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

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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 Materials

Inorganic Materials

Solid Liquid Gas

Engineering (Industrial) Materials

Non-Engineering

Materials

Polymeric Metallic

Ceramic

Composite Video

Selecting Materials

InternalStructure

Types of atoms

Bonds between atoms

Molecularstructure

Property

Physical

Mechanical

Chemical

Thermal

Electrical – Magnetic

Acoustical

Optical

Conditions

ChemicalsRadiation

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