Manufacturing Process1

Manufacturing Processes1. Casting2. Forming

i. Forgingii. Rollingiii. Extrusioniv. Drawingv. Sheet metal process

3. Metal joiningi. Welding Gas, Arcii. Brazingiii. Soldering

4. Machiningi. Latheii. Drillingiii. Milling

Casting method mouldingA look into Melting and

Casting Metal

Casting process Pouring of molten metal

Casting and Foundry Processes

In one step raw materials are transformed

into a desirable shape

Parts require finishing processes

Excess material is recyclable

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Basic Casting Process

A mold is created A cavity that holds the molten material in a desired shape until it is solidified

Multiple-use mold

Single-use molds

Material is heated to a specified temperature

Molten material is poured into a mold cavity

Molten material solidifies into the shape of the cavity

Casting or mold is removed

Casting is cleaned, finished, and inspected

Casting casting is a

process of forming metallic products by melting the metals, pouring into a cavity called mold and allowed to solidify.

Dept. of Mechanical Engg., NIT, Trichy 7

Metal Casting

Create liquid metal - Melting Combustion used to melt material

Electricity used to melt material

Create solid shape - Casting Permanent mold casting

Semi Permanent mold casting

Casting

Pattern Making

Mold Preparation

Melting and Pouring

Solidification

Felting Process

Finishing


Permanent Mold Casting

Mold that can be used repeatedly

Commonly associated with die casting

Mold material varies with metal to be cast

Used for large number of pieces to be cast dueto initial cost of the mold

Pattern Making

Shrinkage Allowance

Machining Allowance

Draft Allowance

Shaking Allowance


Pattern Materials wood Aluminum Plasters Wax

Properties of Mold Sand

Porosity

Refractiveness

Cohesiveness

Adhesiveness

Grain Size and Shape


Sand Casting

Uses sand to hold the desired shape to be cast

Bonded with chemicals or clay with water oroil

Many different types of sand casting

Sand Casting

Permanent Mold Casting

Casting Defects

Blow Holes

Shrinkage

Swell

Hard Spots

Runout

Cracks

Shift

Fins


Wax moulding

Metal Forming

Large group of manufacturing processes inwhich plastic deformation is used to changethe shape of metal work pieces.

The tool, usually called a die, applies stressesthat exceed the yield strength of the metal

The metal takes a shape determined by thegeometry of the die.


Material Properties in Metal Forming

Desirable material properties: Low yield strength

High ductility

These properties are affected by temperature: Ductility increases and yield strength decreases when work

temperature is raised

Other factors: Strain rate and friction


Basic Types of Deformation Processes

1. Bulk deformation Rolling

Forging

Extrusion

Wire and bar drawing

2. Sheet metalworking Bending

Deep drawing

Cutting

Miscellaneous processes


Bulk Deformation Processes

Characterized by significant deformations and massive shape changes

"Bulk" refers to workparts with relatively low surface area-to-volume ratios

Starting work shapes include cylindrical billets and rectangular bars


Utilizes material that has been cast

Modify the shape, size, and physical

properties of the material

Hot and cold forming

Forming and Metalworking Processes

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Rolling Material passes through a series of rollers, reducing its thickness with each pass

Forging Material is shaped by the controlled application of force (blacksmith)

Basic bulk deformation processes: (a) rolling

Rolling


ii. RollingRolling operation

Rolling mill

Rolling of rod

Rolling of sheet metal

Hot rolling operation

Basic bulk deformation processes: (b) forging

Forging


Forging

Forging operation

Hand forging

Shaft forging

Forging products

Cold forming and forging Slugs of material are squeezed into dies

Wire, rod, and tube drawing Material is pulledthrough a die to produce a uniformed cross section

Extrusion Material is compressed and forcedthrough a die to produce a uniformed cross section


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Basic bulk deformation processes: (c) extrusion

Extrusion


Extrusion operation

Tube extrusion

Extrusion products

Basic bulk deformation processes: (d) drawing

Wire and Bar Drawing


Drawing process

Sheet Metalworking

Forming and related operations performed on metal sheets, strips, and coils

High surface area-to-volume ratio of starting metal, which distinguishes these from bulk deformation

Often called pressworking because presses perform these operations Parts are called stampings

Usual tooling: punch and die


Basic sheet metalworking operations: (a) bending

Sheet Metal Bending


Bending

Bending is defined as the straining of the sheet metal

around a straight edge.


