto.com

Turning ProcessesLathes and turning centersProcesses include: Straight, taper, contour turning, facing, forming, necking, parting, boring, threading, and knurlingMachining ProcessesiStockphoto.com iStockphoto.com

Milling ProcessesOperations that create flat or curved surfaces by progressively removing materialCutting tools rotate as the work piece is secured and fed into the toolMachining Processes

Milling ProcessesMills Vertical and horizontalProcesses include: Surfacing, shaping, forming, slotting, T-slotting, angle, straddle, dovetailing, and slab millingMachining Processes

Drilling ProcessesOperations that create holes Cutting tools rotate and are fed into nonmoving secured work piecesMachining Processes

Drilling ProcessesDrilling and boring machinesProcesses include: Drilling, counter drilling, step drilling, boring, counter boring, countersinking, reaming, spot facing, and tappingMachining Processes

Shearing ProcessesOperations that break unwanted material away from the partA material is placed between a stationary and movable surface. The movable surface (blade, die, or punch) applies a force to the part that shears away the unwanted material. Machining Processes

Automated hole punch, squaring shear, and rotary cutterProcesses include: Shearing, blanking, cutoff, and parting; punching, perforating, and slotting; notching, lacing, and trimmingShearing ProcessesMachining Processes

Abrasive Machining ProcessesOperations in which small particles of materials (abrasives) remove small chips of material upon contact Drum, disc, and belt sanders; surface, vertical and horizontal spindle; disc grinders; media blaster; tumblersMachining Processes

Thermal and Chemical ProcessesOperations that cut and shape materials through chemical meansNo mechanical force is usedMachining ProcessesElectrical discharge, electrochemical, chemical, laser, electron beam, flame cutting, and plasma-arc cutting Processes include: Grinding, sawing, cutting, machining, milling, blanking, and etching

Heat Treating ProcessesControlled heating and cooling of a material to alter its properties while maintaining its shapeProperties include: Strength, toughness, machinability, wear resistance, and corrosion resistance90% of heat treating is preformed on steel and other ferrous metals

Heat Treating ProcessesTo aid in the manufacturing process, materials can be treated to be weak and ductile and then can be re-treated to provide high strength.Can also occur incidentally during the manufacturing process

Joining and Assembly ProcessesCan you think of a product with only one part?Most products consist of multiple parts that are assembled to form a finished product.Typical assembly processes include: Mechanical fastening; soldering and brazing, welding; adhesive bonding

Joining and Assembly ProcessesMechanical FasteningUse physical force to hold parts togetherMechanical fasteners or part designScrews, bolts, nails, rivets, cotter pins, retaining clips, and edge designiStockphoto.com iStockphoto.com

Joining and Assembly ProcessesWeldingOperations that use heat, pressure, or both to permanently join partsGas, arc, stud, spot, forge, roll laminating, resistance, and induction welding iStockphoto.com iStockphoto.com

Joining and Assembly ProcessesAdhesive bondingBonding of adjoining surfaces by filling the gap between each surface with a bonding materialGlue, cement, thermoplastic, thermosetting, and elastomersiStockphoto.com iStockphoto.com

Joining and Assembly ProcessesSoldering and BrazingOperation in which metal surfaces are bonded together by an alloyHeated molten alloy flows between the adjoining surfaces When the heat is removed, the molten metal solidifies and the metal surfaces are bondediStockphoto.com

Rapid PrototypingAdditive processParts are produced directly from software applicationsCommon rapid prototyping systems include: stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), laminated object manufacturing (LOM), digital light processing (DLP)

Rapid PrototypingFinished parts can be field tested depending upon building materialCreated parts can be used to create a mold Modifications to design can be implemented quickly

Other Manufacturing ProcessesTestingTransportationMaterial handlingPackagingiStockphoto.com

Material-Specific Manufacturing ProcessesPlastic ProcessesCeramic ProcessesiStockphoto.com

Plastics Manufacturing ProcessesA rotating screw forces plastic through a heating chamber and then through a heated dieProduces long plastic parts with uniform cross sectionsExtrusion

Heated plastic is forced by a movable plunger through a nozzle and then into a mold. The material fills the mold and then is cooled.Most widely used high-volume production processPlastics Manufacturing ProcessesInjection Molding

Plastic is melted and poured into a mold No pressure or fillers are required.Plastics Manufacturing ProcessesCastingA closed mold is filled with a predetermined amount of plastic. The mold is heated, rotated, and then cooled to create a hollow plastic object with uniform wall thickness.Rotational Molding

Plastics Manufacturing ProcessesA solid bottom hollow tube is placed between two mold halves and heated. The heated tube is then expanded into the sides of the mold with compressed air.Blow Molding

Plastics Manufacturing ProcessesLiquid reactants are mixed and then pressurized into a mold. No heat is needed. Curing time is typically less than 1 minute.Reaction MoldingPlastic sheets are heated over an open mold to a working temperature. Once workable, a vacuum is applied to the mold, forcing the plastic sheet to take the shape of the mold. Thermoforming

Ceramic Manufacturing ProcessesTwo distinct classes of materials and processes exist.Glass is heated to a molten state, shaped by viscous flow, and then cooled to produce a solid.Crystalline CeramicsMaterial is shaped and then heated to produce a permanent solid.

Manufacturing Importance Typical product cost breakdown

Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2010*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Society of Manufacturing Engineers (Producer). (2010). Casting. Available from the Society of Manufacturing Engineers, One SME Drive: Dearborn, Michigan 48121.

Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*Introduction to Manufacturing ProcessesPrinciples Of EngineeringTMUnit 3 Lesson 3.2 Material PropertiesProject Lead The Way, Inc.Copyright 2009*