MANUFACTURING PROCESSES

Lecturer: Assistant Prof. Dr. Bora ŞENER

Faculty of Mechanical Engineering
Machine Materials and Manufacturing Technologies Division
Bora SENER’s web page:
http://avesis.yildiz.edu.tr/borasen/

E-Mail: [email protected]
Research Interests:
• Metal Forming
• Deep Drawing
• Finite Element Analysis
• Optimization
 My Expertise Area
▪ Deep Drawing Simulations/Finite Element Method

▪ Parameter Optimization in Metal Forming

 OVERVIEW
• Course Objectives:
- Giving information about technology, production and
manufacturing concepts

• Course Content:
- Introduction to manufacturing processes and concepts
- Fundamentals of casting and casting processes
- Fundamentals of plastic deformation and forming processes
- Fundamentals of machining and machining processes
- Fundamentals of joining and joining processes
 COURSE LEARNING OUTCOMES
1. Having fundamental knowledge about technology, production and
manufacturing concepts

2. Analyzing basic manufacturing problems and interpret the results

3. Gaining ability about determining method and process for a manufactured

good

4. Gaining basic ability to determine the appropriate manufacturing process for a

material

5. Having basic knowledge to follow current and contemporary topics in

manufacturing methods and manufacturing technologies
 Course Activities and Evaluation
• Midterm Exam (2)
• Final Exam (1)
Activity Amount Grade Percentage

Midterm Exam 1 30 %

Midterm Exam 1 30 %

Final Exam 1 40 %
 WEEKLY PROGRAM AND SUBJECTS
Weeks Subjects
1 Introduction to manufacturing processes and basic concepts
2 Principles of casting technique and classification of casting methods
3 Sand casting method (pattern, mold, core materials)
4 Permanent mold casting, die casting, centrifugal casting
5 Principles of metal forming, hot-cold working and Forging
6 Rolling, Extrusion
7 Wire drawing, Sheet metal forming
8 Midterm Exam 1
9 Introduction to machining, chip formation, relative motions
10 Turning, Shaping, Drilling
11 Milling, Grinding
12 Introduction to joining processes, Oxyfuel gas welding
13 Resistance welding, Electric arc welding
14 Shielded metal arc welding (MIG/MAG, TIG), Submerged arc welding
15 Final Exam
 REFERENCES and RECOMMENDED BOOKS
❑ Groover, M.P. Principles of Modern Manufacturing, John Wiley, 2010

❑ John, A.S. Introduction to Manufacturing Processes, McGrawHill

❑ Lyndon, E., Mark, E. Manufacturing with Materials, Butterworth Scientific

❑ Kalpakjan S., Schmid S. Manufacturing Processes for Engineering Materials

❑ Gültekin, N. Kaynak Tekniği

❑ Yurci, M.E. Talaşsız Şekil Verme, YTÜ Yayınları

 WHAT IS MANUFACTURING?
▪ Manufacturing is the process of converting raw materials into products

▪ The word manufacturing is derived from the Latin manu factus, meaning
made by hand

▪ Manufacturing is a complex activity involving a wide variety of resources

- Product design - Purchasing - Marketing
- Process planning - Support services - Sales
- Materials - Production control - Customer service
 WHAT IS PRODUCTION?
Production is creating utility or increase the value of economic
goods
 HISTORY OF MANUFACTURING
• Prior to 19th century, it was carried out by artisans
Handmade products

• Modern mechanization began in Industrial Revolution The use of machinery

The use of steam power Increase human productivity
Provide mechanised version
Reduce the need of human power in manufacturing processes
 HISTORY OF MANUFACTURING
• In the 19th century, assembly line production was discovered
• Henry Ford carried over this idea into automobile production

Ford assembly line (production of model T)

• Reducing of the production time

• Decreasing cost of production
• Decreasing the number of accidents in the work places
• Increasing the gains in productivity
 HISTORY OF MANUFACTURING
• More automated production

• Automation mainly brings different devices and interfaces like mechanics,

hydraulics, pneumatics and electronics

• Industrial automation begins with PLCs (programmable logic controllers)

 MANUFACTURING TODAY
COMPUTER INTEGRATED MANUFACTURING (CIM)
❑ Computer Numerical Control (CNC): Controlling the movements of machine components by coded instructions

❑ Industrial robots

❑ Automated handling of materials Handling of materials by computers

* from storage to machines
* from machine to machine
 MANUFACTURING TODAY
FLEXIBLE MANUFACTURING SYSTEMS (FMS)
FMS Workstations + Industrial robot (several CNC Machines) + Material-Handling System + Storage System

▪ Highly automated system

▪ Involve one or more processes and operations
▪ Improve product quality
▪ Manufacture more product more quickly
▪ Reduce time for product completion
 MANUFACTURING TODAY
JUST-IN-TIME PRODUCTION
This concept was applied in Toyota to eliminate waste of materials, machines, manpower etc.
❑ Parts are produced to order, and the production is matched with demand (Pull system)
❑ Stockless production, demand scheduling
❑ Parts are inspected by the workers as they are manufactured
 MANUFACTURING TODAY
LEAN MANUFACTURING
Lean manufacturing is a methodology that focuses on minimizing waste.
This methodology considers
❑ The efficiency and effectiveness of various operations
❑ The possible dispensability of operations and managers
❑ The efficiency of the machinery and equipment in the operation

Advantages:
❖ Continually improving and profitability of the company
❖ Its results do not necessary cutting back on resources
❖ Removing all waste from the operations
 MANUFACTURING PROCESSES
Manufacturing processes consist of four main processes
❑ Casting

❑ Metal Forming

❑ Machining

❑ Joining
 CASTING
❑ Casting process involve the use of molten material, usually metal.

❑ This molten material is then poured into a mold cavity that takes the form of the finished part

❑ The molten material then cools until it solidifies into the desired shape
 CASTING
Casting Processes

Expendable Mold Permanent Mold

Sand Casting Permanent-mold Casting

Shell-Mold Casting Pressure Casting

Ceramic Mold Casting Centrifugal Casting

Lost Foam Casting

Investment Casting Squeeze Casting

 METAL FORMING

Bulk Deformation Processes Sheet Metal Forming Processes

Forging Shearing

Rolling Bending

Extrusion Deep Drawing

Drawing Spinning
 MACHINING AND FINISHING OPERATIONS

Machining Finishing
• Turning Grinding

• Milling
Honing
• Drilling

• Planing Lapping

• Broaching
 JOINING PROCESSES
Welding Adhesive bonding and Mechanical Fastening
Fusion Welding Processes Brazing, Riveting and Soldering

Solid-State Welding Processes

Resistance Welding Processes

 WELDING PROCESSES
Fusion-Welding Processes
Oxyfuel Gas Welding

Shielded Metal-Arc Welding

Gas Metal-Arc Welding

Flux-Cored Arc Welding

Gas Tungsten-Arc Welding

 WELDING PROCESSES
Solid-State Welding Processes

Cold Welding

Friction Welding
 WELDING PROCESSES
Resistance Welding Processes
Resistance Spot Welding

Resistance Seam Welding