Manufacturing Processes

- II

Manufacturing Processes II Structure &

Syllabus:
GUJARAT TECHNOLOGICAL UNIVERSITY
DEGREE IN MECHANICAL ENGINEERING
PROPOSED TEACHING SCHEME
Semester - V

B. E. SEMESTER: V
MECHANICAL ENGINEERING
Subject Name: Manufacturing
Processes - II

Manufacturing Processes II
Syllabus

Manufacturing
Processes

II
Term Work:
Syllabus
The term work shall
be based on the topics mentioned
Books
above.

Practical / Oral:
The candidate shall be examined on the basis of term-

work.
Reference Books:
1. Production technology, by R.K. Jain, Khanna publishers.
2. Production Technology by P.C. Sharma S Chand & Co Ltd.
3. Manufacturing Technology Vol-II, By P.N. Rao, Tata

McGraw Hill.
4. Manufacturing Engg. & Technology By S. Kalpakajain,
PHI/Pearson.
5. Welding technology, by O. P. Khanna, Dhanpat Rai
publishers.

Introduction to
Importance of manufacturing,
Manufacturing:
Economic and technological definition of

manufacturing,
Classification of manufacturing processes,
Selection of Manufacturing process.

Manufacturing
definition
&
Definition
importance:
Manufacturing includes all steps necessary to

convertraw materials,components,
orpartsintofinished goodsthat meet
acustomer'sexpectations orspecifications.
Manufacturing commonly employs a man-machine
setupwithdivision of laborin a largescaleproduction.
Manufacturing (from Latin manu factura , "making
by hand") is the use of tools and labor to make things
for use or sale.

The term may refer to a range of human activity,

from handicraft to high tech, but is most commonly
applied to industrial production, in which raw materials
are transformed into finished goods on a large scale.

Manufacturing definition &

Manufacturing takes place under all types of

economic systems. (Cont..):
importance
In a free market economy, manufacturing is usually

directed toward the mass production of products for

sale to consumers at a profit.

In a collectivist economy, manufacturing is more

frequently directed by the state to supply a centrally

planned economy.

In free market economies, manufacturing occurs under

some degree of government regulation.

Economicsis thesocial sciencethat is concerned

with
theproduction,distribution,consumptionofgoodsand
services.

Manufacturing definition &

The importance of manufacturing in Indian
economy:
importance
(Cont..):

Production of goods in large quantities after

processing from raw materials to more valuable products
is called manufacturing. For example: paper is
manufactured from wood, sugar from sugarcane, iron
and steel from iron ore and aluminum from bauxite.
i. Manufacturing industries help in modernizing
agriculture, which forms the backbone of our economy.
ii. Manufacturing industries also reduce the heavy
dependence of people on agricultural income by
providing them jobs in secondary and tertiary sectors.
iii. Industrial development is a precondition for
eradication of unemployment and poverty from our
country.

Manufacturing definition &

The importance of manufacturing in Indian
economy (Cont..): (Cont..):
importance
iv. It brings down regional disparities by

establishing industries in tribal and backward areas.

v. Export of manufactured goods expands trade &
commerce, and brings in much needed foreign
exchange.
vi. Countries that transform their raw materials into
a wide variety of furnished goods of higher value
are prosperous.
vii. Industry sector contributes 27 % of GDP out of it
manufacturing accounts for 17 %.

Manufacturing Processes Structure:

In industrial production, many different processes or

manufacturing methods are used.

To be able to select the technically and economically

best manufacturing sequence for a product, it is

necessary to have a broad fundamental
knowledge of the possibilities and limitations of
the various manufacturing processes, including
work materials used and geometries, surface
finishes & tolerances required.
Here, the individual processes are not considered
in detail, but a general picture of the common
structure on which all processes are based is
introduced.

Manufacturing Processes Structure:

The term process can in general be defined as a
change in the properties of an object, including
geometry, hardness, state, information content
(form data), and so on.

To produce any change in property, three

essential agents must be available: (1) material, (2)
energy, and (3) information.

Depending on the main purpose of the process,

it is either a material process, an energy
process, or an information process.

In this topic, only material processes will be

considered, especially those producing geometrical
changes or changes in material properties, or both.

Manufacturing Processes Structure:

The general process model can be illustrated as
shown in Fig. The model shows that a material process
can be described by the associated flow system: material
flow, energy flow, and information flow.

Figure: The general process model. (i) indicates inputs and (o)

outputs.
Material flow can be divided into three main types,
as shown in Fig. in next slide.
Through flow, corresponding to mass-conserving processes.

Diverging flow, corresponding to mass-reducing processes.

Converging flow, corresponding to assembly or joining

processes.

Manufacturing Processes Structure:

Material Flow
FIGURE : The three main types of

material flow:
(a) mass-conserving processes (dM =
0);
(b) mass-reducing processes (dM < 0);
(c) assembly or mass-increasing
processes (dM > 0).
Here M means mass of material, i:
input, and o: output.
The numbers 1 and 2 refer to the
number of material elements.
Depending on the process, Auxiliary
flow of material may be necessary, e.g.
Lubricants, cooling fluids, filler metals,
flux.