Basic sheet metalworking operations: (b) drawing

Deep Drawing


Basic sheet metalworking operations: (c) shearing

Shearing of Sheet Metal


Blanking and punching

Blanking and punching are similar sheet metal cutting operations that

involve cutting the sheet metal along a closed outline. If the part that is cut

out is the desired product, the operation is called blanking and the product

is called blank. If the remaining stock is the desired part, the operation is

called punching. Both operations are illustrated on the example of

producing a washer.


Metal Joining Process


Joining An all-inclusive term covering processes An all

inclusive term covering processes such as

Welding

Brazing

Soldering

Adhesive bonding

Mechanical fastening



WELDING Welding is a materials joining process which

produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material.

Welding is used for making permanent joints.

It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building.


Classification of welding processes

(i). Arc welding Carbon arc Metal arc Metal inert gas Tungsten inert gas Plasma arc Submerged arc Electro-slag(ii). Gas Welding Oxy-acetylene Air-acetylene Oxy-hydrogen

(iii). Resistance Welding Butt Spot Seam Projection Percussion

(iv)Thermit Welding(v)Solid State Welding

FrictionUltrasonicDiffusionExplosive

(vi)Newer WeldingElectron-beamLaser

(vii)Related ProcessOxy-acetylene cuttingArc cuttingHard facingBrazingSoldering


Arc welding

Equipments:

A welding generator (D.C.) or Transformer (A.C.)

Two cables- one for work and one for electrode

Electrode holder

Electrode

Protective shield

Gloves

Wire brush

Chipping hammer

Goggles


Arc Welding Equipments


Metal arc welding


Arc Welding

Uses an electric arc to coalesce metals

Arc welding is the most common method of welding metals

Electricity travels from electrode to base metal to ground


Arc welding

Advantages Most efficient way to join

metals

Lowest-cost joining method

Affords lighter weight through better utilization of materials

Joins all commercial metals

Provides design flexibility

Limitations Manually applied, therefore high

labor cost.

Need high energy causing danger

Not convenient for disassembly.

Defects are hard to detect at

joints.


GAS WELDING

Sound weld is obtained by selecting proper size of flame, filler material and method of moving torch

The temperature generated during the process is 33000c

When the metal is fused, oxygen from the atmosphere and the torch combines with molten metal and forms oxides, results defective weld

Fluxes are added to the welded metal to remove oxides

Common fluxes used are made of sodium, potassium. Lithium and borax.

Flux can be applied as paste, powder,liquid.solid coating or gas.


Oxy-Acetylene welding


Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or

reducing flame.


Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting operations:(a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing flame.


Ferrous metal is heated in to red hot condition and a jet of pure oxygen is projected onto the surface, which rapidly oxidizes

Oxides having lower melting point than the metal, melt and are blown away by the force of the jet, to make a cut

Fast and efficient method of cutting steel to a high degree of accuracy Torch is different from welding Cutting torch has preheat orifice and one central orifice for oxygen jet PIERCING and GOUGING are two important operations Piercing, used to cut a hole at the centre of the plate or away from the

edge of the plate Gouging, to cut a groove into the steel surface

GAS CUTTING


Weld joints


Brazing and Soldering Brazing

It is a low temperature joining process. It is performed at

temperatures above 840 F and it generally affords strengths comparable to those of the metal which it joins. It is low temperature in that it is done below the melting point of the base metal. It is achieved by diffusion without fusion (melting) of the base

Brazing can be classified asTorch brazingDip brazing

Furnace brazingInduction brazing


Advantages & Disadvantages

Advantages

Dissimilar metals which canot be welded can be joined by brazing Very thin metals can be joined Metals with different thickness can be joined easily In brazing thermal stresses are not produced in the work piece. Hence

there is no distortion Using this process, carbides tips are brazed on the steel tool holders

Disadvantages

Brazed joints have lesser strength compared to welding Joint preparation cost is more Can be used for thin sheet metal sections


Soldering

It is a low temperature joining process. It is performed at temperatures below 840F for joining.

Soldering is used for,

Sealing, as in automotive radiators or tin cans

Electrical Connections

Joining thermally sensitive components

Joining dissimilar metals


Friction welding is a solid state joining process that produces coalescence by the heat developed between two surfaces by mechanically induced surface motion.

