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ME 322
MANUFACTURING
PROCESSES
Wg Cdr (R) Dr Fareed Ahmad, PhD (Industrial Engg)
 Course Outline
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 Title:
 ME-322: Manufacturing Processes
 Books
 Fundamentals of Modern Manufacturing, Mikell P. Groover
 Materials and Processes in Manufacturing, Paul Degarmo

 Grading
Quizzes (6) 15%
Assignments (Pres+ Report) 5%
Mid Semester (1) 30%
Final 50%
 Tentative Plan
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Topic Week/
Lecture
Introduction to Manufacturing processes and materials 1-2
Metal Casting 3-4
 Foundry, sand casting, Die casting, permanent mold casting etc.
Forming and Shaping of Plastic and Composite
 Compression/Transfer/Injection molding etc. 5-6
Forming and shaping of metals (Bulk & Sheet metal)
 Rolling, Forging, Extrusion, Forming, Drawing, etc. 7-9
Metal Cutting
 Lathe, Milling, Shaper, Planner, Drilling, Tools, Grinding, Broaching 10-11
etc.
Joining Processes and Equipment
 Temp/Perm joining, Welding, Soldering, Brazing, tec. 12-15
Quality, Measurement and Inspection
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 Course Learning Outcomes
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S.No Outcomes Level of PLO

Learning
1 Describe the manufacturing industry, manufacturing processes and C1 1
properties of materials required for manufacturing

2 Comprehend and distinguish among different machining processes, C2 2

the metal casting, forming and shaping processes

3 Know and choose different assembly processes with respect to the C2 2

industrial / process constraints.
4 Predict the part quality through Measurement and Inspection C3 2

5 Understand the impact of traditional manufacturing techniques on C2 7

environment and the progression towards sustainable
manufacturing.
6 Demonstrate affectively a topic of own interest which deals with the A3 9
latest development in the field of machine tool, manufacturing
processes, research etc.
 Presentation+ Report
(5 Marks)
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 Any Modern/Recent Manufacturing Process/Research/Innovation/discovery

etc.
 Shaping, machining, forming, casting, RP etc..
 3-4 Students (according to attendance sheet) each week
 1students (Max 5min / 7mins)
 Presentation
 Introduction
 Basic principle and operation (with figures)
 Advantage/disadvantage w.r.t. its equivalent processes and its uses
 Effect on environment
 Report (Week 15)
 Same topic as presentation
 A4 page (Brief, intro, detail, importance, impact, conclusion)
 Examples: CNC Milling machine
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 Examples: CMM utility
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 Examples: Forming operation
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 And Many More
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 Welding
 Forging
 Casting
 RP Machine
 Manufacturing System
 Assembly Line (Part/Process Oriented)
 Laser manufacturing, cutting etc.
etc…
 Course Contents
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 Metal Casting
 Foundry, sand casting, Die casting, permanent mold casting etc.
 Forming and Shaping of Plastic
 Compression/Transfer/Injection molding etc.
 Forming and shaping of metals
 Rolling, Forging, Extrusion, Forming, Drawing, etc.
 Metal Cutting
 Lathe, Milling, Shaper, Planner, Drilling, Tools, Grinding etc.
 Joining Processes and Equipments
 Temp/Perm joining, Welding, Soldering, Brazing, tec.
 Quality, Measurement and Inspection
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INTRODUCTION
Ch. 1
 INTRODUCTION
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 What is Manufacturing?
 Materials in Manufacturing
 Manufacturing Processes
 Production Systems
 What is Manufacturing?
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 Manufacture (Latin words)

 manus (hand) and factus (make)
 “made by hand”
 “Made by hand” accurately describes?
 English word “manufacture” was first coined around 1567 A.D.
 Modern manufacturing
 Accomplished by automated and computer-controlled machinery that is
manually supervised
 Can be viewed as
 Technical process
 Economical process
 Manufacturing as a technical process
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 Application of physical and chemical processes to alter the geometry,

properties, and/or appearance of a given material to make parts or
products
 Manufacturing also includes assembling of multiple parts to make products
 Manufacturing is almost always carried out as a sequence of operations
 Manufacturing as a economic process
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 Manufacturing is the transformation of materials into items

of greater value by means of one or more processing
and/or assembly operations
 Manufacturing adds value to the material by changing its
shape or properties, or by combining it with other materials
that have been similarly altered
 Manufacturing / Production
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 Product quantity vs variety?

 Examples?
 Manufacturing Capability
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 A manufacturing plant consists of a set of processes

and systems (people, equipment, procedures)
 designed to transform a certain limited range of materials
into products of increased value
 Manufacturing capability
 Technical and physical limitations of a manufacturing firm
and its plants
 Manufacturing capability includes:
 Technological processing capability
 Physical product limitations
 Production capacity
 Technological Processing Capability
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 The available set of manufacturing processes in the plant

 Certain manufacturing processes are suited to certain materials
 By specializing in certain processes, the plant is also specializing in
certain material types
 Also includes the expertise of the plant personnel
 Physical Product Limitations
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 There are size and weight limitations on the parts or

products that can be made in the plant
 Product size and weight affect:
 Production equipment
 Material handling equipment

