Advance Mfg Processes introduction

MANUFACTURING PROCESSES
LECTURE 1
BY DR LIAQAT ALI
HOD (DESIGN AND MANUFACTURING)
SCHOOL OF MECHANICAL AND
MANUFACTURING ENGINEERING

 Assignments 10 %
 Quizes 10 %
 OHT1 15%
 OHT2 15%
 Final Exam 50%

 Lectures
 Other sources (slides/handouts)
 Books
 Principles of Metal Manufacturing Processes
 by J.BeDoes,M.J.Bibby
 Fundamentals of Modern Manufacturing
 by Mikell P. Groover
 Advance Manufacturing Processes
 by Kalpajain

MAJOR TOPICS
 Introduction to Advance Manufacturing Processes
 Casting Processes
 Metal Deformation processes
 Sheet Metal Working Processes
 Metal Cutting Theory/Machining Processes
 Automated Machining Processes
 Joining Processes
 Surface Protection and Heat Treatment Processes
 Non-Conventional Machining Process

INTRODUCTION
 What is Manufacturing?
 Historical Development of Materials and
Manufacturing Processes
 Product Design and Concurrent Engineering

INTRODUCTION
 Manufacturing is the term used to describe the making of
products. Until the nineteenth century it was largely an
activity reserved for craftsmen. The industrial revolution
during the second half of the nineteenth century
introduced manufacturing mechanization.
 The use of machines for spinning and weaving in the
textile industry is generally acknowledged to be the
beginning of modern manufacturing. During this same
time, Bessemer (1855) in England and William Kelly
(1857) in the United States proposed methods for the
mass production of steel. This was followed by the Hall-
Heroult process (1885) for melting aluminum. These
processes provided relatively cheap sources of the
materials required to drive the industrial revolution.

INTRODUCTION
 One definition of manufacturing is the conversion of
either raw or semi-finished materials into finished parts.
Such a definition serves to emphasize the importance of
materials in manufacturing operations. In fact, the
choice of material for a given manufacturing situation
may be the limiting consideration. In general, a material
must satisfy two criteria.
 First, the relevant mechanical, corrosive, electrical or
physical properties of the material must be sufficient to
ensure failure-free performance of the final product.
Second, the material should be easy and inexpensive to
fabricate. Inexperienced engineers tend to
underestimate the importance of this latter requirement,
often leading to frustration and redesign.

MATERIALS USED IN MANUFACTURING

SELECTING MATERIALS
 Ferrous Metals
 Nonferrous metals and alloys
 Plastics
 Ceramics
 Composite Materials Nanomaterial's, shape-
Memory alloys, metal foams,

SELECTING MATERIALS
 Material Substitution
 Material Properties
 Cost and Availability
 Service Life and Recycling

SELECTING MANUFACTURING PROCESSES
 Part Size and Dimensional Accuracy
 Ultra precision Manufacturing
 Manufacturing and Operational Costs
 Net- Shape Manufacturing

MANUFACTURING OPERATIONS
 Manufacturing operations can be generally
classified into primary and secondary processes.
For metals, primary manufacturing usually refers to
the conversion of ores into metallic materials.
Secondary manufacturing is generally understood
to mean the conversion of the products from the
primary operation into semi-finished or finished
parts. For example, the fabrication of automobile
engine blocks from a primary melt of iron or
aluminum is said to be secondary manufacturing.

METAL PROCESSING & MANUFACTURING
 Primary Processes
 The vast majority of pig iron produced from iron ores is
processed by blast furnaces
 Steel making by Bessemer steel converter

METAL PROCESSING & MANUFACTURING
BLAST
FURNACE

SCHEMATIC OF A BESSEMER STEEL CONVERTER

ELECTRIC ARC FURNACE FOR STEEL PRODUCTION

FLOW DIAGRAM OF THE BAYER PROCESS
(CONVERSION OF BAUXITE INTO ALUMINA)

 The conversion of primary products into secondary
finished or semi-finished components can take place by
one of several alternative routes.

Advance Mfg Processes introduction

CASTING PROCESSES
 Sand Casting
 Lost Wax Casting
 Die Casting Deep
 Fundamentals of Die Casting Design

FORMING PROCESSES
 Upset forging
 Extrusion
 Thread and gear rolling
 Coining (stamping)
 Wire drawing
 Tube drawing
 Impression-die forging
 Deep drawing
 Bending
 Embossing
 Shearing

SHEET FORMING PROCESSES
 Formability
 Shearing
 Bending
 Stretch forming
 Press working of metals

MACHINING PROCESSES
Mechanical Machining methods
Non-traditional machining processes

MACHINING PROCESSES
 Mechanical Machining methods
 Conventional Machining
 Single point machining
 (Tunining, Shaping, Planing etc.)
 Multipoint machining
 Drilling, Milling etc.)
 CNC Machining
 CNC Turning
 CNC Milling

NON-TRADITIONAL MACHINING PROCESSES
 Non-traditional machining processes
 Abrasive water jet Machining
 ECM (Electro-chemical machining)
 EDM (Electro-discharge machining)
 EBM (Electron Beam machining)
 LBM (Laser Beam machining)
 Rapid Prototyping

JOINING PROCESSES
 Welding
 Brazing
 Soldering

HEAT TREATMENT OF MATERIALS
 Annealing
 Normalizing
 Tempering
 Quenching

SURFACE TREATMENT
 Diffusional Processes
 Flame Induction Hardening
 Plating Processes
 Thin film coatings

Advance Mfg Processes introduction

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