Introduction to Manufacturing Processes

Types of Processes Primary Manufacturing Processes –Raw materials to useable material –Raw materials are renewable or exhaustible Secondary Manufacturing Processes –Create products from primary product

Input Process Output Feedback Manufacturing Process

Materials Ceramics, metals, and plastics are well- suited to manufacturing. Their properties determine the process for which they are best suited.

The World of Materials Organic Materials Inorganic Materials SolidLiquidGas Engineering (Industrial) Materials Non- Engineering Materials PolymericMetallic Ceramic

Composite Video

Selecting Materials Internal Structure Types of atoms Bonds between atoms Molecular structure Property Physical Mechanical Chemical Thermal Electrical – Magnetic Acoustical Optical Conditions Chemicals Radiation Mechanical Loads Thermal Electromagnetic Fields Sonic Forces

Casting and Molding

Casting and Molding Videos

Separating Involves the removal of material Also referred to as the subtractive process Includes two types of processes –Chip Forming –Non-Chip Forming

Separating Videos

Joining Also referred to as the additive process Materials added in layers to build a finished part Examples –Welding –Gluing –Soldering –Prototyping

Forming Uses force to cause a material to permanently take a shape Changes some of the material properties

Forming Videos

Finishing May be completed before or after assembly Used primarily to protect a product from various conditions Also used to enhance a product’s appearance

Finishing – Deburring Methods include filing, scraping, and trimming Considerations include actual requirements regarding work piece specifications, production quantities, and cost

Finishing – Cleaning Involves the process of removing unwanted material from work pieces Techniques include –Alkaline cleaning –Electrolitic cleaning –Solvent cleaning –Vapor degreasing –Acid cleaning –Abrasive blasting –Abrasive wheels

Finishing – Coating Involves a material being applied to a work piece May be mechanical, electrolytic, or conversion

Finishing – Assembling Involves putting parts together May be temporary or permanent Includes bonding and mechanical fastening

Finishing – Conditioning Refers to changing the physical or mechanical properties of a material Includes thermal, chemical, and mechanical

Image Resources Custompart.net. (2008). Tutorials. Retrieved February 1, 2008, from Microsoft, Inc. (2008). Clip art. Retrieved February 13, 2008, from us/clipart/default.aspx Society of Manufacturing Engineers (Producer). (2010). Forging. Available from the Society of Manufacturing Engineers, One SME Drive: Dearborn, Michigan The ABB Group. (2008). Photo gallery. Retrieved June 5, 2008, from