1. ME 422 – Manufacturing Processes Page 1/19 Introduction Manufacturing is the act of making a products by hand or machine from raw materials. It seems to be a fundamental human activity, and like design, is an integral part of the rise of civilization. Selecting of appropriate materials and manufacturing processes is a critical part of the design process. In particular, the manufacturing process must be economical and capable of producing the geometric surfaces (see below) and other features embodied in the design.

2. ME 422 – Manufacturing Processes Page 2/19 Process Classification There are seven fundamental classifications for manufacturing processes Molding or casting Forming and shearing Machining (material removal, includes chip-making process, chipless processes, and heat cutting) Heat treatment Finishing (painting, anti-corrosion coatings, etc.) Assembly Inspection Molding Molding is usually used for plastics, casting for metals. There are eight major molding processes Hot compression molding Transfer molding Injection molding Extrusion Laminating Vacuum forming Cold molding

3. ME 422 – Manufacturing Processes Page 3/19 Molding Casting

4. ME 422 – Manufacturing Processes Page 4/19

5. ME 422 – Manufacturing Processes Page 5/19

6. ME 422 – Manufacturing Processes Page 6/19 Forming Operations

7. ME 422 – Manufacturing Processes Page 7/19 Molding Processes (1)

8. ME 422 – Manufacturing Processes Page 8/19 Molding Processes (2)

9. ME 422 – Manufacturing Processes Page 9/19 Sand Casting Techniques for Producing Various Shapes

10. ME 422 – Manufacturing Processes Page 10/19 Design for Efficient Sand Casting

11. ME 422 – Manufacturing Processes Page 11/19 Other Casting Processes

12. ME 422 – Manufacturing Processes Page 12/19 Common Forming and Shearing Processes

13. ME 422 – Manufacturing Processes Page 13/19 Extrusion Processes

14. ME 422 – Manufacturing Processes Page 14/19 Hot Forming Processes - Forging

15. ME 422 – Manufacturing Processes Page 15/19 Other Hot Forming Processes - Forging

16. ME 422 – Manufacturing Processes Page 16/19 Basic Machining Processes Machining Physical removal of unwanted material in the form of chips (usually), leaving a part with the desired geometry and surface finish. Can produce complex shapes, very good dimensional control, and good surface finishes. Tends to be wasteful of material, and expensive in terms of labor and capital.

17. ME 422 – Manufacturing Processes Page 17/19 Operations and Machines for Machining Internal Cylindrical Surfaces

18. ME 422 – Manufacturing Processes Page 18/19 Operations and Machines for Machining Flat Surfaces

19. ME 422 – Manufacturing Processes Page 19/19 Operations and Machines for Machining External Cylindrical Surfaces