IUBAT- International University of Business Agriculture and Technology

Founded 1991 by Md. Alimullah Miyan

COLLEGE OF ENGINEERING AND TECHNOLOGY(CEAT)

Introduction to Manufacturing Process

Course Title: Manufacturing Process
Course Code : MEC 237

Course Instructor: Dr. Md Rakibuzzaman

Manufacturing Process
Chapter 1
(Book: Fundamentals of Modern
Manufacturing by Mikell. P. Groover)

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 Goals and Outcomes

 Manufacturing Process
 Manufacturing Industries and Products
 Planning for Manufacturing
 Steps in Modern Manufacturing
 Classification of Manufacturing Process
 Selecting manufacturing process
 Recent development in Manufacturing
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 Introduction
 What is Manufacturing ?
The word manufacture is derived from two Latin words manus and factus. Manus means hand
and factus means make. So the combination of this two words mean made by hand.
In broadest sense, manufacturing is a well organized method of converting raw material to end
product .
It can be defined in two ways.
Technologically and Economically

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 Technologically :
It is the application of physical and chemical processes to
alter the geometry, properties and appearance of a given
starting material for making parts or products. It also
includes assembly of multiple parts to make products.
This is accomplished by a combination of machinery,
tools, power and manual labor.

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 Economically :
It is the transformation of materials into items of greater
value by means of one or more processing and/or assembly
operations. The key point is that it adds value to the material
by changing its shape or properties or by combining it with
other materials that have been similarly altered. For example
– when sand is transformed into glass, value is added.

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 History of Manufacturing
 Manufacturing started during 5000 – 4000 BC Wood work,
stone and metal work.
 Steel Production 600-800 AD
 Industrial Revolution 1750 AD: Machine tools run by
invention of steam engine
 Mass Production and Interchangeable Parts
 Computer Controlled Machines 1965
 CNC (Computerized Numerical Control), FMS (Flexible
Manufacturing System) systems

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Historical development of materials & Manufacturing Process
- The Early Days

Period Metals and Casting Forming Process

Gold , copper and meteoritic

Before 4000 B.C Hammering
iron
Copper casting, stone and
Egypt ~3100 B.C. to ~ metal molds, lost wax
300 B.C 4000-3000 B.C. Stamping Jewelry
process, Silver, Lead, Tin,
Bronze
Greece ~1100 B.C. to Wire by cutting and
~146 B.C 3000-2000 B.C. Bronze casting
drawing, gold leaf
2000-1000 B.C. Wrought iron, brass
Roman Empire ~500
B.C. to 476 A.D 1000-1 B.C. Cast iron, cast steel Stamping of coins
Armor, coinage, forging,
1 – 1000 A.D Zinc, steel
Middle Ages 476 to steel swords
1492

Renaissance 14th to Blast furnace, type metals, Wire drawing, gold silver
1000-1500 A.D.
16th centuries casting of bells, pewter smith work

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Historical development of materials & Manufacturing Process -
The Industrial Revolution

Water power for metal

working,rolling mill for
1500-1600 A.D. Cast iron cannon, tinplate coinage

Rolling(lead,gold,silver)
Permanent mold casting, brass
1600-1700 A.D. Shape rolling(lead)
from copper and metallic zinc

Industrial Revolution Extrusion (lead pipe),

1750-1850 deep drawing,
1700-1800 A.D. Malleable cast iron,crucible steel rolling(iron bars and
rods)

Centrifugal casting, Bessemer Steam hammer, steel

process, electrolytic aluminum, rolling, seamless tube
1800-1900 A.D. nickel steels, Babbitt, galvanized piercing, steel rail
steel, powder metallurgy, rolling, continuous
tungsten steel, open hearth steel rolling , electroplating

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Historical development of materials & Manufacturing Process -
The Modern Age

1900-1920 A.D. Tube rolling, hot extrusion

1920-1940 A.D. Die casting Tungsten wire from powder
WW I and WW II
Extrusion (steel),swaging,
Lost wax for engineering
1940-1950 A.D. powder metal for
parts
engineering parts

Cold extrusion
Ceramic mold, nodular iron, (steel),explosive
1950-1960 A.D. semiconductors,continuous forming,thermo mechanical
casting treatment

Squeeze casting, single Hydrostatic

1960-1970 A.D
crystal turbine blades extrusion,electroforming
Space Age
Compacted graphite,vacuum
casting,organically bonded Precision forging,
sand,automation of molding isothermal forging, super
1970-1980 s and pouring, large aluminum plastic forming,die design
castings for aircraft by analytical methods, net
structures rapid solidification shape forming
technology
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 Manufacturing Industries
Manufacturing Industries can be classified as -
 Primary Industries: Those who cultivate and exploit
natural resources such as agriculture and mining are called
primary industries.
 Secondary Industries : Those who take the output of the
primary industries and convert them into consumer goods.
Manufacturing is the principal activity in this category. For
example, Automotive industries, computer industries etc.
 Tertiary Industries : Those who constitute the service
sector of the economy are called tertiary industries. Such
as Banking, Hotel etc.

