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MANUFACTURING PROCESS-1 Lecture # 1 By

Ravi Kumar K

DEFINITION AND IMPORTANCE OF MANUFACTURING


Manufacturing: the process of converting raw materials into products; encompasses the deign and manufacturing of goods using various production methods and techniques. ~ came from Latin manu factus made by hand

Interchangeably used with production


discrete vs continuous products

Manufactured item has monetary worth (added value) than raw materials
Manufacturing is closely linked to national and global economy

DESIGN AND MANUFACTURING SEQUENTIAL PROCESS


Design ->Manufacturing Waste resource, waste time Concurrent Process All disciplines are involved in the earliest stages of product design Progress concurrently so iterations results in less wasted effort and time Key to success: well-recognized communication among and within disciplines

CLASSIFICATION OF MANUFACTURING PROCESSES


Casting: expandable molding and permanent molding
Forming and shaping: rolling, forging, extrusion, drawing, sheet forming, powder metallurgy molding Machining: turning, boring, drilling, milling, planing, shaping, broaching, grinding, ultrasonic machining; chemical, electrical, and electrochemical machining and high energy electron beam Machining Joining: welding, brazing, soldering, adhesive bonding and mechanical joining diffusion bonding,

Micro and nano micromachining, dry electroforming

manufacturing: surface and wet etching, and

Finishing: honing, lapping, polishing, burnishing, deburring, surface treating, coating and plating FACTORS AFFECTING PROCESS SELECTION

Component/part shape Materials characteristics castability, formability, machinability, weldability, etc Part size and dimensional accuracy Manufacturing and operational cost

MATERIALS USED IN TODAYS MANUFACTURING

Ferrous metals: carbon steels, alloy steels, stainless steels, and tool and die steels
Nonferrous metals and alloys: Al, Mg, Cu, Ni, superalloys, Ti, refractory metals (Mb, Nb, W, beryllium, Zr, low melting alloys (lead, zinc and tin), and precious metals Plastics: Thermosets, thermoplastics, and elastomers Ceramics: Glass ceramics, glasses, graphite, and diamond Composites: Reinforced plastics, metal-matrix and ceramics-matrix composites, and honeycomb Structures

Nanomaterials, shape-memory alloys, metal foams, amorphous alloys, super conductors and semiconductors
Material properties: mechanical, physical, chemical, manufacturing Cost and availability Service life and recycling

CASTING
An object made by pouring molten metal or other material into a mold. Casting is a mass production process which involves molten materials (such as metals, plastics or resins) being poured into a mold, allowed to solidify and then extracted for use. Casting can be thought of as a method for reproducing something whether a mere part or a single unit by itself.

Casting is a process that can be used to manufacture complex parts which would prove too expensive or time-consuming to produce using other methods such as cutting or shaping these from solid materials.

CLASSIFICATION OF CASTING
Casting processes can be classified into following FOUR categories: 1. Conventional Molding Processes 2. Chemical Sand Molding Processes

3. Permanent Mold Processes


4. Special Casting Processes

1. Conventional Molding Processes


Conventional Molding Processes are four types as follows:

a. Green Sand Molding b. Dry Sand Molding

c. Flask less Molding

2. Chemical Sand Molding Processes:


Chemical Molding Processes are three types as follows:

a. Shell Molding b. Sodium Silicate Molding c. No-Bake Molding


3. Permanent Mold Processes:

a. Gravity Die casting b. Low and High Pressure Die Casting

4. Special Casting Processes:


a. Lost Wax b. Ceramics Shell Molding c. Evaporative Pattern Casting d. Vacuum Sealed Molding e. Centrifugal Casting

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