BASIC MANUFACTURING PROCESSES 1

SKMM 1922

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Salam Sejahtera

Contents

1. Materials in manufacturing

2. Manufacturing processes

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1. Materials in Manufacturing

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• Most engineering materials can be classifee into one of three basic categories:

1. Metals

2. Ceramics

3. Polymers

• Their chemistries are eiferent, their mechanical ane physical propertes are eissimilar, ane these eiferences afect the manufacturing processes that can be usee to proeuce proeucts from them

Engineering Materials

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FIGURE 1.4 An outline of engineering materials

What is Manufacturing?

• Manufacturing as an economic process– Manufacturing is the transformaton of materials into items

of greater value by means of one or more processing ane/or assembly operatons

– Manufacturing adds value to the material by changing its shape or propertes, or by combining it with other materials that have been similarly alteree

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2. Manufacturing Processes

Two basic types:

I. Processing operatons - transform a work material from one state of completon to a more aevancee state– Operatons that change the geometry,

propertes, or appearance of the startng material

II. Assembly operatons - join two or more components in oreer to create a new entty

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I. Processing Operatons

• Alters a workpart's shape, physical propertes, or appearance in oreer to aee value to the material

Three categories of processing operatons:

1. Shaping operatons - alter the geometry of the startng work material

2. Property enhancing operatons ‑ - improve physical propertes of the material without changing its shape

3. Surface processing operatons - performee to clean, treat, coat, or eeposit material onto the exterior surface of the work

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Shaping Operaton – Four Categories

1. Solidifcaton processes - startng material is a heatee liquid or semifuid that solieifes to form part geometry

2. Partculate processing - startng material is a powder, ane the poweers are formee into eesiree geometry ane then sinteree to hareen

3. Deformaton processes - startng material is a ductle solid (commonly metal) that is eeformee

4. Material removal processes - startng material is a solid (euctle or britle), from which material is removee so resultng part has eesiree geometry

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Assoc Prof Zanal Abidin Ahmad 10

4 Major Manufacturing

Processes

Classification of Manufacturing Processes

1. Solidifcaton Processes • Also known as castng process • Startng material is heatee sufciently to transform it

into a liquie or highly plastc state • Examples: Castng for metals, moleing for plastcs

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Parts Maee by Castng

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Parts Maee by Castng

2. Partculate Processing

• Also known as poweer metallurgy process

• Startng materials are poweers of metals or ceramics

• Usually involves pressing ane sintering

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PARTS MADE FROM POWDER METALLURGY PROCESS

3. Deformaton Processes • Also known as metal forming processes• Startng workpart is shapee by applicaton of forces that

exceee the yiele strength of the material• Examples: (a) forging, (b) extrusion

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Bulk Metal Forming Parts

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Sheet Metal Forming Parts

4. Material Removal Processes • Usually known as machining processes

• Excess material removee from the startng workpiece so what remains is the eesiree geometry

• Examples: machining such as turning, erilling, ane milling; also grineing ane nontraeitonal processes

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Machining Parts

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II. Assembly Operatons

Two or more separate parts are joinee to form a new entty

Types of assembly operatons:1. Joining processes – create a permanent joint.

• Examples: welding, brazing, soldering, and adhesive bonding

2. Mechanical assembly – fastening by mechanical methoes

– Examples: use of screws, bolts, nuts, other threaeee fasteners; press fing, expansion fts

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Various type of joining and welding processes

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Mechanical assembly and

fasteners

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Methods of Making a Simple Part

Various methoes of making a simple part. (a) castng or poweer metallurgy, (b) forging or upseing, (c) extrusion, (e) machining, ane (e) joining two pieces.

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