Friction Welding

Solid State Welding


Friction stir welding

used for aluminum requires no filler low distortion low microstructural changes

probe 5-6 mm diameter 5 mm height temps 230 260oC


Ultrasonic Welding

Machining - Material Removal Process


To remove the material Work Piece Tool Relative Motion between the tool and work piece

Machine Tools


It is defined as power- driven machine which is capable of cutting and removing metal in the form of chips to produce desired shape

Machine Tools for cylindrical workTool or work piece is going to rotateEx: Lathe, Drilling, Boring, Cylindrical Grinding etc.

Machine Tools for flat surfaceEx: Milling, Face Grinding, Shaping etc.

TYPES OF MACHINE TOOLS

Lathe: Lathe is a basic machine tool where turning or facing operation is used.The workpiece rotates to provide the cutting motion, and the feed is given by the

motion of the cutting tool. Lathes are used for the production of all kinds of

components, but symmetrical about their axis of rotation.

Drilling Machine: The cutting action results from the rotary movement of the

cutting tool / workpiece. The feed motion of the workpiece or tool is in the

direction of the axis of rotation. Drilling machines are used for drilling, boring,

counter-sinking (A conical hole cut into a manufactured object), reaming (enlarging

the size of a previously formed hole by a small amount but with a high degree of

accuracy) and tapping (form threads) operations.

Counter sunk holes of various chamfer angles

TYPES OF MACHINE TOOLS (Contd..)

Milling Machine: Similar to drilling, in the case of milling, both the tool and the

workpiece can move horizontal or vertical direction. Milling machines are used to

produce flat surfaces, sink, and slot. It uses rotating milling cutter while work piece

reciprocates.

A LATHE

Lathe

Father of Machine Tools

Lathe is a machine, which removes the metalfrom a piece of work to the required shape&size with single point cutting tool.


Specification of Lathe

length of the bed

the largest diameter of the work piece that can be rotted without touching the guide ways

Height of the centers from the bed

The maximum distance between the centers


Types of Lathe

Engine Lathe

The most common form of lathe, motor driven andcomes in large variety of sizes and shapes.

Bench Lathe

A bench top model usually of low power used tomake precision machine small work pieces.

Tracer Lathe

A lathe that has the ability to follow a template tocopy a shape or contour.


Condt..Automatic Lathe

A lathe in which the work piece is automatically fed andremoved without use of an operator. Cutting operations areautomatically controlled by a sequencer of some form

Turret Lathe

lathe which have multiple tools mounted on turret eitherattached to the tailstock or the cross-slide, which allows forquick changes in tooling and cutting operations.

Computer Controlled Lathe

A highly automated lathe, where both cutting, loading, toolchanging, and part unloading are automatically controlledby computer coding.


Component Description


CNC Lathe

LATHE COMPONENTS

COMPONENTS OF A LATHE

The spindle is a part of the lathe that rotates. Work holding attachments

such as chucks (3 or 4 jaws), collets, and centers can be held in the spindle.

Three jaw chuck Four jaw chuck

Collet chuck

Three Jaw Chuck

Dept. of Mechanical Engg., NIT, Trichy90

- For holding cylindrical stockcentered.- For facing/center drilling the

end of your aluminum stock

Four Jaw Chuck- This is independent chuckgenerally has four jaws ,which are adjustedindividually on the chuckface by means of adjustingscrews

Thin jobs can be held by means of

magnetic chucks.


Collet Chuck

Magnetic Chuck

Collet chuck is used to hold small workpieces

Thin jobs can be held by means of magnetic chucks.

COMPONENTS OF A LATHE (Contd..)

The spindle is driven by an electric motor through a system of belt drives and geartrains. Spindle rotational speed is controlled by varying the geometry of the drivetrain.

The tailstock is used to support the end of the workpiece with a center, or to hold

tools for drilling, reaming, threading, or cutting tapers. It can be adjusted in position

along the ways to accommodate different lengths of work pieces. The tailstock

barrel can be fed along the axis of rotation with the tailstock hand wheel.


The CARRIAGE is used for giving various movements to the cutting tool. Thus it controls andsupports the cutting tool. It consists of,- A saddle (4), H shaped casting fixed over the bed. The saddle slides along the ways. Itcarries the cross slide and tool post.

