Unit III Introduction to

Manufacturing
Mr. A. S. Apate
Assistant Professor
AISSMS-IOIT, Pune
 Syllabus
• Conventional Manufacturing Processes:
Casting, Forging, Metal forming (Drawing,
Extrusion, etc.), Sheet metal working, Metal
joining, etc. Metal cutting processes and
machining operations- Turning, Milling and
Drilling, etc. Metal Joining Processes
• Micromachining. Additive manufacturing and
3D Printing. Introduction to Robotics

2
 Manufacturing Process

Manufacturing Process

Raw Machine Finished

Material Tool Product

3
 Manufacturing
Processes
Cutting Non- Cutting Fabrication
Lathe Casting Welding
Drilling
Rolling Brazing
Milling
Grinding Soldering
Forging
Shaping Riveting
Boring Press Work Screw
Fastening
Sawing Molding
NC Wire
Machines Drawing
Gear Cutting 4

Finishing
 Classifications of Manufacturing Processes

Process Machining Casting

effecting
Metal Sheet Power Surface Metal
joining metal metallurgy finishing • Material forming • Pouring of
change in •Joining of working •Pressing and removal by •Plastic metal into
properties the •Making heating of • Surface cutting tool Deformation mould
components components metal finishing into desired
• Change of powder • Turning • Sand
properties •Welding, from metal by tool shape casting Die
brazing, sheets mixture shaping
• Heat • Grinding, milling •Forging press casting
soldering, •Bending,
treatment work, rolling, centrifugal
Reverting drawing, honing drilling
extrusion
hot screw boring. casting
blanking, lapping,
working, fastening punching
cold pressing. buffing,
working polishing.

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 Casting Process
It is the process in which the molten metal is poured into a mould or cavity

Casting process
Melting the metal such as cast
iron, copper, brass, aluminum.
Pouring the molten metal into
cavity or mould.
Allowing the molten metal to
cool and solidify in the mould.
Removing the component from
mould

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 Plaster mould
Types of Casting Process Casting Process

Permanent
mould Casting
Process
Sand Casting
Process
Die-Casting
Process
Casting Process
Shell mould
Casting Process

Special Casting
Process Centrifugal
Casting Process

Continuous
Casting Process
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 SandCasting Process
It is the process in which the casting are made using sand mould.

• Pattern is model or replica of a

Pattern Making casting used for making a cavity

• It is the process of making a cavity

Mould Making which confirm to the shape

• Core is pre defined shape made

Core Making from the sand and placed into
mould

Melting and • Metal is melted in furnace and

Pouring of metal poured in to mould cavity

Cooling and • Molten metal is allowed to cool

Solidification and solidify in the mould.

Cleaning and • After solidification the sand mould is

broken to take out casting is then mould
Inspection cavity. The cleaned and inspected. 8
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 Casting Process
Advantages Limitation Application

• No restriction of shape • Restrictions on the • Automobiles:- Engine

• No restriction on the minimum thickness of block, piston cylinder,
type of metal or alloy component, less then piston ring , gear box,
• Economical suitable for 6mm cannot be gear blanks, etc
both small and big size manufactured. • Aircraft:- Jet engine
component • Casting process require blades gearbox, etc
• Cost of component is melting metals so it is • Machine tools:-
very low high power consuming machine tools beds,
process. frames, gear box
• Good dimension
accuracy • In this process housing, gears, etc.
environment pollution • Turbines:- wheels and
• High production rate
is very high. housings of steam and
• Better in daming
• The blow holes, gas hydraulic turbine,
property.
cavity and non-metallic turbine vanes etc.
insursions in process • Piping:- water supply,
reduce the strength of sewer pipes, etc
component.
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Applications of casting process.

1. Automobiles:
1. Engine Blocks 3. Machine tool:
2. Cylinder blocks
1. Machine tool beds
3. Pistons.
2. Frames
4. Piston rings
3. Gear box housing
5. Clutch Housing, etc
4. Gears
2. Aircrafts: 5. Machine tool slides and heavy
1. Jet engine blades components, etc
2. Gear box housing 4. Water Pump Casings.
3. Gear blank, etc
5. Turbine casings.
4. Pulleys.
6. Flywheels. 12
 Metal Forming process
It is the process in which the component of desire size and shape is obtained
through the plastic deformation of metal or alloy under extremely applied force.