 The production and material handling equipment, and plant

size must be planned for products that lie within a certain
size and weight range
 Production Capacity
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 The production quantity that can be produced in a given

time period (e.g., month or year)
 Commonly called plant capacity, or production capacity,
 The maximum rate of production that a plant can achieve under
assumed operating conditions
 Operating conditions refer to number of shifts per week, hours per
shift, direct labor manning levels in the plant, and so on
 Usually measured in terms of output units, such as tons of
steel or number of cars produced by the plant
 Materials in Manufacturing
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 Most engineering materials can be classified

into one of three basic categories:
1. Metals
2. Ceramics
3. Polymers
 Materials in Manufacturing
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 Metals
 Usually alloys, which are composed of two or more elements,
at least one of which is metallic
 Ceramics
 compounds containing metallic/semi-metallic and nonmetallic
elements. Typical nonmetallic elements are oxygen, nitrogen,
and carbon. Ceramics are typically hard and chemically non-
reactive. Cement, refractory bricks, glass etc are few
examples
 Polymers
 Polymers comprise of large molecules composed of repeating
chemical subunits known as monomers. Examples of synthetic
polymers include nylon, polyethylene, polyester, Teflon, and
epoxy
Materials in Manufacturing
 In addition to the three basic categories, there
are: Composites
 Non-homogeneous mixtures of the other three basic
types rather than a unique category
 Manufacturing Processes
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 Processing operations
 Transform a work material from one state of completion
to a more advanced state
 Consist of operations that change the geometry,
properties, or appearance of the starting material

 Assembly operations
 Join two or more components in order to create a new
entity
 Processing Operations
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 Shaping operations
 Alter the geometry of the starting work material

 Property-enhancing operations
 Improve physical properties of the material without
changing its shape

 Surface processing operations

 Performed to clean, treat, coat, or deposit
material onto the exterior surface of the work
 Shaping Processes – Four Categories
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 Solidification processes
 starting material is a heated liquid or semi-fluid that solidifies to form
part geometry
 Particulate processing
 Starting material is a powder, and the powders are formed into desired
geometry and then sintered to harden
 Deformation processes
 Starting material is a ductile solid that is deformed

 Material removal processes

 Starting material is a solid (ductile or brittle), from which material is
removed so resulting part has desired geometry
 Solidification Processes
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 Starting material is heated sufficiently to transform it

into a liquid or highly plastic state
 Examples: Casting for metals, molding for plastics
 Particulate Processing
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 Starting materials are powders of metals or ceramics

 Usually involves pressing and sintering, in which powders are
first squeezed in a die cavity and then heated to bond the
individual particles
 Deformation Processes
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 Starting work part is shaped by application of forces

that exceed the yield strength of the material
 Examples: (a) forging, (b) extrusion
 Material Removal Processes
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 Excess material removed from the starting work piece so what

remains is the desired geometry
 Examples: machining such as turning, drilling, and milling; also
grinding and nontraditional processes

It is desirable to minimize waste and scrap in part shaping

 Assembly Operations
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 Two or more separate parts are joined to form a new

entity
 Temporary Joining
 screws, bolts, nuts, other threaded fasteners; press
fitting
 Permanent Joining
 Welding, Soldering(filler temp<450), Brazing (filler
temp>450) etc. In welding the base material is heated
to melting point. In soldering base material is not
heated, whereas in brazing base material is heated,
but below melting point.
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 Production Systems
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 The people, equipment, and procedures designed for

the combination of materials and processes that
constitute a firm's manufacturing operations
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MECHANICAL PROPERTIES
OF MATERIALS
Ch. 3
 Mechanical Properties in
Design and Manufacturing
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 Mechanical properties determine a material’s

behavior when subjected to mechanical stresses
 Properties include elastic modulus, ductility,
hardness, and various measures of strength
 MECHANICAL PROPERTIES
OF MATERIALS
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 Stress-Strain Relationships
 Hardness
 Effect of Temperature on Properties
 Fluid Properties
 Stress-Strain Relationships
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 Three types of static stresses to which materials can

be subjected:
1. Tensile - tend to stretch the material
2. Compressive - tend to squeeze it
3. Shear - tend to cause adjacent portions of material to
slide against each other
 Stress-strain curve
 basic relationship that describes mechanical properties for
all three types
 Stress-Strain Relationships
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 Yield point Y can be identified by the

change in slope at the upper end of
the linear region
 Y = a strength property
 Other names for yield point = yield
strength, yield stress, and elastic limit
 The stress corresponds to the
maximum load the object supports is
refer to as the tensile strength TS or
ultimate tensile strength
 Ability of a material to plastically
strain without fracture is called
DUCTILITY

Typical engineering stress-strain plot

in a tensile test of a metal
 Two Regions of Stress-Strain Curve
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 Elastic region
Hooke's Law : e = E ɛ
 Plastic region
 After yielding of the material
 The stress-strain relationship is no longer guided by Hooke's
Law
 As load is increased beyond Y, elongation proceeds at a
much faster rate than before, causing the slope of the curve
to change dramatically
 Necking
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 True stress-strain curve
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True stress-strain curve for the previous engineering

stress-strain plot
 Strain Hardening in Stress-Strain Curve
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 In the engineering stress-strain curve, the stress was

based on an incorrect area value
 True stress increases continuously in the plastic region
 It means that the metal is becoming stronger as strain
increases
 This is the property called strain hardening, a relationship
b/w true stress and true strain
  K n
 K is strength coefficient, equal to true stress at strain=1, n is
strain hardening exponent,
 Brittle Materials
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 Hard brittle materials (e.g., ceramics) possess

elasticity but little or no plasticity
 Often tested by a bending test (also called flexure
test)
 Brittle materials do not flex
 They deform elastically until fracture
 stress-strain curve (compression)
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 stress-strain curve (Shear)
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 Hardness
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 Resistance to permanent indentation

 Good hardness generally means material is resistant
to scratching and wear
 Most tooling used in manufacturing must be hard for
scratch and wear resistance
 Effect of Temperature on Properties
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Hot Hardness
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THE END