1.

Introduction to Manufacturing Processes

2. Journey of manufacturing industry untill 2021

3. Manufacturing processes

3. Conventional Machining processes and tools used

4. CNC Machining processes and tools used

5. 3.D Manufacturing and rapid prototyping techniques

6. Conclusion

7. SUMMARY

. Introduction to Manufacturing Processes

The term manufacture comes from two Latin words, manus (hand) and factus (make). As per oxford English dictionary manufacture
refers “to make or produce goods in large quantities, using machinery”. A manufacturing process is at the basic level a method
through which raw materials are transformed into a final product. .in technologically  Manufacturing is the application of physical
and chemical processes to alter the geometry, properties and or appearance of a given starting material to make parts or
product. In economically Manufacturing is the transformation of materials into items of greater value by means of one or more
process and or assembly operation.

Journey of manufacturing industry untill 2021:

In the past, if you wanted to know how a machine was performing on a shop floor, you would have had to put pencil to paper and note the
throughput, the error rate, the quality, all manually. You would have to look at the quality of the inputs and the available supply of the raw
materials. You would have had to look at the throughput over time to see if there was a consistency to quality or errors that needed to be
investigated. In other words, you were looking at potentially weeks of manual effort to figure out why and how a manufacturing process was
going awry. That, in and of itself, isn’t a good use of anyone’s time and is a pretty inefficient way to become more profitable. Then came
Industrial IoT (IIoT) and the ability to monitor machines directly, providing quantities of data from the machine, as well as the operator, that can
be analyzed in order to improve both production and quality. According to research, IoT has the ability to push the manufacturing industry’s
productivity rate and generate approximately $1.2 trillion for manufacturers worldwide.
The First Industrial Revolution took place from the 18th to 19th centuries in Europe and North America. It was a period when mostly
agrarian, rural societies became industrial and urban. The iron and textile industries, along with the development of the water wheel and
then the steam engine, played central roles in the Industrial Revolution.The impact of the First Industrial Revolution was felt on the
agricultural community. Work was predominately performed by hand.  People who no longer were able to farm as their land got taken
over by factories, reskilled to become boiler makers, ironsmiths, mechanics, etc as these industries now has machines that need to be
fabricated or repaired.  These skills were previously in low demand.  There was short-term job losses, but different jobs were created that
did not previously exist.
The Second Industrial Revolution took place between 1870 and 1914, just before World War I. It was a period of growth for pre-existing
industries and expansion of new ones, such as steel, oil and electricity, and used electric power to create mass production. Major
technological advances during this period included the telephone, light bulb, phonograph and the internal combustion engine. With the
transition from steam power to electricity, there may have been short-term job losses but if the steam mechanics reskilled to electricians,
they would have retained their jobs. Yet again there were new skills to be acquired that previously did not exist. Also, with mass
production lines, more jobs were created than previously required.
The Third Industrial Revolution, or the Digital Revolution, refers to the advancement of technology from analogue electronic and
mechanical devices to the digital technology available today. The era started during the 1980s. Advances during the Third Industrial
Revolution include the personal computer, the Internet, and information and communications technology (ICT). Mass production with
small batches but with wider varieties was possible. Jobs got replaced by computers and robots, however if you weren’t computer literate
then you may have who lost their jobs.  Yet again, new jobs were created that previously did not exist e.g. Software and hardware
engineers.
The Fourth Industrial Revolution builds on the Digital Revolution, representing new ways in which technology becomes embedded within
societies and even the human body. The Fourth Industrial Revolution is marked by emerging technology breakthroughs in a number of
fields, including robotics, artificial intelligence, nanotechnology, quantum computing, biotechnology, The Internet of
Things (iot), decentralized consensus, 3D printing and autonomous vehicles. The biggest impact of the Fourth Industrial Revolution is to
improve the quality of life, reduce inequality of the world’s population and raise income level.

Manufacturing processes:

Classifi cati on of manufacturing processes.

 
Manufacturing processes can be classified as  processing operation and assembly operation.
 
In processing operation the work material is transformed from one state to other advanced state.Through this operation value is
added to the work material by changing the geometry; shape properties, appearance etc. of the starting work material. Usually
 processing operations are performed on individual component. But in some cases like aerospace industry, the processing operations
are performed on assembled items also.
 
