Introduction to Manufacturing
Processes
Types of Processes
• Primary Manufacturing Processes
– Raw materials to useable material
– Raw materials are renewable or exhaustible
• Secondary Manufacturing Processes
– Create products from primary product
Input Process Output
Feedback
Manufacturing Process
Materials
• Ceramics,
metals, and
plastics are well-
suited to
manufacturing.
• Their properties
determine the
process for
which they are
best suited.
The World of Materials
Organic
MaterialsInorganic
Materials
Solid Liquid Gas
Engineering
(Industrial)
Materials
Non-
Engineering
Materials
Polymeric Metallic
Ceramic
Composite Video
Selecting Materials
Internal
Structure
Types of atoms
Bonds between
atoms
Molecular
structure
Property
Physical
Mechanical
Chemical
Thermal
Electrical –
Magnetic
Acoustical
Optical
Conditions
Chemicals
Radiation
Mechanical
Loads
Thermal
Electromagnetic
Fields
Sonic Forces
Casting and Molding
Casting and Molding Videos
Separating
• Involves the removal of material
• Also referred to as the
subtractive process
• Includes two types of processes
– Chip Forming
– Non-Chip Forming
Separating Videos
Joining
• Also referred to as the additive process
• Materials added in layers to build a finished part
• Examples– Welding
– Gluing
– Soldering
– Prototyping
Forming
• Uses force to cause
a material to
permanently take a
shape
• Changes some of
the material
properties
Forming Videos
Finishing
• May be completed before
or after assembly
• Used primarily to protect
a product from various
conditions
• Also used to enhance a
product’s appearance
Finishing – Deburring• Methods include filing, scraping, and trimming
• Considerations include actual requirements regarding work piece specifications, production quantities, and cost
Finishing – Cleaning
• Involves the process of removing
unwanted material from work pieces
• Techniques include
– Alkaline cleaning
– Electrolitic cleaning
– Solvent cleaning
– Vapor degreasing
– Acid cleaning
– Abrasive blasting
– Abrasive wheels
Finishing – Coating
• Involves a material
being applied to a
work piece
• May be mechanical,
electrolytic, or
conversion
Finishing – Assembling
• Involves putting parts together
• May be temporary or permanent
• Includes bonding and mechanical fastening
Finishing – Conditioning
• Refers to changing
the physical or
mechanical properties
of a material
• Includes thermal,
chemical, and
mechanical
Image ResourcesCustompart.net. (2008). Tutorials. Retrieved February 1,
2008, from
http://www.custompartnet.com/wu/InjectionMolding
Microsoft, Inc. (2008). Clip art. Retrieved February 13,
2008, from http://office.microsoft.com/en-
us/clipart/default.aspx
Society of Manufacturing Engineers (Producer). (2010).
Forging. Available from the Society of Manufacturing
Engineers, One SME Drive: Dearborn, Michigan 48121.
The ABB Group. (2008). Photo gallery. Retrieved June 5,
2008, from http://www.abb.com