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Chapter 1: Introduction

Process Planning Project: Pawn for chess

Who needs to know manufacturing processes?

Both Manufacturing and Design Engineers need to learn

the manufacturing processes

Considering Design for Manufacturing (DFM) and

machinability
Geometric simplicity

A process or manufacturing engineer needs to list a sequence of the

fabrication processes that fabricates the part. The planning is based on the
specifications shown on the engineering drawing, or called blue print, as
well as the experience and knowledge.

Spline curve

Processes:
1. solid rod (by casting)
2. turning process (using a CNC lathe)
rough turn
finish turn
3. grinding (super finish if needed)
4. cutting
5. inspection and wash

Note: This course will discuss the diverse topics of manufacturing

processes, including casting processes, metal forming processes,
material removal processes, welding processes, and advanced mfg.
processes, ...etc.

Material ease

5. 3D Printing (Additive manufaturing)- material accumulation

Ti: light weight and strong, but expensive

Mg (Magnesium): light weight, high strength,
and not expensive

Chrysler Corp., U.S.A.

Before: design engineer and mfg. engineer are separated.
Now: they are in the same roof.

Manufacturing Processes:
1. Casting processes (solidification) - starting material is a heated
liquid, and pouring into a mold to form the part shape.
2. Metal forming processes (deformation) - starting material is a
solid metal, applying a load to form the part shape.
3. Machining processes (material removal) - starting material is a
metal, using cutting tool to remove the chip and form the part
shape.
4. Welding processes joint 2 or more parts together.

A new designed transmission hub contains a

spline curve feature

Manufacturing Engineer

Design Engineer

Try to use tough material/

complicated design to make
sure the product can be
operated properly.
Focus on the product itself /
reliability

Hope to get the soft

material/ simple design to
make the fabrication easier
Focus on the process / cost

Manufacturing is Important! Why?

GDP

Manufacturing Is Important Economically

2013

20,900

24,400

54,700

2010

18,500

20,757

2006

16,494

2000

14,519

Manufacturing is a means by which a nation creates wealth

U .S . e c o n o m y :

S e c to r

% of
GNP

M a n u fa c tu r in g

20%

A g r ic u ltu r e , m in e r a ls , e tc .

5%

C o n s tr u c tio n & u tilitie s

5%

S e r v ic e s e c to r r e ta il,
tr a n s p o r ta tio n , b a n k in g ,
c o m m u n ic a tio n , e d u c a tio n , a n d
g o v e rn m e n t

6,900

34,163

52,800

38,500

49,800

4,400

31,600

47,100

42,500

18,401

28,852

2,026

28,222

43,774

35,169

10,938

23,079

847

25,426

34,548

36,602

70%

(Yr. 2002)

(2012.01.10)
(2011) 9,600

Whats Manufacturing?
Manufacturing is derived from two Latin words
Manus (hand) + Factus (make).

(Yr. 2012)
In the U.S. manufacturing constitutes ~ 12% of GNP (Yr.
2012), GNP: gross national product
In Taiwan (2004), 26% of GNP contributed by mfg. sector
where the total GNP was US$333 Billions,
GDP (); GNP ()
2011GNP

2012GNP

Make by hand
Advanced Manufacturing Systems
(computer controlled machinery)
(as technical process) Manufacturing is the application of

2010 GNP

2014GNP

14,660,000

15,227,074

15,094,400

16,799,700

5,878,000

6,515,861

7,484,070

9,181,377

5,459,000

5,821,945

5,872,931

4,901,532

3,316,000

3,518,592

3,578,554

3,635,959

430,600

503,941

466,981

489,213

physical and chemical processes to alter the geometry, properties,

and/or appearance of a given starting material to make parts or
products; manufacturing also includes assembly of multiple
parts to make products.

Manufacturing History

Fig. 1.1 (a)

(as economic process) Manufacturing is the
transformation of materials into items of greater value by
means of one or more processing and/or assembly
operations

The 20 Century, Advanced machine tools (CNC)

CNC Computer Numerical Control

1950, the first NC by MIT

1970, CNC (computer numerical control), Robotics

Manufacturing adds value to the material by changing

its shape or properties, or by combining it with other
materials that have been similarly altered

Fig. 1.1(b)

The New Stone Age, Simple tools from nature

The Bronze/ Iron Ages, Metal tools
The Industrial Revolution, Watts steam engine in the
18th century

Manufacturing Process is an operation that transforms the

raw material into the finished product.

1980, CAD/CAM, FMS, CIM, Automation

(Just-in-Time, Quality Control, AGV)

1990, IVHS, MEMS (Micro-actuator/sensor, smart

material), Rapid prototyping(3D printing)

The 21st Century, The Next Generation

Manufacturing Systems
Miniaturization Tech., Nanotechnology, Green/ Inverse Mfg.,
Concurrent Mfg., Networked Mfg., E-Business, E-Automation,
Biomedical/BioTechnology/Bio Eng. and Mfg.

Process Planning is to choose the proper manufacturing

processes to fabricate the designed product.

The selection is based on the design requirements

specified in the part print

Example for process plan (p. 2)

Considerations for Process Planning

Quality, surface finish, dimension tolerance

Production rate,

Four kinds of Plant Layout

1. Fixed-position layout (Fig. 1.11-a)

production 1,000,000 parts/yr

11.5 sec/part (cycle time)
Time: 1 yr=200(days)*2(shift/day)

Cost, (operation, tooling, machinability cost)

Circular arcs
Ti, Mg

Spline curves

Steel

Flexibility, product changes

Characteristics, special manufacturing process

Production Facilities

Three types of Production

Low-quantity production (1 to 100 units/yr, ship, aircraft)

Medium-quantity production (100 to 10,000 units/yr)
High-quantity production (10,000 to millions units/yr)

2. process layout, collect same processes in an area, the

changeover between products takes time (Fig. 1.11-b)

3. Cellular layout, each cell contains several different types of

machines, good for production of similar parts

4. Product layout, or called transfer line layout.

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