Manufacturing Processes Structure:

If the processes are evaluated:

Most processes aiming to at a change in materials

properties is without change in geometry are mass

conserving ones.
The energy flow associated with a process can be

characterized as energy supply, energy transmission to

work piece
Information flow includes shape and property

information. A certain geometry for a certain material can

be characterized as shape information for the material.
In a geometry-changing process, shape-change

information is impressed on the material so that the final

shape information is equal to the SUM of the initial shape
info and the shape-change info impressed by the process.

Manufacturing Processes Structure:

The shape-change information is created by an

INTERACTION between tool/ die and a pattern of

MOVEMENT for work material and the tool/die.
This means that a geometry-changing process is

characterized by a material flow on which, by means of

an energy flow, the shape-change info corresponding to
the info flow is impressed.
Impressing a change in geometry on material can be

carried out in one or more steps:

Io = Ii + Ip1 + Ip2 ++ Ipn where Io:

desired geometry; Ii: initial shape info; and Ipn

is the shape change info for single process.

Manufacturing Processes Structure:

Similarly, the property info flow, hardness, strength,

involves the sum of the properties of the initial

material and the changes in properties produced by
various processes.
The proper interaction between these 3

fundamental flow systems, yielding to the desired

component, is governed by the control info,
which includes knowledge of forces, power,
friction and lubrication, cutting data, etc..
A complete model of manufacturing process is

shown in figure.

Manufacturing Processes Structure:

Material Process

Figure: Complete model of a material Process.

The Morphological Structure of Material

Processes:

The Morphological structure of material

processes is the form & structure of material
processes.
All manufacturing processes can be described by a

general morphological model built up from few

fundamental elements related to the 3 flow systems.

By combining these elements, a process

morphology is obtained from which all
manufacturing processes can be deduced.

The Morphological Structure of Material

Processes:

Each of these elements can have different values,

as in fig. 1.4. by choosing a value from each column the
fundamental basis for a material process is obtained.
Some of the combinations are physically impossible
but, in general, the model contains all the basic
ingredients necessary to establish a process.

The Morphological Structure of Material

Processes:
The fundamental elements in this
morphological model are:

Material flow: - basic process - state of

material - type of flow [process type]

Energy flow: - tool/die [energy supply, transfer

medium] - equipment [energy characteristics, type
of energy]

Information flow: - surface creation principles

- pattern of movement for material & tool/die]

The Morphological Structure of Material

Processes:

Basic Processes:

Basic processes are defined as those processes

that create changes in the geometry and/or the
properties of the materials. The basic
processes are characterized by the nature of

Basic
Processes
(Cont..):
Schematic illustration of the Material Flow System

Basic
Processes
(Cont..):
A manufacturing process normally consists of a series

of basic processes, which constitute the structure of the

material flow.
Any series of basic processes can be divided
into three typical phases:

Phase 1, which consists of the basic processes that

bring the material into a suitable state-geometry and/or
properties (heating, melting, sawing, cropping, etc. i-for
the primary change in geometry and/or properties.

Phase 2, which consists of the basic processes that

create the desired geometry and/or change in properties.

Phase 3, which consists of the basic processes that

bring the component into the specified end state
(solidification, cooling, deburring, etc.)

Basic Processes (Cont..):

This division is illustrated in Fig. shown in earlier slide,

where the basic processes associated with phase 2

are called the primary basic processes (according to
the primary goal).
The basic processes associated with phases 1 and 3

are called secondary basic processes. The structure

shown in Fig. shown in earlier slide is very useful
when analyzing and designing manufacturing
processes.

The basic processes can be divided into three

main categories, as shown in Table [next slide].

Each of these categories is characterized by the

nature of the interaction with the work material.

Basic Processes (Cont..):

When the main objective for a process has been

established, relevant series of primary and

secondary basic processes can be found. Here the
actual type of material has a significant influence,
since the materials react differently when subjected
to mechanical, thermal, or chemical actions.
If only processes aiming at geometrical changes

are considered, the number of possible primary

basic processes (phase 2 in Fig. in previous slide) is
reduced to those shown in Table [second table].
It is the primary basic process and the way in

which it is established that determines the types

and number of secondary basic processes required.

Main categories of basic

processes:

Primary Basic Processes used in Material Processes

that change Geometry:

Selection of flow or process type depends on

the requirements of material, geometry,
surface, tolerance, number, price and other

Classification of
technological Material
Processes used in Shaping
Materials:

Examples of
Manufacturing Processes:

Examples of
Manufacturing Processes:

Summary of Classification of Manufacturing

Processes:
1. Classification as per the main purpose of the
process:
A material process,
An energy process, or
An information process.
2. Classification as per the mass modifying

process:
Mass-conserving processes (dM = 0)
Mass-reducing processes (dM < 0)
Assembly or mass-increasing processes (dM >

0).

Summary of Classification of Manufacturing

Processes:
3. Classification as characterized by the
nature of their interaction with the material.
Basic pre-processing processes (Secondary

processes)
Basic primary processes
Basic post-processes (Secondary processes).
4. Classification as per the flow system:
Material flow type processes,
Energy flow type processes,
Information flow type processes.

Summary of Classification of Manufacturing

Processes:
5. Classification as per category of
basic processes:
Mechanical basic processes,
Thermal basic processes,
Chemical basic processes.

Topic 1 Completed

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