General forging process

 in this process the material is
deformed into desired shape
between two parts called dies.
The forging press consist of
lower die fix. Upper die
connected motor through crank
rod shaft and gear.
During downward stoke of ram
the upper die exert the sudden
compressive force on the hot
material. Then it converted into
desired shape.
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 Types of Forging Process
Forging Process

Based on die of Based on mode of

forging process application of
compressive force.

Open die Closed die

forging forging
process process

Hand Press Machine

Drop Forging Forging
Forging Forging
Process Process
Process Process
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Forging process based on Types of dies
Open forging Process Closed forging Process

In this process the material In this process the material is
deform between the two dies
is deform between the two which have the impression of
flat dies desired shape 16
Types

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 Forging process based on mode of
application of compressive force
Hand forging process Drop forging process

It is process of deforming the It is process of deforming the hot

hot material into desired shape material into desired shape by
by applying the repeated blow rising die and allowing it to fall so
of hand held hammer. impact the blow on material
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 Metal forging process
Advantages Limitation Application

• High dimensional • Brittle material like cast • It is use for making I.C.
accuracy and surface iron cannot be forged engine parts like
finish. • Complex component crankshafts, connecting
• Reduce the grain size with intricate shapes rods, rocker arms etc
due to this it improve can't be produced by • It is use for making gear
the strength. this process. blanks, levers
• Produces high strength • Normally forged • it also use for making
and weight ratio. component cost more automobile and aircraft-
• Produce the component than cast component component.
with thin section without • The cost of forging dies is
reducing strength. high.
• Produces the component
without shrinkage
cavities blow holes and
machine scratches.
• Component offers better
resistance to shock and
vibration. 20
 Sheet Metal Process
• It is the process of manufacturing of component or parts from the sheet metals
• It is carried out with the machine tool called as press therefore it is called as Press working

Sheet metal process

The pieces of metal sheer which
is to be given a shape is kept
over the die.
The force is applied through the
punch.
Small clearance is kept between
the punch and die for the
thickness of metal-sheet.
The tool used on the press for
carrying out the sheet metal
working are called die and punch 21
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Sheet Metal Working
Sheet Metal Cutting (Shearing) Operations
• Piercing
• Punching
• Blanking
• Perforating
• Notching
• Lancing
• Slitting

Sheet Metal Forming Operations

• Bending
• Drawing & Deep Drawing
• Embossing
• Forming 23
• Coining (Squeezing)
 Sheet Metal Working Process
Sheet-Metal cutting or shearing Sheet-Metal forming
process process

Piercing Drawing and deep

drawing

Punching
Bending

Blanking

Forming
Performing

Slitting
Coining

Lancing

embossing
notching 24
 Sheet Metal cutting Process
It is the process in the metal-sheet is cut using punch and die and desire part of
sheet is used and remaining part of metal-sheet is discarded

• It is the operation of
producing a hole of any
Piercing desired shape in metal sheet
by using a punch and die

• It is the operation of
producing a cicular hole in a
Punching metal sheet using punch and
a die

• It is the operation of cutting

out a piece of required shape
Blanking from a metal sheet using
punch and a die 25
 • It is the operation of producing a
number of evenly spaced holes in
Perforating metal sheet by using a punch and
die

• It is the operation of cutting metal

Slitting sheet in a straight line along the
length

• It is the operation of cutting out

part of metal sheet through some
Lancing portion of its length and then being
the cut portion

• It is the operation of removal of

small part of the metal sheet of the
Notching desired shape from the edge of the
metal sheet. 26
Prof.A.J.More AISSMSIOIT,Pune 27
 Sheet Metal Forming Process
It is the process in in which the flat plate of metal sheet is converted into a desired
shape without wasting material.

