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MAE364 Manufacturing Processes Spring 2005 Instructor: T. Kesavadas (Prof. Kesh) Associate Professor, Mechanical and Aerospace Engineering, 1006 Furnas Hall. Teaching Assistants (more details later):

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MAE364 Manufacturing Processes Spring 2005

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mae364 manufacturing processes spring 2005

MAE364Manufacturing ProcessesSpring 2005

Instructor: T. Kesavadas (Prof. Kesh)

Associate Professor,

Mechanical and Aerospace Engineering,

1006 Furnas Hall.

Teaching Assistants (more details later):

Govindarajan Srimathveeravalli Sridhar Seshadri

what is manufacturing
What is Manufacturing?







Manu Factus : Latin for ‘made by hand’


A Well organized method of converting raw material to end product

End Product: Value and utility added to output.

history of manufacturing
History of Manufacturing
  • Manufacturing started during 5000 – 4000 BC Wood work,ceramics,stone and metal work
  • Steel Production 600-800 AD
  • Industrial Revolution 1750 AD: Machine tools run by invention of steam engine
  • Mass Production and Interchangeable Parts
  • Computer Controlled Machines 1965
  • CNC,FMS systems
requirements of a good manufacturing system
Requirements of a good manufacturing system
  • Product should meet design requirement
  • Economical Process
  • Quality should be built into the system
  • Should be flexible and responsive to new technology
  • High productivity: Best utilization of man, material, machine, capital and available resources.
steps in modern manufacturing
Steps in Modern Manufacturing

Definition of product need, marketing information

Design analysis;codes/standards review; physical and analytical models



Conceptual design and

evaluation Feasibility study

Prototype production

testing and evaluation

Inspection and quality



Production drawings; Instruction manuals

Packaging; marketing and

sales literature

Material Specification; process

and equipment selection; safety review


Pilot Production

manufacturing of a paper clip
Manufacturing of a Paper Clip
  • What is the function
  • How long does it last
  • How critical is the part
  • Material Metallic - what type

Non metallic – plastic

  • Dimension Diameter of clip

Shape of clip

  • Method of manufacturing Manual


  • Function based design Stress, Strain

Life of clip


  • Style Appearance,Color,Finish


manufacturing of a bicycle

AISI 1010 welded tubing, assembly resistance welded and electrostatically painted

Aluminum alloy forging, polished and buffed

Forged aluminum tubing(alloy similar to 6063), polished and buffed

Manufacturing of a bicycle

AISI 1010,swaged and cadmium plated

AISI 1008,press formed resistance welded and painted

AISI 1020,forging and chromium plated

AISI 1010, luster finished coil stock,profile milled,resistance welded and chromium plated formed,welded and plated

AISI 1008, press formed,welded and plated

Cold drawn medium carbon steel,( similar to AISI 1035) bright zinc plated

AISI 1020 tubing, machine threaded and painted

AISI 1010,stamped and coined and chromium plated

Seamless AISI 1020 tubing swaged tube sections brazed into fork crown,painted

AISI 1010, stamped and chromium plated

Headed brass,nickel plated

AISI 1040 forging,carburized and chromium plated

Aluminum permanent mold casting,machined , polished and buffed

Case hardened forging quality steel parts, black oxide coating

Hardened high-carbon steel,thread rolled and chromium plated

AISI 1010,stamped and chromium plated

assignment 1
Assignment 1
  • Select a simple product of your choice
    • Try to analyze the different materials, processes, etc
    • Use library resources
    • We will discuss this in the class on Friday
selection of process topic to be covered
Selection of Process: Topic to be covered


  • Sand/Expandable Mold,Permanent Mold

Forming and Shaping

  • Rolling,forging,extrusion,powder metallurgy


  • Turning,Boring,Drilling,Milling,Planing,Broaching,Grinding
selection of process
Selection of Process

Unconventional Method

  • EDM,ECM,Ultrasound,High Energy Beam,machining


  • Welding,Brazing,Soldering


  • Honing,Lapping,Polishing,Burnishing,Deburring
objectives of this course and what is expected of you
Objectives of this course and what is expected of you
  • Manufacturing processes and fundamentals
  • Selection of appropriate process to meet design requirements
  • Effect of process parameters and variables on the quality of parts produced
  • Effect of material properties on a given process
  • Decision and methods for different product size and mix
  • Effect of design on manufacturability
  • Overview of computer aided methods in traditional manufacturing processes

Two methods of forming a dish shaped part from sheet metal

Left: conventional hydraulic/mechanical press using male and female dies

Right: explosive forming using only one die.


Upper die



work piece

Lower Die


Three methods of casting turbine blades

A: conventional casting with ceramic mold

B: directional solidification

C: Method to produce single crystal blade

selection of process depends on
Selection of Process depends on
  • Dimensional and surface finish requirements
  • Operational Cost
  • Design and strength requirements
  • Consequences of various methods
design for assembly
Design for Assembly
  • Design of the product to permit assembly
  • Possibility of multipurpose parts
  • Capability of manufacturing process to consistently produce parts which can be assembled without problem
  • Method or process of assembly

Automated Systems,Manual Systems etc

automation and impact of computers
Automation and Impact of Computers

Machine Control Systems

Computer Numerical Control machines, Robots,Machines,Processes

Computer Integrated Technology

  • Responsive to market change
  • Better use of process,man,machining management etc
  • CAD/CAM: Computer Aided Design And Manufacturing
  • FMS: Flexible Manufacturing System
  • GT: Group Technology
  • VR: Virtual Reality