In assembly operation two or more components are joined to create a new entity. The new entity is called assembly, subassembly
based on its state in the product. If the entity is an intermediate state of the product, it is called subassembly. Some other terms are
also referred based on the joining process. The assembly created by welding operation is called weld met.

LIST OF MANUFACTURING PROCESSES:

 Casting:
 Labeling and painting
 Moulding.
 Forming
 Machining
 Joining
 Additive manufacturing

Manufac
turing Processes Classifi cati on:

 There are six basic / fundamental classifications of manufacturing processes.

 
1. Metal casting or Molding: expendable mold and permanent mold
 
2. Metal Forming and Shearing: rolling, forging, extrusion, drawing, sheet forming, powder metallurgy
 
3. Material Removal Processes / Machining Processes: turning, boring, drilling, milling, planing, shaping, broaching, grinding,
ultrasonic machining, chemical machining, electrical discharge machining (EDM), Abrasive flow machining (AFM), abrasive jet
machining (AJM), electrochemical machining, high-energy beam machining, laser beam machining (LBM) etc.
 
4. Joining: welding, brazing, soldering, diffusion bonding, adhesive bonding, mechanical joining, plasma arc, plasma MIG, projection
welding, ultrasonic, electron beam welding, laser welding etc.
 
5. Finishing (painting, anti-corrosion coatings, etc.)
 
6. Rapid Manufacturing: stereo-lithography, selective laser sintering, fused deposition modeling, three dimensional printing,
laminated object manufacturing, laser engineered net shaping.
.
Conventional Machining processes and tools used:
Machining is a processes in which a piece of raw material is cut into a desired final shape and size by a controlled material-
removal process. Conventional machining uses tools, such as lathes, milling machines, boring machines, drill presses, or others,
with a sharp cutting tool to remove material to achieve the desired geometry. Usually there is a direct contact between the tool
and raw material. In conventional processes, the relative motion between the tool and work piece is typically rotary or reciprocating.
Thus, the shape of the work surfaces is limited to circular or flat shapes. In spite of widely used CNC systems, machining of three-
dimensional surfaces is still a difficult task. Most non-traditional processes were develop just to solve this problem. Machining of
small cavities, slits, blind or through holes is difficult with conventional processes, where as, it is a simple work for some non-
conventional processes. Conventional processes are well established, use relatively simple and inexpensive machinery and readily
available cutting tools. Non- conventional processes require expensive equipment and tooling as well as skilled labor, which increases
significantly the production cost. Conventional machining processes are those in which material removal is by plastic deformation
and cutting off of the job material by the tool material. This mechanism is used in conventional machining processes like
turning, milling, drilling, sawing etc. Any other process that uses some other material removal mechanism is a non conventional
machining process. For example-EDM, Wire EDM, Electrochemical Machining, Waterjet Machining, Ultrasonic machining etc.

Drilling: In drilling process holes are created in the metal through circular cylinders. A twist drill is used for accomplishing this task.
75% of the metal cutting material is removed through the drilling operation. The drill enters the workpiece and cuts a hole which is
equal to the diameter of the tool that was used for cutting the whole. A drill has a pointed end which can easily cut a hole in the
work piece

Milling: Milling is one of the fundamental operations in machining. This manufacturing process is less accurate than the turning
processes because the degree of freedom is high. Milling fabricates the object which is not axially symmetric. A milling machine is
required for this purpose along with a fixture, cutter and of course the workpiece. The workpiece here is the material that is already
shaped and it needs milling. It is secured to the fixture, ready for being milled. The cutter is also secured to the machine. It has sharp
teeth and it rotates at a high speed. The workpiece is fed to the cutter and it removes the unwanted metal from the piece.  