1) Drawing and deep drawing 2) Forming process

It is the process of shaping a metal-

It is process of forming flat metal- sheet into a surface of desired
sheet into a three dimensional profile
hallow shape by means of punch In this process shape of die and
and die punch is directly reproduced.
Example:- drums, cans etc Ex:- aircraft parts, steel furniture,
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toys, etc.
 Sheet Metal Forming Process
3)Coining (squeezing) 4) Embossing

It is the process of producing the

It is process of cold squeezing of depressed or raised impression of
metal in which all the surface are letter figure or design on metal
confined within a set of dies sheet.
Example:- coins, medals, badges It is used in production of name
plate identification tags etc. 29
 Sheet Metal Forming Process
5)Bending

Bending methods
1. V-bending
It is a metal forming process by 2. U-bending
which a straight length metal 3. Edge bending
sheet is transformed into a
curved length. 4. Angle bending
5. Curling 30
 Sheet-metal working
(Press working)
Advantages Limitation Application

• Component produced • There is limitation on • Automobile

by sheet-metal working the thickness of metal- • Aircraft body parts
are light in weigh. sheet is used • Steel furniture
• The Component • The sheet metal • Utesils
produced by sheet- component have
• Electronic appliances
metal working are relatively low strength.
cheap.
• The rate of production
is high.
• It gives high
dimensional accuracy
and good surface
finishing
• It doesn’t require skill
labour 31
 Metal Forming processes
• It is a process in which flat plate metal sheet is converted into
a desired shape without wasting the material.

• Drawing and deep drawing

• Bending
• Forming
• Coining
• Embossing

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Bending Methods-

U Bending

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Angle Bending

Bending and wiping/

Edge bending

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Forming-
Process of converting flat metal sheet into a surface of a desired
profile.

Curling
an edge of circular cross section is formed along a sheet or at the end
of the tube.

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 Metal Joining Processes
It is the process in which the various parts are joined together to form product.

Welding

Brazing

Soldering

Mechanical Fasteners

Adhesive Bending

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 Welding
It is the process of joining two metallic part together by heating them to a plastic or
semi molten state .

Welding process require three input

Filler
1. Heat :- heat is required for fusing Material
the two part. It is essential for
(Optional)
welding
Application
2. Application of pressure :- the Heat
of Pressure
application of pressure is an (Essential)
(Optional)
optional input element in
welding process.
3. Filler Material:- it is also optional Welding
input. In some welding process it
supplied by welding rod.

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Types of Forge welding Spot welding

Welding Pressure
welding
Electric
resistance
Seam welding

Pressure Projection
welding welding
Welding
process Shlelded Metal
arc welding
Non-pressure
thermit welding
Tugston insert
gas arc welding
Non-pressure Electric arc
welding welding
Metal insert gas
arc welding
Gas welding
Carbon arc
welding
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 Non-Pressure (Fusion) welding
The two metal part to be joined are heated to molten state and allowed to solidify to
make the joint with out external pressure

Electric arc welding Gas welding

 It is non-Pressure welding in which heating is  it is the non-pressure welding
done due to electric arc and no need of process in which heating is done due
external pressure but require filler material. to combustion of gas
 Advantages:- the process can be used for any
complicated shape.  filler metal is generally used
 Some common electric arc welding process  In resistance welding the amount of
are heat generated is given by H=I2RT
1. SMAW (Shield Metal Welding)  Types of Gas welding is
2. TIG (tungsten inert gas) arc welding 1. Oxyacetylene gas welding
3. MIG (metal inert gas) arc welding
2. Ox hydrogen gas welding
4. Carbon arc welding
3. Air acetylene gas Welding

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Uses an electric arc to coalesce metals

Arc welding is the most common method

of welding metals

Electricity travels from electrode to

base metal to ground

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 Welding
Advantages Limitation Application

• Gives light weight • Not possible to • Fabrication of bridges

construction . disassemble the parts. electric and
• High strength joint • Joint weak against transmission towers
• High rate of production vibration • Manufacturing of
• Mechanization and • Quality and strength of automobile bodies
automation possible joint is operated • Building of ships and
• Ability to produce depend aircrafts
complicated shapes. • Result is residual • Manufacturing of
• Used effectively for stresses distortion boilers, pressure
repeating broken parts • Gives harmful vessels, storage tanks,
radiations pipelines
• Low cost process
• Manufacturing of steel
• Ability to produce fluid
furniture, window and
tight joints.
doors frames, grills

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Shielded metal arc welding (Stick welding, Manual metal arc
welding) uses a metallic consumable electrode of a proper
composition for generating arc between itself and the parent work
piece. The molten electrode metal fills the weld gap and joins the
work pieces.