1 - tool post2 - compound rest2a - hand wheel on compound rest2b - protractor on the base of compound

rest3 - cross-slide3b - hand wheel on cross-slide4 - saddle5 - apron5a - hand wheel for carriage motion


- An apron (5) that controls the feed mechanism. The apron has gears, levers and othermechanisms for moving the carriage. The apron hand wheel is used for the carriagemotion parallel to the lathe axis.

- A cross-slide (3) that controls transverse motion of the tool (toward or away from theoperator).

- A compound rest (2) that can be adjusted to allow angular tool movement. It is markedin degrees and used during taper turning operation during which the tool is fed at anangle to the lathe axis.

- A tool post (1) that holds the cutting tool (normally single point).

THREE IMPORTANT ELEMENTS

In order to get an efficient process and a neat surface duringmachining, it is important to adjust the following parameters:

rotating speed of the work piece cutting depth of the tool sending speed (Feed rate) of the tool.

However, these parameters are not unique and vary with the typematerial, its hardness, size & shape of the part, etc.

1. CUTTING SPEED

It is the number of rotations (rpm) of the chuck of a lathe. When the

rotating speed is high, processing speed becomes quick, and the work

piece surface is finely machined. However, a little operation mistake

may lead to serious accidents, and it is better to set low rotational

speeds at the initial stages.

2. DEPTH OF CUT

The cutting depth of the tool affects the processing speed and the

roughness of surface. When the cutting depth is high, the processing

speed becomes quick, but the surface temperature becomes high

leading to a rough surface. If a suitable cutting depth is not known, it is

better to set a small value as an initial step.

3. FEED RATE

The sending speed (Feed rate) of the tool also affects the processing

speed and the surface roughness. When the sending speed is low, the

surface is finished beautifully. There are 'manual sending' which turns

and operates a handle, and 'automatic sending' which advances a tool

automatically.

A beginner of a lathe must operate with low rotational speeds,

small cutting depths and low feed rates for safety.

CUTTING TOOLS

Single point cutting tool

TYPES OF TOOL MATERIALS

Carbon + medium alloy steel

High speed steel (HSS)

Cast cobalt alloys

Carbides

Coated tools

Ceramics

Silicon nitride

Diamond

LATHE OPERATIONS

TURNING

Turning is a simple machining process to produce parts round inshape by a single point cutting tool on lathes.

The tool is fed either linearly in the direction parallel orperpendicular to the axis of rotation of the workpiece, or alonga specified path to produce complex shapes.

The primary motion of cutting process in turning is the rotationof the workpiece, and the secondary motion of cutting is thefeed motion.

OPERATIONS IN TURNING

a). Turning of cylindrical surfaces:

Turning is not a single process but class of many and differentoperations performed on a lathe. The lathe can be used toreduce the diameter of a part to a desired dimension. Theresulting machined surface is cylindrical.

Lathe operations-Turning

b) Turning of flat surfaces:

A lathe can be used to create a smooth, flat face very accurately perpendicular to the axis ofa cylindrical part. Tool is fed radially or axially to create a flat machined surface.

Facing is the process of removing metal from the end of a workpiece to produce a flatsurface. Most often, the workpiece is cylindrical, but using a 4-jaw chuck you can facerectangular or odd-shaped work to form cubes and other non-cylindrical shapes.

FACING OPERATION

Lathe operations- facing

Lathe operations-Taper turning

PRODUCTION OF A CUBOID ON LATHE

c) THREADING

Different methods are available to produce a thread using a lathe.

Threads are cut using lathes by advancing the cutting tool at a feed exactly equal to the threadpitch.

The single-point cutting tool cuts in a helical band, which is actually a thread. Another possibility isto cut threads by means of a thread die (external threads), or a tap (internal threads). Theseoperations are generally performed manually for small thread diameters.

Threading

Lathe operations- Threading

d) FORM TURNING

Cutting tool has a shape that is imparted to the workpiece by

plunging the tool into the workpiece.

In form turning, cutting tool is complex and expensive but feed is

linear and does not require special machine tools or devices.

Lathe operations- Forming

Lathe operations- Knurling

e) CONTOUR TURNING (PROFILING)

Cutting tool has a simple shape, but the feed motion is complex;cutting tool is fed along a contour thus creating a contoured shape onthe workpiece.

For profiling, special lathes or devices are required.

