M105.1 1

DEPARTMENT OF TECHNICAL EDUCATIONANDHRA PRADESH

Name : K. Madhu KumarDesignation : Sr. lecturerBranch : Mechanical Engg.Institute : GIPDCET , VisakhapatnamYear/Semester : I YearSubject : Workshop TechnologySubject Code : M-105Topic : Basic Workshop Tools and

operations Duration : 50 minsSub Topic : Manufacturing process

(Introduction)Teaching Aids : Ppt

M105.1 2

Objectives

• On completion of this period you would be able to

• State various manufacturing processes

• State importance of manufacturing processes

M105.1 3

• Have you seen manufacturing of gates, grills etc. ?

• What type of manufacturing process is it ?

M105.1 4

• It is a fabrication process involving welding as joining

method.

M105.1 5

• In a similar way all the articles we use in daily life are

produced by different manufacturing processes.

• In this lesson we will introduce ourselves to some basic

manufacturing processes

M105.1 6

•It is an activity of making goods and articles by hand or machine

•It is a transformation of raw materials or semi finished products

into finished products

•It can be done either.

•by hand or

•by machine.

What is a manufacturing process ?

M105.1 7

Block diagram of production

Primary Manufacturing process

Semi finishedproducts

Rawmaterials

SecondaryMfg process

Finished productsWith shape, size & finish

Fig 1 Block diagram of production

M105.1 8

Types of manufacturing process

• Shaping processes

• Metal forming & metal working processes

• Machining processes

• Joining processes

• Surface finish processes

• Processes affecting change in properties

M105.1 9

Shaping process

• This is called casting process.

• Casting is shaping of material in molten state poured in

cavity(mould)

• After solidification it is removed from mould,cleaned and

machined

• Shape and size of the product is the shape of the mould

M105.1 10

Castings

Fig 2. Casting process

M105.1 11

Metal forming & metal working process

•Here metal is shaped by plastic deformation.

•Heat may or may not be applied.

•Pressure is applied by external means.

M105.1 12

Classification of Metal Forming

Metal Forming

Hot Working Cold Working

M105.1 13

Comparison Between Hot Working and Cold Working

• Hot Working• Metal shaped above

Recrystallisation Temperature.

• Examples:

• Forging

• Hot rolling

• Hot extrusion

• Cold Working• Metal shaped below

Recrystallisation Temperature

• Examples:

• Cold drawing

• Bending

• Squeezing

M105.1 14

Forging

Fig 3. Forging process

M105.1 15

Cold bending

Fig 4 cold Bending

M105.1 16

Joining process

This process is used for joining of metal parts together in fabricating works

•The common joining processes are

•Welding

•Soldering

•Screwing

M105.1 17

Common joining processes (contd)

• Riveting

• Adhesive joining

• Brazing

• Pressing

M105.1 18

Welding

Fig 5 Welding process

M105.1 19

Surface finishing process

•In this process a very negligible amount of metal is removed or added to provide good surface finish of metal surface

The common processes are

Buffing Lapping Electroplating

Polishing Super finishing Metal spraying

Honing Belt grinding Anodizing etc

M105.1 20

Process effecting change in properties

These processes are to impart certain specific properties to metal parts for particular operation like,

• Hardening,

• softening

• Grain refinement,

•Change in internal structure

•Resistance to fatigue

M105.1 21

A few prominent processes are,

•Heat treatment

•Cold working

•Hot working

•Shot peening

M105.1 22

Importance of manufacturing process

• Economic use of resources i.e men materials machines &

energy

• Economic development

• Competing on global basis

M105.1 23

Basic work shop process

• Carpentry

• Fitting

• Forging

• Sheet metal

• Cold working

• Hot working

M105.1 24

Summary

In this period we have learnt about:

• Methods of manufacturing processes

• Importance of manufacturing processes

• Introduction to basic Workshop processes

M105.1 25

Quiz

1 In hot working process the metal is shaped at a temperature

a . Above recrystalization

b . Below recrystalization

c . At recrystalization

d . None of the above

M105.1 26

Questions

1. What is the importance of Manufacturing process?

2. List out various Manufacturing process?

3. Explain about Joining Process?