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Introduction of Manufacturing

Manufacturing is the process of making products from raw materials using various processes,
equipment, operations and manpower according to a detailed plan. During the processes, raw
material undergoes changes to allow it to become a part of products.
Manufacturing includes:

The design of product.


The selection of raw materials.
The sequence of processes through which the product will be manufactured.

Production can also be called as manufacturing. Manufacturing can be defined in two aspects.
Technology:
Manufacturing is the application of physical and chemical processes to alter the geometry,
properties and appearance of a given starting material to make parts or products. Manufacturing
also include the assembly of multiple parts to make products. This type of manufacturing
involves the combination of machinery, tools, power and manual labor.
Economic:
Manufacturing is the process of transformation of cheap things into the items of greater value by
means of one or more involved processes.
Simply a manufacturing process can be defined with this figure.

Raw Material

Product and
Profit
Machinery,
Tooling, Power,
Labor

Manufacturing Demands:

A product must fully meet the design requirements and specifications.


Manufactured environmental friendly and economical method.
Quality is built in each manufacturing stage.

Production methods must be flexible to respond to changing market demands, types of


products, production rates and deliver time required.
New development in technology and managerial activities must constantly evaluated.
Manufacturing activities can be modeled to study the effects of factors on product quality.
Organization must strive for higher quality and productivity.

Manufacturing is done in different types of industries according to the type of work.


1) Primary Industry:
Those industries that cultivate and exploit natural resources like agriculture and mining.
2) Secondary Industry:
Uses the output of primary industries and convert them into the consumer and capital goods.
3) Tertiary Industry:
This industry constitute with service sector of economy.
Types of manufacturing Processes:
I.

Casting:

It is one of the oldest manufacturing processes. It involves filling a mold with molten material.
This material upon solidification takes the shape of mold. There are two types of metal casting
processes, expendable mold and permanent mold. Castings can be made into final shape or
molded and then converted to final product by tooling. All sizes of products can be manufactured
by casting from jewelry to the large machinery parts weighing tons. This type of manufacturing
has flaws like less accuracy to achieve desired results, lower strength and ductility.
II.

Forming:

This type of manufacturing includes large type of manufacturing that uses force to make the
changes in shape of material. The most appropriate material for forming process is the one with
high ductility, malleability and a lower yield strength of elevated temperature. When working
with metals, the rise in temperature will cause higher ductility and lower yield strength. In the
process of forming the mechanical properties of the material can be changed. Forming removes
vacancies in metal, breaks the metal and distribute the impurities making a stronger product. This
process is known to produce parts with superior mechanical properties. With respect to
temperature there are three types, cold forming, warm forming and hot forming. With respect to
surface area to volume two types are bulk deformation and sheet forming.
III.

Joining Process:

Every joining technique has particular design requirements, while certain joint requirements may
suggest a particular joining technique. Design for assembly, automation, and fastener selection
impose their own requirements.

Bolting is a common fastening method, for example, but welding may reduce the weight of an
assembly. Naturally, joints designed for the two techniques would differ greatly. However, all
joint designs must consider characteristics such as load conditions, assembly efficiency,
operating environment, overhaul and maintenance, and the materials used.
Welding is often a cost-effective way to fabricate. It does not require overlapping materials, so it
eliminates excess weight caused by other fastening means. Fasteners do not have to be bought
and kept in inventory. Welding also can reduce costs associated with extra elements, such as
angles fastened between parts.
Welded joints distribute operating stresses evenly. However, design of a welded joint
significantly affects the welding processes that are used. Many design options permit excellent
welding performance. Nevertheless, designers who are unaware of the range of technology and
methods available may fail to realize welding's potential.
There are a variety of joining methods that do not use fasteners. Alternative methods are
especially important for some materials.
Methods to join materials without the use of fasteners include adhesives, welding, and brazing,
soldering, clinching, and injected-metal assembly. In addition, materials such as plastics,
composites, and metal-ceramic combinations may indicate the use of certain joining methods.
IV.

Machining:

In this type of manufacturing, the product is created to its desired geometric dimensions by
removal of excess material from a work piece through a force exerted through a certain material
removal tool. Qualities of material should be:

Low shear strength to make cutting easier.


Shock resistant to withstand impact loading.
Material must not have a tendency to stick to cutting tool.
Material removed should separate from the work easily and completely.

Materials ability to be machined is called machinability. Ceramics cant be machined because of


higher shear strength. They are not shock resistant. Polymers have low yield strength and melt in
the process and stick to the tool. Machining is generally applicable to metals. Machinability
changes with the metals. Hardened material present particular problems due to high shear
strength. Machining can produce high dimensional accuracy. Tolerance is less than 0.001. It can
make sharp corners and flat surfaces. It provides surface smoothness. Different machining
operation can produce a very good product. Disadvantage of machining is that the material
removal. `Number of products is small but labor, energy, equipment and scrap cost are relatively
high. Machining is very applicable for finishing operations on manufacturing goods.

http://www.thelibraryofmanufacturing.com/
http://www.slideshare.net/juffrizal/lecture-01-introduction-to-manufacturing

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