Introduction to Manufacturing Processes

Pt. 1

© 2012 Project Lead The Way, Inc.Principles Of Engineering

Product Creation CycleDesign → Material Selection → Process Selection → Manufacture → Inspection → Feedback

Typical product cost breakdown

Products and Manufacturing

Manufacturing Process

A sequence of operations and processes designed to create a specific product

The process of turning materials into a product

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Engineers in Manufacturing

Manufacturing EngineerSelect and coordinate specific processes and equipment

Industrial EngineerResponsible for the manufacturing system design

Materials EngineerDevelop and select materials based on desired material properties and manufacturing processes

Manufacturing System Designs

Small quantities of products Large variety of productsProducts move through the shop to various machinesGeneral-purpose machines

Job Shop

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Manufacturing System Designs

Flow ShopLarger quantities of productsProduction lineSpecial purpose machines

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Manufacturing System Designs

Linked-Cell ShopManufacturing and subassembly cells connected to final assemblyLean production systemOne piece flow system

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Manufacturing System DesignsProject Shop

Product being manufactured cannot be easily moved during productionProduction processes are brought to the productExamples: Bridges, ships, large airplanes, locomotives, large machinery

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Manufacturing System Designs

Continuous ProcessLarge plantsUtilized in the manufacture of liquids, oils, gases, and powders

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Manufacturing System Designs

Lean Manufacturing100% “good” units flow from process to process Integrated quality control (IQC)All employees are inspectors

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Basic Manufacturing ProcessesCasting and Foundry Forming or MetalworkingMachiningJoining and AssemblyRapid PrototypingOther

Casting and Foundry ProcessesIn one step raw materials are transformed into a desirable shape

Parts require finishing processes

Excess material is recyclable

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Basic Casting ProcessA mold is created – A cavity that holds the molten material in a desired shape until it is solidified Multiple-use mold

Single-use molds

Material is heated to a specified temperature

Molten material is poured into a mold cavity

Molten material solidifies into the shape of the cavity

Casting or mold is removed

Casting is cleaned, finished, and inspected

Utilizes material that has been cast

Modify the shape, size, and physical properties of the material

Hot and cold forming

Forming and Metalworking Processes

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Forming and Metalworking Processes

Rolling – Material passes through a series of rollers, reducing its thickness with each pass

Forging – Material is shaped by the controlled application of force (blacksmith)

Wire, rod, and tube drawing – Material is pulled through a die to produce a uniformed cross section

Extrusion – Material is compressed and forced through a die to produce a uniformed cross section

Forming and Metalworking Processes

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Cold forming and forging – Slugs of material are squeezed into dies

Forming and Metalworking Processes

Machining ProcessesControlled removal of material from a part to create a specific shape or surface finish

Cutting element is used

Movement must exist between the part and cutting element

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Turning ProcessesOperations that create cylindrical parts

Work piece rotates as cutting tool is fed into the work

Machining Processes

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Turning ProcessesLathes and turning centers

Processes include: Straight, taper, contour turning, facing, forming, necking, parting, boring, threading, and knurling

Machining Processes

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Milling ProcessesOperations that create flat or curved surfaces by progressively removing material

Cutting tools rotate as the work piece is secured and fed into the tool

Machining Processes

Milling ProcessesMills – Vertical and horizontal

Processes include: Surfacing, shaping, forming, slotting, T-slotting, angle, straddle, dovetailing, and slab milling

Machining Processes

Drilling ProcessesOperations that create holes

Cutting tools rotate and are fed into nonmoving secured work pieces

Machining Processes

Drilling ProcessesDrilling and boring machines

Processes include: Drilling, counter drilling, step drilling, boring, counter boring, countersinking, reaming, spot facing, and tapping

Machining Processes

Shearing ProcessesOperations that break unwanted material away from the part

A material is placed between a stationary and movable surface. The movable surface (blade, die, or punch) applies a force to the part that shears away the unwanted material.

Machining Processes

Automated hole punch, squaring shear, and rotary cutter

Processes include: Shearing, blanking, cutoff, and parting; punching, perforating, and slotting; notching, lacing, and trimming

Shearing ProcessesMachining Processes

Abrasive Machining ProcessesOperations in which small particles of materials (abrasives) remove small chips of material upon contact

Drum, disc, and belt sanders; surface, vertical and horizontal spindle; disc grinders; media blaster; tumblers

Machining Processes

Thermal and Chemical ProcessesOperations that cut and shape materials through chemical means

No mechanical force is used

Machining Processes

Electrical discharge, electrochemical, chemical, laser, electron beam, flame cutting, and plasma-arc cutting

Processes include: Grinding, sawing, cutting, machining, milling, blanking, and etching