Lathe operations- Contour turning

f) MISCELLANEOUS OPERATIONS

Some other operations, which do not use the single-point cuttingtool, can be performed on a lathe, making turning one of the mostversatile machining processes.

Lathe operations - Boring

g) KNURLING

This is not a machining operation at all, because it does not involvematerial removal.

Instead, it is a metal forming operation, used to produce a regularcrosshatched pattern on the work surface.

LATHE OPERATIONS

Drilling Process

Drilling is the operation of producing circular hole in the work-piece by using a rotating cutter called DRILL.

The machine used for drilling is called drilling machine.

The drilling operation can also be accomplished in lathe, in which the drill is held in tailstock and the work is held by the chuck.

The most common drill used is the twist drill.


Drilling Machine

It is the simplest and accurate machine used in production shop.

The work piece is held stationary ie. Clamped in position and the drill rotates to make a hole.

Types :-a) Based on construction:

Portable, Sensitive, Radial, up-right, Gang, Multi-spindle

b)Based on Feed:

Hand and Power driven


DRILLING MACHINE

A hand drill is commonly used for drilling of small holes, but a drill press

is preferable when the location and orientation of the hole must be

controlled accurately.

A drill press is composed of a base that supports a column; the column

in turn supports a table. Work can be supported on the table with a vise

or hold down clamps, or the table can be swiveled out of the way to

allow tall work to be supported directly on the base.

Height of the table can be adjusted with a table lift crank, then locked in

place with a table lock.

The column also supports a power head containing a motor. The motor

turns the spindle at a speed controlled by a variable speed control dial.

The spindle holds a drill chuck to hold the cutting tools (drill bits, center

drills, reamers, etc.).

A DRILLING MACHINE

HAND DRILLING MACHINE

Sensitive Drilling Machine

Drill holes from 1.5 to 15mm

Operator senses the cutting action so sensitive drilling machine


Up-Right Drilling Machine

Drill holes upto 50mm

Table can move vertically and radially


A RADIAL DRILLING MACHINE

It is the largest and most versatile machine used for drilling medium tolarge and heavy work pieces. It has a radial arm along which the drillinghead can be moved and clamped.

OTHER DRILLING MACHINES

The gang drill is a drill press consisting of a series of drillpresses connected together in an in-line arrangement so thata series of drilling operations can be done in sequence.

In the multiple-spindle drill, several drill spindles areconnected together to drill multiple holes simultaneously intothe workpiece.

Multiple-spindle drill Gang drilling machine

TWIST DRILL NOMENCLATURE

Tool Nomenclature


Drilling tools

Types of cuttersReamers :-

Multi tooth cutting tool

Accurate way of sizing and finishing the pre-existing hole.

Accuracy of 0.005mm can be achieved

Boring Tool:-

Single point cutting tool.

Boring tool is held in the boring bar which has the shank.

Accuracy of 0.005mm can be achieved.Dept. of Mechanical Engg., NIT, Trichy 134

Countersinks :-

Special angled cone shaped enlargement at the end of the hole

Cutting edges at the end of conical surface.

Cone angles of 60, 82, 90, 100, 110, 120

Counter Bore Tool:-

Special cutters uses a pilot to guide the cutting action .

Accommodates the heads of bolts.Dept. of Mechanical Engg., NIT, Trichy 135

Types of cutters

Drill Materials

The two most common types are

1. HSS drill

- Low cost

2. Carbide- tipped drills

- high production and in CNC machines

Other types are

Solid Carbide drill, TiN coated drills, carbide coated masonry drills, parabolic drills, split point drill


Drilling Operations

Operations that can be performed in a drillin g machine are

Drilling

Reaming

Boring

Counter boring

Countersinking

TappingDept. of Mechanical Engg., NIT, Trichy 137

DRILLING OPERATIONS

Drilling is used to make a round blind or through hole in a solid

material. If the hole is larger than 30 mm in diameter, its a good idea

to drill a smaller pilot hole before core drilling the final one. For

holes larger than 50 mm, three-step drilling is recommended.

Core drilling is used to increase the diameter of an existing hole.

Step drilling is used to drill a stepped (multi-diameter) hole in a solid

material.

Counter boring provides a stepped hole again but with flat and

perpendicular relative to hole axis face. The hole is used to seat

internal hexagonal bolt heads.

Countersinking is similar to counter boring, except that the step is

conical for flat head screws.

