Not applicable

1. IPE 111: Manufacturing
Processes-I
Dr. M. Muhshin Aziz Khan
Associate Professor

2. IPE-111 MANUFACTURING PROCESSES ‑ I
3 Hrs/week, 3.00 credits
Classification of manufacturing processes;
Machining Processes: types, definition, concepts and applications:
Turning, Drilling, Shaping, Milling, Knurling; Thread cutting, Grinding
Reaming, Boring, Broaching, etc.;
Forming Processes: Classification, Molding: design of molds, riser, runner,
gate spur and core, cost analysis; Casting: casting processes for ferrous and
non ferrous metals, sand, die, centrifugal, slush, plaster mould, loam mould,
precision investment casting etc., casting defects;
Joining Processes: Classification: soldering, brazing, welding, conventional
welding processes, Gas, Arc, TIG, MIG, Termite, resistance, Friction, Electro
slag etc;
Syllabus

3. Reference Books
1. Fundamentals of Modern Manufacturing Materials, Processes, and
Systems
Mikell P. Groover
Fourth Edition
John Willy & Sons, Inc.
2. Introduction to Basic manufacturing Processes and Workshop
Technology
Rajender Singh
New Age International P. Limited

4. Definition of Manufacturing
manufacturemanusfactus
Latin words
+
= Made by hand

5. In modern context: Manufacturing
Involves making or processing a raw
material into a finished product,
 by using various processes,
 by making use of machines, tools and
even computers

6. Duality
Technical Activity Economic Activity
Added value

7. Manufacturing as a Technical Activity
Processed
PartStarting
material
Scrap and
waste
Manufacturing Process
Machinery
Power
Labor
Tools

8. Manufacturing as an Economic Activity
Processed
Part
Starting
material
Material in
Processing
$
Value added $$
Manufacturing Process
$$$

9. Requirements for a Manufacturing
Activity
Manufacturing process and its interaction with the five Ms:

10. Primary vs. Secondary
Manufacturing
 Primary processes convert raw
materials into standard stock
 bauxite ore  aluminum
 petroleum  polyester resin
 wood  lumber
 Secondary processes convert
standard stock into usable parts
 aluminum rod  fuel valve
 polyester resin  medical tubing
 lumber  furniture

11.  Products are often made by putting many parts together
 Ball pen: Body, refill, barrel, cap, and refill operating
mechanism.
 Car: More than 20000 parts are put together
 Machine Tool: More than 24000 parts are assembled
together.
Manufactured Products
 Consumer goods: products purchased directly by consumers
 Example: cars, personal computers, TVs, tires, and rackets etc.
 Capital goods: products purchased by companies to produce
goods and/or provide services.
Example: aircraft, PC, buses.

12. Secondary Manufacturing
Processes
 Casting and Molding
 Forming
 Separating / Material Removal
 Conditioning
 Assembling / Joining
 Finishing

13. Secondary Processes
 Casting and Molding processes hold liquid or semi-liquid
materials in a mold cavity until the material hardens.
 Very intricated shapes can be manufactured.
 Range of size of the products manufactured by the
casting process is unlimited.
 Forming processes use a shaping device and suitable
force, pressure, stress or their combination to cause
permanent deformation of a material to give it a required
shape and size.
 No material is removed and wasted, but is only
displaced and deformed.
 Separating processes remove unwanted material from a
given workpiece to get a desired size, shape and surface
finish.
 Material is removed from unwanted region of the raw
material.

14. Secondary Processes
 Conditioning processes use heat, chemical
reactions, or mechanical means to change the
properties of a material
 Assembly processes join two or more parts or
assemblies to produce the required size and
shape of the product.
 Parts can be joined through mechanical,
thermal, or chemical means
 Joint can be permanent, semi-permanents and
temporary
 Finishing processes modify the surface of a
material to improve appearance or performance

15. Manufacturing Work Flow
 Custom
 Intermittent / Batch
 Continuous

16. Custom manufacturing
 Job shop production (low volume of
production and variety of work)
 Limited number of products built to
customer specifications.
 Requires highly skilled labor.
 Least efficient (but most flexible) form of
manufacturing

17. Batch manufacturing
 Parts made in lots of 10 – 1,000
 Orders of the product may be repetitive or
nonrepetitive.
 General-purpose machinery (table saw,
vertical mill) is used, often run by hand
 Setup times per part decreases as batches get
larger

18. “Continuous” manufacturing
 Same product made repeatedly by
dedicated machinery (custom built
machine – NOT CUSTOM built product)
 Automation becomes more cost-effective
 Some processes still require batch staging
 Tooling and setup are large initial expenses

19. Industries can be classified as primary, secondary, and
tertiary.
Primary industries, cultivate and exploit natural resources,
such as agriculture and mining.
Secondary industries, take outputs of the primary
industries and convert them into consumer and capital
goods.
Tertiary industries, constitute the service sector of the
economy.
Manufacturing Industries

20. Manufacturing operations can be divided into two basic types:
(1) Processing operations, and
(2) Assembly operations.
Processing operations-
Transforms a work material from one state of completion to
a more advanced state that is closer to the final desired
product.
It adds value by changing the geometry, properties, or
appearance of the starting material.
Assembly operation-
Joins two or more components to create a new entity, called
an assembly, subassembly, or some other specific terms, e.g.,
in the joining process, a welded assembly is called a weldment.
Classification of Manufacturing Processes

21. Fig.: Classification of Manufacturing
Processes.

22. Manufacturing in the Economy

23. Manufacturing in the Economy
 The reason for manufacturing's stability is that there is a synergy
between manufacturing and other sectors.
 Manufacturing generates most of the economy's productivity and
technology,
 while other sectors such as services generate the largest share
of new employment.
 The productivity generated by manufacturing
 raises the wages of workers employed in all sectors.
 boost activity in other sectors.
 As these sectors become more successful, they, in turn, create
more demand for manufactured goods and its high-paying jobs.
http://
www.vpmep.org/mfgstats.htm

24. Contributions to Economic Growth,
1992-1997
Manufacturing
also contributes
to technological
advances, with
significant
investments in
R&D
http://www.vpmep.org/mfgstats.htm