introduction to Manufacturing processes

1. Introduction to Production Technology
(Machining Processes)

2. Definition of Manufacturing
The word manufacturing is derived from Latin:
manus = hand, factus = made
• the process of converting raw materials into products
• economic term for making goods and services available to satisfy customers.
• the conversion of stuff into things.
2

3. Types of manufacturing processes
Manufacturing processes can be grouped as:
• Casting, foundry or moulding processes.
• Forming or metal working processes.
• Machining (metal removal) processes.
• Joining and assembly
• Surface treatments (finishing).
• Heat treating
3

4. 4

5. Manufacturing system and Production system
• Manufacturing system:
A collection of operations and processes
used to obtain a desired product(s) or
component(s) is called a manufacturing
system.
• Production system:
A production system includes people,
money, equipment, materials and
supplies, markets, management and the
manufacturing system.
People, Money, Equipment, Materials
and Supplies, Markets, Management
Manufacturing system
Manufacturing
Processes
5

6. Application of manufacturing process
6

7. Application of Manufacturing process
7

8. 8
Taper turingTurning Knurling

9. 9
Milling Drilling Grinding

10. 10
Tapping Hobbing Broaching

11. 11

12. Lathe Machine
• A lathe is a machine that rotates a workpiece about an axis of rotation to perform
various operations such as cutting, threading, knurling, drilling, facing, and turning,
with tools that are applied to the workpiece to create an object with symmetry about that
axis.
• Some of the most common products of the lathe machine are crankshafts, camshafts,
screw, bolt, bowls, and candlestick holders.

13. Capstan & turret lathe Machine
• Capstan and turret lathes are semiautomatic.
• Its holds large number of cutting tools; up to four in
indexable tool post on the front slide, one in the rear slide
and up to six in the turret.
• It is more productive for quick engagement and overlapped
functioning of the tools in addition to faster mounting and
feeding of the job and rapid speed change.

14. Drilling machine
• Drilling covers the methods of making cylindrical holes
in a workpiece with metal cutting tools.
• The machine tool is called a drill.
• Typical operations: trepanning,
counterboring, countersinking,
reaming, boring, tapping, center
and pilot hole drilling,…
Tool: drill

15. Shaper machines • Tool has reciprocating motion.
• Workpiece is clamped on the table which is
stationary.

16. Planner machines
• Tool is stationary.
• Workpiece is clamped on the table which has
reciprocating motion.
• It allows machining of much larger parts.

17. Slotter machine • Identical machine to a horizontal shaping
machine but inclined 90º.
• It allows a higher cutting power as the
workpiece is better hold on the working
table.

18. Milling • Milling is the process of machining using rotary cutters to remove
material by advancing a cutter into a workpiece.
Milling cutter

19. Milling

20. Hobbing
• Hobbing is a machining process for gear cutting,
cutting splines, and cutting sprockets on a hobbing
machine, which is a special type of milling machine.

21. Broaching
• It is a machining process that uses a multiple-
tooth cutting tool, called broach, moved
linearly relative to the workpiece. Each tooth is
successively higher than the previous tooth.
• It works best on soft materials: aluminium,
bronze, brass, wood, plastics, composites,
graphite.

22. Grinding machine
• Grinding is a process of removing material
by abrasive action of a revolving wheel on
the surface of a work-piece in order to bring
it to required shape and size.
Abrasive wheel (Grinding wheel)

23. NC & CNC machine tools
• CNC (Computer Numerical Control (CNC) refers to the method of controlling a
machine tool or the machining process by means of a computer.
• Coded numerical instructions are inserted into the CNC-PROGRAMMING
LANGUAGE

24. NC & CNC machine tools

25. NC & CNC machine tools

26. Computer aided part programming

27. 27
Mechanical:
• Erosion of the work material by a high velocity stream of abrasives or fluids (or both)
Thermal:
• The thermal energy is applied to a very small portion of the work surface, causing that
portion to be removed by fusion and/or vaporization of the material. The thermal energy
is generated by conversion of electrical energy.
Electrochemical:
• Mechanism is reverse of electroplating.
Classification of Non-Traditional Machining
(or) Advanced Machining Processes

28. 28
Advanced Machining Processes or Non-traditional Machining

29. 29
• Ultrasonic Machining (USM) and Water jet
Machining (WJM) are typical examples of single
action, mechanical non traditional machining
processes.
• The machining medium is solid grains suspended in
an abrasive slurry in the former, while a fluid is
employed in the WJM process.
• The introduction of abrasives to the fluid jet
enhances the machining efficiency and is known as
abrasive water jet machining. Similar case happens
when ice particles are introduced as in Ice Jet
Machining.
Mechanical Non-Traditional Machining

30. 30
• Thermal machining removes materials by
melting or vaporizing the work piece
material.
• Many secondary phenomena occur during
machining such as microcracking, formation
of heat affected zones, striations etc.
• The source of heat could be plasma as during
EDM and PBM or photons as during LBM,
electrons in EBM, ions in IBM etc.
Thermal Non-Traditional Machining

31. 31
• Chemical milling and photochemical
machining or photochemical blanking all
use a chemical dissolution action to
remove the machining allowance through
ions in an etchant.
• Electrochemical machining uses the
electrochemical dissolution phase to
remove the machining allowance using
ion transfer in an electrolytic cell.
Chemical and electrochemical Non-Traditional Machining

32. EDM
• Metal removal by a series of discrete electrical
discharges (sparks) causing localized temperatures
high enough to melt or vaporize the metal.
• Can be used only on electrically conducting work
materials
• Drilling of micro-holes, thread cutting, helical profile
milling, rotary forming, and curved hole drilling.
WIRE CUT EDM PROCESS

33. LASER BEAM MACHINING
• Uses the light energy from a laser to remove
material by vaporization and ablation.
• The laser is focused onto the surface to be
worked and the thermal energy of the laser is
transferred to the surface, heating and
melting or vaporizing the material.
• Laser beam machining is best suited for
brittle materials with low conductivity, but
can be used on most materials.

34. Water Jet Cutting (WJC)
• Uses high pressure, high velocity
stream of water directed at work
surface for cutting
• WJC is used on
metals, paper, cloth,
leather, rubber,
plastics, food, and
ceramics.