Introduction to Manufacturing Processes 2/5/2025
Course
Course Title: Manufacturing Processes
Introduction to Code: IPDC0102
Manufacturing Credits 4: 3 1 0
Syllabus
Course outcomes
CO1: Understanding the fundamental concepts of manufacturing
processes
CO2: Analysing the material properties for specific applications
CO3: Recommend appropriate part manufacturing processes when
provided a set of functional requirements and product development
constraints.
CO4: Applying manufacturing processes and tools for typical
applications in the industries.
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Introduction to Manufacturing Processes 2/5/2025
Manufacturing Process
Books The process of turning raw material into a
“Manufacturing Science” by Ghosh A and Mallick A K
The book basically relies upon manufacturing properties of various materials. Various manufacturing processes like
machining, joining, forming, casting are nicely explained in the book.
finished product
“Manufacturing Technology: Foundry, Forming and Welding” by Rao P N
This book contains new welding processes like ultrasonic welding, laser welding, vacuum casting, riser simulation,
explosive forming, rolling defects and many other topics. There are many discussion sessions on no bake moulding,
A sequence of operations and processes
plaster moulding, pit moulding. Extensive coverage is also done on brazing, unconventional metal forming
processes, casting defects, plastic materials and properties. designed to create a specific product
“Manufacturing Process for Engineering Materials” by KALPAKJAIN
This book provides a detailed overview on the manufacturing process for engineering materials. It gives a balanced
coverage of the fundamentals of materials and processes. It outlines an analytical approach and describes various
applications in manufacturing engineering. It enables the reader to be able to properly assess the capabilities,
limitations and potential of manufacturing processes and their competitive aspects.
“Manufacturing Processes” by S K Sharma and Savita Sharma
This book provides a comprehensive overview on manufacturing processes. It deals with the fundamental concepts of
materials & metallurgy, foundry, metal working, and much more. It talks about welding techniques, pattern making & carpentry,
industrial safety, metal cutting, and other machine tools. It describes the non-conventional machining techniques and quality
control methods.
“Workshop technology” by Hajra Choudhary
“Workshop technology” by B.S. Raghuwanshi
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Basic Manufacturing Processes Casting and Foundry Processes
• Primary Processes: In one step raw materials are transformed
(i) Casting and Foundry into a desirable shape
(ii) Forming or Metalworking Parts require finishing processes
Excess material is recyclable
• Secondary Processes:
(i) Machining
(ii) Joining and Assembly
• Heat treatment processes
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Introduction to Manufacturing Processes 2/5/2025
Basic Casting Process Forming and Metalworking Processes
• A mold is created – A cavity that holds the molten Utilizes material that has been cast
material in a desired shape until it is solidified
Modify the shape, size, and physical
• Material is heated to a specified temperature properties of the material
• Molten material is poured into a mold cavity Hot and cold forming
• Molten material solidifies into the shape of the
cavity
• Casting or mold is removed
• Casting is cleaned, finished, and inspected
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Forming and Metalworking Processes Forming and Metalworking Processes
Extrusion – Material is compressed and forced
Rolling – Material passes through a series of through a die to produce a uniformed cross section
rollers, reducing its thickness with each pass
Forging – Material is shaped by the controlled
application of force (blacksmith)
Wire, rod, and tube drawing – Material is pulled
through a die to produce a uniformed cross section
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Introduction to Manufacturing Processes 2/5/2025
Forming and Metalworking Processes Manufacturing Processes: Forming and Shaping
Manufacturing Processes: Machining
Machining Processes
Controlled removal of material from a part to
create a specific shape or surface finish
Cutting tool is used
Movement must exist between the part and
cutting element
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Introduction to Manufacturing Processes 2/5/2025
Machining Processes Machining Processes
• Machining categories: Turning Processes
–Cutting involves single-point or Lathes and turning centers
multipoint cutting tools, each with a Processes include: Cylindrical, taper,
clearly defined geometry. contour turning, facing, forming, necking,
–Abrasive processes, such as grinding. parting, boring, threading, and knurling
–Non traditional machining, utilizing
electrical, chemical, and optical sources
of energy.
©iStockphoto.com ©iStockphoto.com
Machining Processes Machining Processes
Milling Processes Milling Processes
Operations that create Mills – Vertical and horizontal
flat or curved surfaces Processes include: Surfacing, shaping,
by progressively forming, slotting, T-slotting, angle, straddle,
removing material dovetailing, and slab milling
Cutting tools rotate as
the work piece is
secured and fed into the
tool
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Introduction to Manufacturing Processes 2/5/2025
Machining Processes Machining Processes
Drilling Process Drilling Processes
Operations that create holes
Drilling and boring machines
Cutting tools rotate and are fed into
nonmoving secured work pieces Processes include: Drilling, counter drilling,
step drilling, boring, counter boring,
countersinking, reaming, spot facing, and
tapping
Machining Processes Machining Processes
Shearing Processes Shearing Processes
Operations that break unwanted material away Automated hole punch, squaring shear, and
from the part rotary cutter
A material is placed between a stationary and Processes include: Shearing, blanking, cutoff,
movable surface. The movable surface (blade, and parting; punching, perforating, and slotting;
die, or punch) applies a force to the part that notching, lancing, and trimming
shears away the unwanted material.
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Introduction to Manufacturing Processes 2/5/2025
Machining Processes Non-Conventional Machining
Abrasive Machining Processes
• Ultrasonic Machining (USM)
Operations in which small particles of materials • Water-Jet Machining & Abrasive-Jet
(abrasives) remove small chips of material upon Machining
contact
• Chemical Machining
• Electrochemical Machining (ECM)
• Electrical-Discharge Machining (EDM)
• High-Energy-Beam Machining
– Laser-beam machining (LBM)
– Electron-beam machining (EBM)
Conventional vs. Non-Conventional Heat Treating Processes
Machining Controlled heating and cooling of a material to
alter its properties while maintaining its shape
• Primary source of energy
– Conventional: mechanical. Properties include: Strength, toughness,
– Non- Conventional : electrical, chemical, machinability, wear resistance, and corrosion
optical resistance
90% of heat treating is preformed on steel and
• Primary method of material removal other ferrous metals
– Conventional: shearing
– Non- Conventional: does not use shearing
(e.g., abrasive water jet cutting uses Erosion)
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Introduction to Manufacturing Processes 2/5/2025
Manufacturing Processes: Joining
Joining and Assembly Processes
Mechanical Fastening:
Use physical force to hold parts together
Mechanical fasteners: Screws, bolts, nails,
rivets, cotter pins, retaining clips, and edge
design
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Joining and Assembly Processes Joining and Assembly Processes
Welding Adhesive bonding
Operations that use heat, pressure, or both Bonding of adjoining surfaces by filling the
to permanently join parts gap between each surface with a bonding
material
Gas, arc, resistance, solid state, stud, spot,
forge, and induction welding Glue, cement, thermoplastic, thermosetting,
and elastomers
©iStockphoto.com ©iStockphoto.com ©iStockphoto.com
©iStockphoto.com
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Introduction to Manufacturing Processes 2/5/2025
Joining and Assembly Processes
Soldering and Brazing
Operation in which metal surfaces are
bonded together by an alloy
Heated molten alloy flows between the
adjoining surfaces Thanks!
When the heat is removed, the molten
metal solidifies and the metal surfaces are
bonded
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