Manufacturing Processes

Manufacturing is a process that converts raw materials into

products, it constitute:

The selection of raw materials

The selection of manufacturing process
The sequence of processes needed to
manufacture the product

Ken Youssefi

Mechanical Engineering

Material Selection
Function dictates the choice
of material and shape.

Function

Material

Process is influenced
by material

Shape restricts the

choice of material
and process.

Shape

Process

Process interacts
with shape.

Material selection and process cannot be separated from the shape

and the function of the product, two way interaction.
Ken Youssefi

Mechanical Engineering

Engineering Materials
Materials
Metals

Ferrous

Non-ferrous

Plastics

Thermoplastics

Thermosets

Elastomers

Steel

Aluminum

Acrylic

Phenolic

Rubber

Stainless steel

Copper

Nylon

Polymide

Polyurethane

Die & tool steel

Zinc

ABS

Epoxies

Silicone

Cast iron

Brass

Polyethylene

Polyester

Titanium

Polycarbonate

Tungsten

PVC

Ken Youssefi

Mechanical Engineering

Engineering Materials
Materials

Metals

Ceramics
Glass

Plastics

Carbides
Nitrides
Graphite
Diamond
Glasses

Composites

Reinforced
plastics
Metal-Matrix
Ceramic-Matrix
Laminates

Glass ceramics
Ken Youssefi

Mechanical Engineering

Manufacturing Processes
Shaping
Processes

Processing
Operations

Surface
Processing
Operations

Manufacturing
Processes

Assembly
Operations

Ken Youssefi

Property
Enhancing
Processes

Mechanical Engineering

Permanent
Joining
Processes
Mechanical
Fastening
5

Shaping Processes

Shaping
Processes

Casting

Sand, expendable pattern,

permanent mold

Forming and
Shaping

Rolling, forging, extrusion,

drawing, sheet forming,
powder metallurgy, molding

Machining

(material removal)

Ken Youssefi

Mechanical Engineering

Turning, milling, drilling

grinding, boring, ..

Manufacturing Processes

Property
Enhancing
Processes

Surface
Processing
Operations

Ken Youssefi

Heat Treatment

Changing mechanical
properties of a material

Cleaning and
surface
treatments

Polishing, burnishing,
deburring, lapping, ..

Coating and
deposition
process

Mechanical Engineering

Coating and plating

Assembly Operations
Welding
Permanent
Joining
Processes

Brazing and
soldering
Adhesive
bonding

Assembly
Operations

Mechanical
Fastening

Threaded
fasteners
Rivets

Ken Youssefi

Mechanical Engineering

Casting Process
Selecting a suitable casting method.
Preparing a mold cavity of the desired shape with
proper allowance for shrinkage.
Melting the metal with acceptable quality and
temperature.
Pouring or forcing the metal into the cavity and
providing means for the escape of air or gases.
Solidification process, must be properly designed
and controlled to avoid defects.
Mold removal.
Finishing, cleaning and inspection operations.
Ken Youssefi

Mechanical Engineering

Sand Casting
Metals

Ken Youssefi

Mechanical Engineering

10

Casting process Classifications

Expendable Mold / Reusable Pattern
Sand Mold Casting
Plaster Mold Casting
Ceramic Mold Casting

Expendable Mold / Expendable Pattern

Investment Casting (Lost-wax process)
Evaporative Foam Casting

Permanent Mold / No Pattern

Permanent Mold Casting
Die Casting
Centrifugal Casting
Ken Youssefi

Mechanical Engineering

11

Casting Materials
Metals most commonly used in casting are;

Ken Youssefi

Iron (cast iron)

Steel

Stainless steel

Aluminum alloys

Brass, bronze and other copper alloys

Magnesium alloys

Nickel based supperalloys

Mechanical Engineering

12

Large and small parts

Ken Youssefi

Mechanical Engineering

13

Shaping Processes

Shaping
Processes

Casting

Sand, expendable pattern,

permanent mold

Forming and
Shaping

Rolling, forging, extrusion,

drawing, sheet forming,
powder metallurgy, molding

Machining

(material removal)

Ken Youssefi

Mechanical Engineering

Turning, milling, drilling

grinding, boring, ..

14

Manufacturing Processes Forming

Extrusion (uniform
cross section)

Ken Youssefi

Mechanical Engineering

15

Manufacturing Processes Forming

Rolling

Ken Youssefi

Mechanical Engineering

16

Manufacturing Processes Forming

Forging

Ken Youssefi

Mechanical Engineering

17

Forged parts
Machine parts

Brass
and
steel
fittins
Ken Youssefi

Mechanical Engineering

18

Manufacturing Processes Forming

Deep drawing

Ken Youssefi

Mechanical Engineering

19

Metal-Forming Process
for Food and Beverage
Containers

How aluminum
cans are made

Ken Youssefi

Mechanical Engineering Dept.