This is the most popular welding process capable to produce a

great variety of welds.

The electrodes are coated with a shielding flux of a suitable

composition. The flux melts together with the electrode metallic
core, forming a gas and a slag, shielding the arc and the weld pool.
The flux cleans the metal surface, supplies some alloying elements
to the weld, protects the molten metal from oxidation and
stabilizes the arc.
The slag is removed after Solidification.

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 Advantages of Shielded Metal Arc Welding (SMAW):
•Simple, portable and inexpensive equipment;
•Wide variety of metals, welding positions and electrodes are
applicable;
•Suitable for outdoor applications.

Disadvantages of Shielded Metal Arc Welding (SMAW):

•The process is discontinuous due to limited length of the
electrodes;
•Weld may contain slag inclusions;
•Fumes make difficult the process control.

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Applications of welding:
•Buildings and bridges structures;
•Automotive, ship and aircraft
constructions;
•Pipe lines;
•Tanks and vessels;
•Rairoads;
•Machinery elements.

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Basic Metal Cutting Process
•Turning,
•Milling and
• Drilling

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Metal Cutting Process:
Metal cutting is the process of producing a job by removing a layer of
unwanted material from a given work piece.
1.Turning -Turning is the process of machining external, or internal cylindrical
and conical surfaces in which the part is rotated as the tool is held against it
on a machine called a lathe. Excess Material is removed to reduce Diameter
2.Drilling –Process of producing cylindrical hole
3.Milling-Process of removing undesirable material from work piece by
feeding work piece past rotating multipoint cutting tool called milling
cutter

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 Material Removal Processes

 Excess material removed from the starting piece

so what remains is the desired geometry
 Examples: (a) turning, (b) drilling, and (c) milling

https://www.youtube.com/watch?v=8EsAxOnz
Ems
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 Material Removal
 The family tree Processes

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 Turning

 Single point cutting tool removes material from

a rotating workpiece to form a cylindrical shape

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Operations on Lathe Machine

Turning Facing Chamfering 53

Operations on Lathe Machine

Grooving

Knurling

Parting off Threading 54

 Operations on Lathe Machine

Reaming

Drilling Boring
Forming Taper turning 55
 Drilling

 Used to create a round

hole, usually by means
of a rotating tool (drill
bit) with two cutting
edges

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 Drilling Operations

Drilling: Producing the hole Reaming: Finishing the hole produced

Boring: Enlarging the hole produced

Spot Facing: Finishing the top
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surface of a hole
 Drilling Operations

Counter Boring: Producing stepped hole

Tapping

Counter Sinking: Producing conical shapes Trepanning: Large size holes or jobs 58
 Milling
 Rotating multiple-cutting-edge tool is moved
across work to cut a plane or straight surface
 Two forms: (c) peripheral milling and (d) face
milling

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MILLING OPERATIONS

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milling operations

Facing Partial facing End milling

Profiling Pocketing Surface contouring

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 Nature of Relative
Motion Between Tool
and Workpiece

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 Machining Conditions
 Cutting parameters  Environment  Workholder
• Depth of cut • Lubricant • Fixtures
• Speed (cutting fluid) • Jigs
• Feed • Oxygen • Chucks
• Temperature • Collets
 Cutting speed (v) – primary motion
The speed at which the work moves
with respect to the tool(rpm)
 Feed (f) – secondary motion(mm/rev)

 Depth of cut (d) – penetration of tool

below original work surface (mm)
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 Cutting Tool Classification
1. Single-Point Tools
 One dominant cutting edge
 Point is usually rounded to form a nose radius
 Turning uses single point tools
2. Multiple Cutting Edge Tools
 More than one cutting edge
 Motion relative to work achieved by rotating
 Drilling and milling use rotating multiple cutting edge
tools

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 Micromachining, Additive manufacturing
and 3D Printing
• Micromachining:Micromachining refers to
techniques for fabrication of 3D structures on
the micrometer scale.
• Removal of material in the form of chips or
debris having the size in the range of microns.
• Definition: material removal at micro/nano
level with no constraint on the size of the
component being machined.