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 Planning for Manufacturing
Traditional steps required to convert an idea into a finish product
Original Concept (Invention-Research)

Design Sketches (Preliminary design)

Working Drawing (Development)

First Model (Prototype)

Testing (Verification)

Revised Model (Innovation)

Material Specification Tool Selection and Design

Production Planning and Scheduling Tool Constriction

Process Selection Tool installation and checking

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Manufacturing
 Steps in Modern Manufacturing
Definition of product need,
CAM and CAPP
marketing information
Design analysis ;
codes/standards review;
physical and analytical models Production

Conceptual design and

Evaluation, Feasibility study
Prototype production,
testing and evaluation Inspection and quality
assurance
CAD
Production drawings;
Instruction manuals Packaging; marketing and
sales literature

CAD – Computer Aided Design

Material Specification;
CAM – Computer Aided Process and equipment
Product
Manufacturing selection;
CAPP – Computer Aided safety review
Process Planning

Pilot Production

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 Requirements of a good manufacturing system

 Product should meet design requirement

 Economical Process
 Quality should be built into the system
 Should be flexible and responsive to new technology
 High productivity: Best utilization of manpower, material,
machine, capital and available resources.

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Classification of Manufacturing Processes

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 Processing Operation
• A processing operation uses energy to alter a work part's shape, physical properties, or
appearance in order to add value to the material.
• The forms of energy include mechanical, thermal, electrical and chemical.
• More than one processing operation is usually required to transform the starting
material into final form.
• The energy is applied in a controlled way by means of machinery and tooling. Human
energy may also be required, but the human workers are generally employed to control
the machines, oversee the operations, and load and unload parts before and after each
cycle of operation.

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Shaping Processes:

It alter the geometry of the starting material by various methods. Common

shaping processes are casting, forging and machining.

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i) Solidification Processes
The processes in which the starting material is a heated liquid or
semi liquid that cools and solidify to form the part geometry.

ii) Particulate Processing

The processes in which the starting material is powder that
squeezed first into a die cavity under high pressure for getting
desired geometry and then heated to bond the individual
particles together .

iii) Deformation Processes

The processes where starting material is a ductile solid that is
deformed to shape the part.

iv) Material Removal Process

The processes in which the starting material is a solid, from
which material is removed so that the resulting part has the
desired geometry. 18
Property enhancing processes:
This process add value to material by improving its physical properties without changing
its shape. Heat treatment is the most common example.

i) Heat treatment:
Heat Treatment is the controlled heating and cooling of metals to alter their physical
and mechanical properties without changing the product shape.

Physical properties are the Measurable properties which describe the physical system's
state such as Density.
Mechanical property is a property which is the behavior of the material when its
linked to the application of force such as Strength.
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Surface processing operations:
They are performed to clean, treat, coat or deposit
material onto the exterior surface of the work.
Painting is an example.

i) Cleaning & Surface Treatment:

Cleaning includes both chemical and mechanical
processes to remove dirt, oil and other contaminants
from the surface. Surface treatments includes
mechanical like sand blasting and physical processes
like ion implantation.

ii) Coating & deposition processes:

This processes apply a coating of material to the
exterior surface of the work part. Common coating
processes include electroplating, anodizing of
aluminum, organic coating (call it painting) and
porcelain enameling.

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 Assembly Operations
The second basic type of manufacturing operation is assembly in which two or
more separate parts are joined to form a new entity. Parts are joined either
permanently or semi permanently.

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i) Permanent joining processes: are welding, brazing, soldering and adhesive
bonding.

ii) Mechanical Fastening:

One technique is using screws, bolts and other treaded fasteners.
Other is using rivets, press fitting, and expansion fits.

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Materials processing families, subgroups, and typical processes
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 Selecting Manufacturing Processes
Many processes are used to produce parts and shapes.
The broad categories of processing methods for materials are as follows -

A. Casting : Expandable mold and permanent mold

B. Forming & Shaping: Rolling, forging, extrusion, drawing, sheet forming, powder
metallurgy and molding.
C. Machining: Turning, boring, drilling, milling, planning, shaping, broaching and
grinding.
Ultrasonic Machining, chemical, electrical and electrochemical machining and
high energy beam machining.
D. Joining: Welding, brazing, soldering, diffusion bonding, adhesive bonding and
mechanical joining.
E. Finishing: Honing, lapping, polishing, burnishing, deburring, surface treating,
coating and plating.

Selection of particular manufacturing processes depends not only on the

shape to Produced but also on many others factors pertaining to material
properties.
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Selecting Manufacturing Processes

Casting, foundry or molding process

Forming or Metal working process

Joining and assembly

Powder- and Ceramics Processing

Plastics processing

Cutting

Sheet metal processing

Surface treatment

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 Recent Developments in Manufacturing

• Microelectronics
• Computerization of manufacturing
• Flexible manufacturing
• Microfabrication and nanotechnology
• Lean production and six sigma
• Globalization, and
• Environmentally conscious manufacturing

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