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Introduction

Manufacturing is the act of making a products by hand or machine from raw materials. It seems to be a fundamental human activity, and like design, is an integral part of the rise of civilization. Selecting of appropriate materials and manufacturing processes is a critical part of the design process.

In particular, the manufacturing process must be economical and capable of producing the geometric surfaces (see below) and other features embodied in the design.

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Process Classification

There are seven fundamental classifications for manufacturing processes

• Molding or casting• Forming and shearing• Machining (material removal, includes chip-making process, chipless

processes, and heat cutting)• Heat treatment• Finishing (painting, anti-corrosion coatings, etc.)• Assembly• Inspection

Molding

Molding is usually used for plastics, casting for metals. There are eight major molding processes

• Hot compression molding• Transfer molding• Injection molding• Extrusion• Laminating• Vacuum forming• Cold molding

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Molding

Casting

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Forming Operations

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Molding Processes (1)

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Molding Processes (2)

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Sand Casting Techniques for

Producing Various Shapes

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Design for Efficient Sand Casting

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Other Casting Processes

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Common Forming and Shearing Processes

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Extrusion Processes

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Hot Forming Processes - Forging

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Other Hot Forming Processes - Forging

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Basic Machining Processes

Machining

Physical removal of unwanted material in the form of chips (usually), leaving a part with the desired geometry and surface finish.

• Can produce complex shapes, very good dimensional control, and good surface finishes.

• Tends to be wasteful of material, and expensive in terms of labor and capital.

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Operations and Machines for Machining Internal Cylindrical Surfaces

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Operations and Machines for Machining Flat Surfaces

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Operations and Machines for Machining External Cylindrical Surfaces