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Basic MachineBasic MachineProcessesProcesses

Competency D403.00 Competency D403.00 

Identify the basic concepts of Identify the basic concepts of the manufacturing processes.the manufacturing processes.

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Basic Machine ProcessesBasic Machine Processes

Objective D403.01Objective D403.01

Explain the concepts of Explain the concepts of 

the manufacturingthe manufacturingprocess.process.

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ManufacturingManufacturing  Arrived from the Latin word

³manu factus´ , meaning ³madeby hand´.

Manufacturing is the process of converting raw materials into

products.

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WHY STUDYWHY STUDYMANUFACTURING PROCESSES?MANUFACTURING PROCESSES?

The designer and the drafter 

must have a working knowledge

of the various processes that

could produce a part in order to:lower cost and reduce

production time.

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Three Phases Of TheThree Phases Of The

Manufacturing ProcessManufacturing Process

1. Product design.2. Selection of materials.

3. Selection of productionmethods and techniques.

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The information needed to produce a

part, most often comes in the form of a:

WorkingDrawing

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Three Main Stages Of TheThree Main Stages Of The

Production Of A Machined PartProduction Of A Machined Part

Rough FormingCasting, Forging, Welding

FinishingDrilling, machining, surfacing

 AssemblingThe assembly of parts

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The Casting Process

First a pattern is made.

Then a cavity is made by placing a pattern in

wet sand.

Next molten metal is poured into the cavity of 

damp sand.

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The Casting Process

The rough casting is now ready for the machine shop.

Holes are then bored and reamed.

Top and bottom surfaces are machined

Smaller holes will be drilled and counterbored.

 All corners on cast parts are fillets and rounds.

Rough

Casting

Machined

Finish

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Forging Process

Forging is produced by using heavy mechanical

presses or hammering heated bars of metalbetween dies.

 Advantages of forging over sand casting are that

forged parts are much stronger and less brittle.

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Welding

Welding is the fusion or joining of 

two pieces of metal by means of heat, with or without the application

of pressure.

Cast

Welded

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ManufacturingManufacturing MaterialsMaterialsFall into three general categories:

1. Metal

2. Plastic

3. Inorganic materials

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Metals are classified as:Metals are classified as:Ferrous - contain iron and steel.

Nonf errous - do not have iron content

(such as copper and aluminum).

Alloys - mixture of two or more metals.

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Inorganic Materials Include:Inorganic Materials Include:

� Carbon and graphite - have low

tensile strength (ability to bestretched).

� Ceramics are clay and glassmaterials. (resistant to heat, 

chemicals, & corrosion).

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HeatHeat--Treating:Treating:

Annealing ± is the process generally used

to soften metal by heating followed by slow

cooling.

Hardening±

requires heating and then

rapid cooling in oil or water.

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Plastics ProcessingThe plastics industry represents one of the

major manufacturing segments.

Thermoplastic±

becoming or remainingsoft and moldable when subjected to heat.

Thermosetting±

becoming permanentlyhard and unmoldable when once subjectedto heat.

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Typical Plastic Processing Operations Include:

Extrusion

Blow Molding

Injection MoldingThermoforming

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ExtrudingExtruding

The process of producing

shapes by forcing hot metalthrough a die that has and

opening of the desired shape.

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Blow Molding

Used in the production of 

bottles, automotive ductwork, 

hollow toy components, and

door panels.

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Injection Molding

Used to manufacture products such

as housings for electronic

implements, automotive components, food storage containers, and

components for medical applications.

.

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Thermoforming

Used in the manufacturing of thin-walledpackages for the food industry.

Manufactured primarily by injection molding.

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CAD in Manufacturing

The process of developing a design drawing on aCAD system and producing it on a computerizedmachine is called CAD/CAM.

The process of converting the CAD drawing into a

preprogrammed, coded instructions is calledComputer Numerical Control (CNC).

The advantages of the (CNC) is, better production andcontrol, increased productivity, decreased labor andlower production costs.

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The Machinist Steel Ruler 

Commonly used measuring tool for getting

rough measurements on a part.

The smallest division on the fractional

scale is 1/64´ (.016).

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Vernier Caliper Vernier Caliper 

Precise measuring.

Decimal, fractional, or 

metric. Often used by drafters

to record dimensions

from a machined

prototype or part.

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6´ Dial Caliper 

Inside Inside

Outside

DepthStep

 4-way

Measurement

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6´ Dial Caliper  ± Three Scales

METRIC

(mm)

DECIMAL

(.XX)

FRACTIONAL

(1/64´)