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 Why Micro Machining?
Present day High-tech Industries, Design requirements are
stringent.
– Extraordinary Properties of Materials (High Strength, High
heat Resistant, High hardness, Corrosion resistant etc)
– Complex 3D Components (Turbine Blades),Medical applications
– Miniature Features (filters for food processing and textile
industries having few tens of microns as hole diameter and
thousands in number)
– Nano level surface finish on Complex geometries (thousands
of turbulated cooling holes in a turbine blade)
– Making and finishing of micro fluidic channels (in
electrically conducting & non conducting materials, say glass,
quartz, &ceramics) 67
Micromaching

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Internet on things

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IOT

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 What is Smart Manufacturing
Value Chain Networked-Based Manufacturing
EDI transaction
lot & quality
certifications
Business Mapping SAP information
Systems, ERP
Into operation

Customer
Supply Chain
Distribution Center
Smart
Factory
Tracking &
traceability
Dynamic plant configuration and readiness
Smart Grid
Dynamic product component/material configuration
Dynamic inventory minimization & management
 What is Additive Manufacturing?
 The process of joining materials to make objects from three-
dimensional (3D) model data, usually layer by layer
 Commonly known as “3D printing”
 Manufacturing components with virtually no geometric limitations or
tools.
 AM uses an additive process
 Design for manufacturing to manufacturing for design
 Distinguished from traditional subtractive machining techniques

727
2
Additive Manufacturing :Additive manufacturing is a process
that adds successive layers of material to create an object,
often referred to as 3D printing.

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Functional principle
 The system starts by applying a thin layer of the powder material to the
building platform.
 A powerful laser beam then fuses the powder at exactly the points
defined by the computer-generated component design data.
 Platform is then lowered and another layer of powder is applied.
 Once again the material is fused so as to bond with the layer below at
the predefined points. 5
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 ADVANTAGES
 Freedom of design
 Complexity for free
 Potential elimination of tooling
 Lightweight design
 Elimination of production steps

DISADVANTAGES
 Slow build rates
 High production costs
 Considerable effort required for application design
 Discontinuous production process
 Limited component size.
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 Applications
AM has been used across a diverse array of
industries, including;

 Automotive
 Aerospace
 Biomedical
Consumer goods and many others

https://www.youtube.com/watch?v=Vx0Z6Lpl
aMU

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 3D PRINTING

• 3D printing or additive manufacturing is a process of

making three dimensional solid objects from a digital file.
• The creation of a 3D printed object is achieved using
additive processes. In an additive process an object is
created by laying down successive layers of material until
the object is created. Each of these layers can be seen as a
thinly sliced horizontal cross-section of the eventual object.
• 3D printing is the opposite of subtractive manufacturing
which is cutting out / hollowing out a piece of metal or
plastic with for instance a milling machine.
• 3D printing enables you to produce complex shapes using
less material than traditional manufacturing methods.

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Steps in 3D printing

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Reconfigurable Manufacturing system(RMS)
• A reconfigurable manufacturing
system (RMS) is one designed at the outset
for rapid change in its structure, as well as its
hardware and software components, in order
to quickly adjust its production capacity and
functionality within a part family in response
to sudden market changes or intrinsic system
change

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 RMS Principles

 The RMS is designed for adjustable production resources to respond to

imminent needs, The RMS functionality is rapidly adaptable to the
production of new products.
 To enhance the speed of responsiveness of a manufacturing system, core
RMS characteristics should be embedded in the whole system as well as in
its components (mechanical, communications and controls).
 The RMS possesses hardware and software capabilities to cost-effectively
respond to unpredictable events — both external (market changes) and
intrinsic events (machine failure)
 The RMS is designed around a part family, with just enough customized
flexibility needed to produce all parts in that family.