CNC Machining processes and tools used: The term CNC stands for 'computer numerical control', and the CNC machining definition
is that it is a subtractive manufacturing process which typically employs computerized controls and machine tools to remove layers
of material from a stock piece—known as the blank or workpiece—and produces a custom-designed part. This process is suitable for
a wide range of materials, including metals, plastics, wood, glass, foam, and composites, and finds application in a variety of
 industries, such as large CNC machining and CNC machining aerospace parts. When speaking in terms of the machine itself, the CNC
machine definition is that it represents the actual programmable machine that is capable of autonomously performing the
operations of CNC machining. CNC machining is a manufacturing process which utilizes computerized controls to operate and
manipulate machine and cutting tools to shape stock material—e.g., metal, plastic, wood, foam, composite, etc.—into custom parts
and designs. While the CNC machining process offers various capabilities and operations, the fundamental principles of the process
remain largely the same throughout all of them. The basic CNC machining process includes the following stages:

 Designing the CAD model

 Converting the CAD file to a CNC program
 Preparing the CNC machine
 Executing the machining operation

The main parts of the CNC machine are

(i) Input Devices: These are the devices which are used to input the part program in the CNC machine. There are three commonly
used input devices and these are punch tape reader, magnetic tape reader and computer via RS-232-C communication.

(ii) Machine Control Unit (MCU): It is the heart of the CNC machine. It performs all the controlling action of the CNC machine, the
various functions performed by the MCU are

 It reads the coded instructions fed into it.

 It decodes the coded instruction.
 It implements interpolation ( linear, circular and helical ) to generate axis motion commands.
 It feeds the axis motion commands to the amplifier circuits for driving the axis mechanisms.
 It receives the feedback signals of position and speed for each drive axis.
 It implements the auxiliary control functions such as coolant or spindle on/off and tool change.
(iii) Machine Tool: A CNC machine tool always has a slide table and a spindle to control of the position and speed. The machine table
is controlled in X and Y axis direction and the spindle is controlled in the Z axis direction.

(iv) Driving System: The driving system of a CNC machine consists of amplifier circuits, drive motors and ball lead screw. The MCU
feeds the signals (i.e. Of position and speed) of each axis to the amplifier circuits. The control signals are than augmented (increased)
to actuate the drive motors. And the actuated drive motors rotate the ball lead screw to position the machine table.

(v) Feedback System: This system consists of transducers that act as sensors. It is also called a measuring system. It contains position
and speed transducers that continuously monitor the position and speed of the cutting tool located at any instant. The MCU receives
the signals from these transducers and it uses the difference between the reference signals and feedback signals to generate the
control signals for correcting the position and speed errors.

(vi) Display Unit: A monitor is used to display the programs, commands and other useful data of CNC machine.
 How CNC Machine Works?
 First, the part program is inserted into the MCU of the CNC.
 In MCU all the data process takes place and according to the program prepared, it prepares all the motion commands and
sends it to the driving system.
 The drive system works as the motion commands are sent by MCU. The drive system controls the motion and velocity of the
machine tool.
 The feedback system records the position and velocity measurement of the machine tool and sends a feedback signal to the
MCU.
 In MCU, the feedback signals are compared with the reference signals and if there are errors, it corrects it and sends new
signals to the machine tool for the right operation to happen.
 A display unit is used to see all the commands, programs and other important data. It acts as the eye of the machine.

3.D Manufacturing and rapid prototyping techniques:

Allows for fast fabrication of computer models designed with three-dimension (3D) computer aided design (CAD) software. RP is used in a wide
variety of industries, from shoe to car manufacturers. Allows for fast realizations of ideas into functioning prototypes, shortening the design time
Lead towards successful final products.
.

Stereolithography (SL) is one of several methods used to create 3D-printed objects. It's the process by which a uniquely designed 3D
printing machine, called a stereolithograph apparatus (SLA) converts liquid plastic into solid objects.

Three Dimensional Printing (Powder Based RP Systems);

Process steps

◦ Spread a layer of powder

◦ Print the cross section of the part.

◦ Spread another layer of powder.

◦ Parts are printed with no supports to remove.

 Powder 3DP process begins by spreading a layer of fine powder material evenly across the piston. The X-Y positioning system and
the print head are synchronized to print the desired 2D pattern through the selective deposition of binder droplets onto the powder
layer. After printing, the piston, powder bed, and printed part are lowered, and the next layer of powder is spread . The drop-
spread-print cycle is repeated until the entire part is completed. Removal of the unbound powder reveals the fabricated part. 3D
printing or additive manufacturing is manufacturing objects without the use of dies, molds, or machining. Instead, it lay down
successive layers of material under computer control by using a 3D model.