Lecture 31:

Processes and Process

Selection

Jayant Jain

Assistant Professor,
Department of Applied Mechanics,
IIT Delhi, Hauz Khas, 110016

Classification of processes
There are mainly three broad classes of manufacturing
processes
1) Shaping
2) Joining and
3) Finishing
Note the shaping can further be divided into primary and
secondary shaping processes

Primary: creates shapes

Secondary: modify shapes and properties

Classifying processes

Materials Selection in Mechanical Design, 4th Edition, 2010 Michael Ashby

Classifying processes
Similar to what we did for materials here we do a classification of
processes

Shaping family is expanded, each member is characterized by

a set of attributes, process selection involves matching of these
with design requirements
Materials Selection in Mechanical Design, 4th Edition, 2010 Michael Ashby

Classifying processes

Depending on the type of process the attributes

can be significantly different

Pictorial view of various key

processes

Primary Shaping

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David
Cebon

Secondary Processes

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Joining

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David
Cebon

Surface Treatment

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David
Cebon

Process Selection Flow Chart

The selection strategy for processes

is similar to that for materials
Design requirements should be put
in terms of constraints and
objectives to be used to screen, rank,
and finally select an appropriate
process

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Translation of process requirements

*Process chain option: may combine two or more processes to get the job done
e.g. casting followed by machining

Selection Charts:
Charts obtained by displaying
the process attributes
Why do we need them??
Required for screening!

Process-selection charts/matrix
Similar to materials property charts, shape selection
charts one can show the process selection charts
Each process is characterised by set of attributes. Each
attribute can be displayed as simple matrices or bar charts

They provide the selection tool that we need for

screening
Design constraints can be applied on process-selection
charts to identify or to screen out the processes that meets
the requirements

Material Process Compatibility

Each of the three process
families shaping, joining,
and surface treatment has
its own set of characteristic
attributes
Diagonal alignment of process
Red dot indicates that the
pair are compatible

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Do you envisage any problem in the current

representation??
In my opinion the resolution of these
charts is very limited
e.g. It tells me for metals, welding is
compatible. This is very vague statement
For a particular metal may be a particular
welding method might be good

Shape
A key attribute of a process is the families of
shapes it can make there are three
generic classes of shape, each subdivided
in two

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Shape-Process Compatibility

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Process-size chart
There are limits to the size of a component that
a process can make: Size can be measured by mass

Inclusion of joining
allows simple
process chains
to be explored

Processes that can make

small size components

Processes that can make

large size components

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Along with mass, there is a limiting value for

section thickness that a given shaping
process can handle

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Physical Limits to Size and

Section Thickness
Take an example of Casting
What factors limits its size (both lower and
upper limit)
Lower limit: surface tension forces and
viscous forces
Upper limit: shrinkage cavity, internal
defects due to residual stresses
Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Physical Limits to Size and

Section Thickness
Casting and molding rely on material flow in
the liquid or semi-liquid state
Lower limits on section thickness
are imposed by the physics of
flow flow of liquid metal or polymer
into thin sections is opposed by
surface tension and viscous forces
loss of heat into the mold increases
viscosity and may result in premature
solidification

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon