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BASIC MANUFACTURING PROCESSES 1
SKMM 1922
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Salam Sejahtera
Contents
1. Materials in manufacturing
2. Manufacturing processes
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1. Materials in Manufacturing
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• Most engineering materials can be classifee into one of three basic categories:
1. Metals
2. Ceramics
3. Polymers
• Their chemistries are eiferent, their mechanical ane physical propertes are eissimilar, ane these eiferences afect the manufacturing processes that can be usee to proeuce proeucts from them
Engineering Materials
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FIGURE 1.4 An outline of engineering materials
What is Manufacturing?
• Manufacturing as an economic process– Manufacturing is the transformaton of materials into items
of greater value by means of one or more processing ane/or assembly operatons
– Manufacturing adds value to the material by changing its shape or propertes, or by combining it with other materials that have been similarly alteree
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2. Manufacturing Processes
Two basic types:
I. Processing operatons - transform a work material from one state of completon to a more aevancee state– Operatons that change the geometry,
propertes, or appearance of the startng material
II. Assembly operatons - join two or more components in oreer to create a new entty
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I. Processing Operatons
• Alters a workpart's shape, physical propertes, or appearance in oreer to aee value to the material
Three categories of processing operatons:
1. Shaping operatons - alter the geometry of the startng work material
2. Property enhancing operatons ‑ - improve physical propertes of the material without changing its shape
3. Surface processing operatons - performee to clean, treat, coat, or eeposit material onto the exterior surface of the work
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Shaping Operaton – Four Categories
1. Solidifcaton processes - startng material is a heatee liquid or semifuid that solieifes to form part geometry
2. Partculate processing - startng material is a powder, ane the poweers are formee into eesiree geometry ane then sinteree to hareen
3. Deformaton processes - startng material is a ductle solid (commonly metal) that is eeformee
4. Material removal processes - startng material is a solid (euctle or britle), from which material is removee so resultng part has eesiree geometry
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Assoc Prof Zanal Abidin Ahmad 10
4 Major Manufacturing
Processes
Classification of Manufacturing Processes
1. Solidifcaton Processes • Also known as castng process • Startng material is heatee sufciently to transform it
into a liquie or highly plastc state • Examples: Castng for metals, moleing for plastcs
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Parts Maee by Castng
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Parts Maee by Castng
2. Partculate Processing
• Also known as poweer metallurgy process
• Startng materials are poweers of metals or ceramics
• Usually involves pressing ane sintering
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PARTS MADE FROM POWDER METALLURGY PROCESS
3. Deformaton Processes • Also known as metal forming processes• Startng workpart is shapee by applicaton of forces that
exceee the yiele strength of the material• Examples: (a) forging, (b) extrusion
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Bulk Metal Forming Parts
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Sheet Metal Forming Parts
4. Material Removal Processes • Usually known as machining processes
• Excess material removee from the startng workpiece so what remains is the eesiree geometry
• Examples: machining such as turning, erilling, ane milling; also grineing ane nontraeitonal processes
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Machining Parts
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II. Assembly Operatons
Two or more separate parts are joinee to form a new entty
Types of assembly operatons:1. Joining processes – create a permanent joint.
• Examples: welding, brazing, soldering, and adhesive bonding
2. Mechanical assembly – fastening by mechanical methoes
– Examples: use of screws, bolts, nuts, other threaeee fasteners; press fing, expansion fts
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Various type of joining and welding processes
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Mechanical assembly and
fasteners
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Methods of Making a Simple Part
Various methoes of making a simple part. (a) castng or poweer metallurgy, (b) forging or upseing, (c) extrusion, (e) machining, ane (e) joining two pieces.
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