20

Material Removal Processes - Turning

In turning operations the workpiece rotates and the cutting
tool is stationary. The process produces parts that are
round in shape. Parts as small as a screw with 1 mm in
diameter to pistons with several inches in diameter can be
machined

Ken Youssefi

Mechanical Engineering

21

Turning Operations

Ken Youssefi

Mechanical Engineering

22

Turning Operations

Ken Youssefi

Mechanical Engineering

23

Material Removal - Turning

General view of a typical lathe, showing various components.

Source: Courtesy of Heidenreich & Harbeck.
Ken Youssefi

Mechanical Engineering

24

Material Removal Processes - Milling

Peripheral (slap) milling the
axis of the tool is parallel to the
surface of the workpiece

Face (End) milling, the axis of the cutter is perpendicular to the workpiece

End Milling
Ken Youssefi

Mechanical Engineering

25

Material Removal Processes - Milling

There are two basic types of knee-column milling machines

Face milling vertical

milling machine

Peripheral milling
horizontal milling machine

Ken Youssefi

Mechanical Engineering

26

Manufacturing Processes Material Removal

Drilling

Grinding
Broaching
Ken Youssefi

Mechanical Engineering

27

Manufacturing Processes
Plastics

Ken Youssefi

Injection Molding

Rotational Molding

Extrusion

Blow Molding

Thermoforming

Compression molding

Foam Molding

Mechanical Engineering

28

Manufacturing Processes - Plastics

Injection
Molding

Ken Youssefi

Mechanical Engineering

29

Injection Molding Machine

Ken Youssefi

Mechanical Engineering

30

Injection Molding Parts

Ken Youssefi

Mechanical Engineering

31

Manufacturing Processes - Plastics

Rotational Molding (large parts)

Vertical wheel machine

Ken Youssefi

Mechanical Engineering

32

Products made by
Rotational Molding
process

Ken Youssefi

Mechanical Engineering

33

Manufacturing Processes - Plastics

Blow Molding

Ken Youssefi

Mechanical Engineering

34

Manufacturing Processes
A salt shaker and a pepper mill set has metallic and nonmetallic
parts

Ken Youssefi

The bodies are made of Acrylic (thermoplastic) using injection

molding

The top of the salt shaker is made of sheet steel (stamping) and
is plated for appearance.

The knob on top of the pepper mill is made of steel by

machining (threaded on the inside)

The square rod in the pepper mill is made of steel by extrusion

The two grinder parts are made of stainless steel using powder metallurgy.
Too expensive to machine or cast.
Mechanical Engineering

35

Numerical Control
Numerical Control (NC) is a method of
automatically operating a manufacturing machine
based on a code of letters, numbers, and special
characters.
The numerical data required to produce a part is
provided to a machine in the form of a program,
called part program or CNC program.
The program is translated into the appropriate
electrical signals for input to motors that run the
machine.
Ken Youssefi

Mechanical Engineering Department

36

Three-axis Cincinnati Hydrotel milling machine, 1952

Ken Youssefi

Mechanical Engineering Department

37

Modern CNC Milling Machines

Ken Youssefi

Mechanical Engineering Department

38

Manufacturing Processes Material removal

Computer Numerical Control (CNC)
Computer Numerical Control machines are used to fabricate
complex shapes with better dimensional accuracy than
conventional machining.

Ken Youssefi

Machining Centers
Mechanical Engineering

39

CNC Machines
Machining Centers, equipped with automatic tool changers,
are capable of changing 90 or more tools. Can perform
milling, drilling, tapping, boring on many faces.

Ken Youssefi

Mechanical Engineering Department

40

CNC Machines
Turning Centers are capable of executing many different types
of lathe cutting operations simultaneously on a rotating part.

Ken Youssefi

Mechanical Engineering Department

41

Computer Numerical Control (CNC)

A CNC machine is an NC machine with the added feature of
an on-board computer.
1
2

A solid model of the part is

created.
The program path is generated
by computer

Ken Youssefi

Mechanical Engineering Department

42

Electrical Discharge Machine - EDM

Die-sinking EDM systems, the electrode (cutting tool) and workpiece are
held by the machine tool. The power supply controls the electrical
discharges and movement of the electrode in relation to the workpiece.
During operation the workpiece is submerged in a bath of dielectric fluid
(electrically nonconducting). (Die-Sinking EDM is also called Sinker,
Ram-Type, Conventional, Plunge or Vertical EDM)

Ken Youssefi

Mechanical Engineering Department

43

Intricately detailed automobile part

Ken Youssefi

Mechanical Engineering Department

Small gear (with insect

for scale) shows a
capability of EDM
micromachining.
44

CNC Machines
Laser Machining and Cutting (thermal cutting)
The machine utilizes an intense beam of focused laser light to cut the part.
Material under the beam experiences a rapid rise in temp. and is vaporized.
Laser cuts with a minimum
of distortion, no mechanical cutting forces.
.

Ken Youssefi

Gas is blown into the cut to clear away molten metals,

or other materials in the cutting zone. In some cases,
the gas jet can be chosen to react chemically with the
workpiece to produce heat and accelerate the cutting
speed
Mechanical Engineering Department
45

Water Jet Machining

Uniform thickness parts

Ken Youssefi

Mechanical Engineering

46

Water Jet Machining

Ken Youssefi

Mechanical Engineering

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