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

MaterialsInorganic

Materials

Solid Liquid Gas

Engineering

(Industrial)

Materials

Non-

Engineering

Materials

Polymeric Metallic

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 ResourcesCustompart.net. (2008). Tutorials. Retrieved February 1,

2008, from

http://www.custompartnet.com/wu/InjectionMolding

Microsoft, Inc. (2008). Clip art. Retrieved February 13,

2008, from http://office.microsoft.com/en-

us/clipart/default.aspx

Society of Manufacturing Engineers (Producer). (2010).

Forging. Available from the Society of Manufacturing

Engineers, One SME Drive: Dearborn, Michigan 48121.

The ABB Group. (2008). Photo gallery. Retrieved June 5,

2008, from http://www.abb.com