DRILLING OPERATIONS

Reaming provides a better tolerance and surface finish to an

initially drilled hole. Reaming slightly increases the hole diameter.

The tool is called reamer.

Center drilling is used to drill a starting hole to precisely define

the location for subsequent drilling. The tool is called center drill.

A center drill has a thick shaft and very short flutes. It is therefore

very stiff and will not walk (move) as the hole is getting started.

Gun drilling is a specific operation to drill holes with very large

length-to-diameter ratio up to L/D300. There are several

modifications of this operation but in all the cases, cutting fluid is

delivered directly to the cutting zone internally through the drill

to cool and lubricate the cutting edges, and to remove the chips.

Operations in drilling machine


Drilling method

Drilling operation

Reaming operation

Drill fixed to the spindle


Drilling operations

Drilling Centre Hole

Drilling Deep Holes

Drilling Thin Material

Drilling Pilot Hole

Tool Holding devices

The different methods used for holding drill in a drill spindle are

By directly fitting in the spindle hole.

By using drill sleeve

By using drill socket

By using drill chuck


Work Holding Devices


Work Holding Devices 1. Machine Table Vice


Work Holding Devices

Step Blocks

Clamps

V-Blocks

Angles

Jigs

T- Slots Bolt


Precautions for Drilling machine Lubrication is important to remove heat and

friction.

Machines should be cleaned after use

Chips should be removed using brush.

T-slots, grooves, spindles sleeves, belts, pulley should be cleaned.

Machines should be lightly oiled to prevent from rusting


Safety Precautions

Do not support the work piece by hand use work holding device.

Use brush to clean the chip

No adjustments while the machine is operating

Ensure for the cutting tools running straight before starting the operation.

Never place tools on the drilling table

Avoid loose clothing and protect the eyes.

Ease the feed if drill breaks inside the work piece.


Milling Processes


Milling Processes

Milling is one of the basic machiningprocesses. Milling is a very versatile processcapable of producing simple twodimensional flat shapes to complex threedimensional interlaced surfaceconfigurations.


Horizontal milling machine

Vertical milling machine

Horizontal Milling Machine



Vertical Milling Machine

The Process

The milling process: Typically uses a multi-tooth

cutter

Work is fed into the rotating cutter

Capable of high MRR

Well suited for mass production applications

Cutting tools for this process are called milling cutters


Related Operations

Side milling - machining a plane surface perpendicularto the milling machine arbor with an arbor mountedtool. This tool is called a side mill.

Straddle milling - milling two parallel surfaces usingtwo cutters spaced apart on an arbor.

Gang milling - milling multiple surface simultaneouslyusing multiple cutters mounted on an arbor.

Thread milling - milling treads using the capability of athree axis contouring CNC machine.


Milling operations

Milling Cutters


Production Engineering


It is defined as converting raw materials in to finished products.Production engineering is a combination ofManufacturing technology with ManagementScience. A production engineer typically has a wideknowledge of engineering practices and is aware ofthe management challenges related to production.The goal is to accomplish the production process inthe smoothest, most-judicious and most-economicway.

Product Creation CycleDesign Material Selection Process Selection Manufacture Inspection Feedback

Typical product

cost breakdown

Products and Manufacturing

Manufacturing Process

A sequence of operations and processes designed to create a specific product

The process of turning materials into a

product

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Engineers in Manufacturing

Manufacturing EngineerSelect and coordinate specific processes and equipment

Industrial EngineerResponsible for the manufacturing system design

Materials EngineerDevelop and select materials based on desired material properties and manufacturing processes

Manufacturing System Designs

Small quantities of products

Large variety of products

Products move through the shop to various machines

General-purpose machines

Job Shop



Flow Shop

Larger quantities of products

Production line

Special purpose machines



Linked-Cell Shop

Manufacturing and subassembly cells connected to final assembly

Lean production system

One piece flow system



Project ShopProduct being manufactured cannot be easily moved during production

Production processes are brought to the product

Examples: Bridges, ships, large airplanes, locomotives, large machinery



Continuous Process

Large plants

Utilized in the manufacture of liquids, oils, gases, and powders



Lean Manufacturing

100% good units flow from process to process

Integrated quality control (IQC)

All employees are inspectors


Manufacturing Process1

Documents

permanent mold casting

metal casting

die casting mold material

mechanical engg

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mold preparation

basic casting processa

material electricity