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WS Lecture 1 -Manufacturing Processes

Engineering Skills - Workshop Practice introductory lecture

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WS Lecture 1 -Manufacturing Processes

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  1. Engineering Skills DevelopmentWorkshop Practice By: Nalin Fernando BSC (Eng) Hons.,MBA (Colombo), MIE (Aust), MSOE, MIPlantE, MSLID(SL), MIPM(SL) Consulting Mechanical Engineer

  2. What is a Workshop • A room, group of rooms, or building in which work, especially mechanical work, is carried on. • Work done: Repair, Maintenance, Fabrication / Manufacture items, small machinery and equipment – and related work. • Requirements / facilities needed : Tools and Machinery, Raw materials, Fabrication / making / assembly facilities, Measuring tools

  3. Manufacturing

  4. WHY STUDYMANUFACTURING PROCESSES? The designer must have a working knowledge of the various processes that could produce a part at the lowest cost and the shortest time

  5. Three Phases of The Manufacturing Process

  6. The information needed to produce a part, most often comes in the form of a: WorkingDrawing

  7. Classification of Manufacturing Processes

  8. Casting Making objects by pouring molten metal into an empty shaped space. The metal then cools and hardens into the form given to it by this shaped mould Casting is often a less expensive way to manufacture a piece compared with machining the part out of a piece of solid metal.

  9. The Casting Process • First a pattern is made. • Then a cavity is made by placing a pattern in wet sand. • Next molten metal is poured into the cavity of damp sand.

  10. The Casting Process Rough Casting • The rough casting is now ready for the machine shop. • Holes are then bored and reamed. • Top and bottom surfaces are machined • Smaller holes will be drilled and counterbored. • All corners on cast parts are fillets and rounds.

  11. Forging Process • Forging is produced by using heavy mechanical presses or hammering heated bars of metal between dies. • Advantages of forging over sand casting are that forged parts are much stronger and less brittle.

  12. Welding Welded Welding is the fusion or joining of two pieces of metal by means of heat, with or without the application of pressure. Cast

  13. ManufacturingMaterials Can be categorized as : • Metal • Plastic • Inorganic materials

  14. Metals are classified as: • Ferrous - contain iron and steel. • Nonferrous - do not have iron content (such as copper and aluminum). • Alloys - mixture of two or more metals.

  15. Inorganic Materials Include: • Carbon and graphite - have low tensile strength (ability to be stretched). • Ceramics are clay and glass materials. (resistant to heat, chemicals, & corrosion).

  16. Heat-Treating: • Annealing – is the process generally used to soften metal by heating followed by slow cooling. • Hardening – requires heating and then rapid cooling in oil or water.

  17. Plastics Processing The plastics industry represents one of the major manufacturing segments. • Thermoplastic – becoming or remaining soft and moldable when subjected to heat. • Thermosetting– becoming permanently hard and unmoldable when once subjected to heat.

  18. Typical Plastic Processing Operations Include: • Extrusion • Blow Molding • Injection Molding • Injection Blow Molding • Thermoforming

  19. Extruding The process of producing shapes by forcing hot plastic through a die that has and opening of the desired shape.

  20. Blow Molding Used in the production of bottles, automotive ductwork, hollow toy components, and door panels.

  21. Injection Molding . Used to manufacture products such as housings for electronic implements, automotive components, food storage containers, and components for medical applications.

  22. Thermoforming • Used in the manufacturing of thin-walled packages for the food industry. • Manufactured primarily by injection molding.

  23. CAD in Manufacturing • The process of developing a design drawing on a CAD system and producing it on a computerized machine is calledCAD/CAM. • The process of converting the CAD drawing into a preprogrammed, coded instructions is calledComputer Numerical Control(CNC). • The advantages of the (CNC) is, better production and control, increased productivity, decreased labor and lower production costs.

  24. End

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