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Characteristics of RMS

• Modularity: The compartmentalization of production functions and

requirements into operational units that can be manipulated between
alternate production schemes to achieve the optimal arrangement to fit
a given set of needs. In a reconfigurable manufacturing system, many
components are typically modular (e.g., machines, axes of motion,
controls, and tooling.)
• Integrability: the ability to integrate modules rapidly and precisely by a set
of mechanical, informational, and control interfaces that enable
integration and communication. At the machine level, axes of motions and
spindles can be integrated to form machines.
• Customization: to design system/machine flexibility just around a product
family, obtaining thereby customized-flexibility, as opposed to the general
flexibility of FMS/CNC.

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• Convertibility: the ability to easily transform the
functionality of existing systems, machines, and controls to
suit new production requirements. System convertibility may
have several levels.
• Scalability : the ability to easily change production capacity
by rearranging an existing manufacturing system and/or
changing the production capacity of reconfigurable stations.
• Diagnosability : the ability to automatically read the current
state of a system for detecting and diagnosing the root-cause
of output product defects, and subsequently correct
operational defects quickly.

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 Numerical Control (NC)
Defined
 NC (numerical control) machine tools are the
machine tool, of which the various functions
are controlled by : letters , numbers and
symbols.
 The NC machine tool runs on a program fed to
it; without human operator. The NC program
consist of a set of instruction or statement for
controlling the motion of the drives of the
machine tools as well as the motion of the
cutting tool.

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 Numerical Control [NC] Machines
 NC machine tools , one or more of the following function may be
automatic :

i. Starting and stopping of the machine tool spindle;

ii. Controlling the spindle speed;

iii. Positioning the tool at the desired location and guiding it along the desired
path by automatic control of the motion of slides;

iv. Controlling the feed rate; and

v. Changing the tools

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 Conventional vs. CNC machine
• Conventional machine
 eyes, hands, brain, skill

• CNC machine
Program Control unit Motor Motion

Measuring & Reflection Unit

No skill is required for operating CNC m/c .

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 Advantages of CNC
• Flexible, high accuracy
• Short production time
• Complex shapes can be manufactured
• Short setting time
• No skill requirement
• Short inspection time/ high quality product
• Low cost of production

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 Disadvantages of CNC
• High machine cost
• Complicated maintenance
• Skill & training are required for programming
and maintenance.
• Parts are imported from aboard.
• High tooling cost
• Temperature, humidity & dust must be
controlled.
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CNC [Computer Numerical Control]:

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• Input / Output Console : It is the unit through which part
program is fed to the CNC machine tool system and required
output is taken out. It basically consists of monitor and
Keyboard.

• Microprocessor : This controller takes input from Input /

Output device, Feedback from feedback unit and actuates the
drives as well as the tool of the machine tool.

• Memory : It consists of RAM & ROM. The RAM stores part

program, while ROM stores
the programs for machine control.

• Feedback unit : The feedback unit takes input from machine

tool and transfers it to control unit for necessary corrections.

• Machine tool : Machine tool is operated by the control unit.

• Interfaces : They are the connections

between the different components of the CNC
machine tool system.
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 Difference between NC and CNC
SN NC MACHINE TOOL CNC MACHINE TOOL
01 The part program is fed to the In CNC machine tool system, the
machine through the tapes or other program is fed to the machine through
such media. the computer.
02 In order to modify the program, The programs can be easily modified
with the help of computer
the tapes have to be changed.
03 In NC machine tool system, tape The microprocessor or minicomputer
reader is a part of machine control forms the machine control unit. The
unit. CNC machine does not need tape
reader.
04 System has no memory storage and It has memory storage ability, in which
each time it is run using the tape part program can be stored.

05 It can not import CAD files System can import CAD files and
convert it to part program.
06 It can not use feedback system The system can use feedback system.
07 They are not software driven. The system is software driven.
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Thank You all!

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