Manufacturing

***Definition:
✧Manufacturing is an industrial activity that changes the form of raw material to create product. In other words
manufacturing encompasses design and fabrication of goods by means of various production methods and technique.

✧To be profitable an enterprise establishes a manufacturing system that facilities the flow of information to
coordinate input, processes and outputs.

✧The word manufacturing is derived from latin word manufactus or literally made by hand. The word production is
also used interchangeably with the word manufacturing.

✧Generally, higher the level of manufacturing in a country, the higher the standard of living of its people.

✧Manufactured products are also used to make other product.

Need of Manufacturing:
Everyday in the field of engineering there is an increasing necessity for components with greater strength,
superfine surface finish and intricate shapes. All this is possible due to the introduction of variety of new techniques and
processes, replacement and improvement of a large number of old processes, new and compact designs, better
accuracy in dimension, efficient and appropriate methods of production, automatic and numerical control systems and
greater mechanisation and optimal output.

Importance of manufacturing:
=>By manufacturing we may produce discrete products means individual parts or pieces of parts or we may produce
continuous products. Nuts, Bolt, Gears, Engine blocks are examples of discrete products. Metal or plastic sheet, wire,
hose and pipe are continuous products.
=>Manufacturing adds value to the product.

Economic and technological considerations in manufacturing:

=>The economic aspects of material selection are as important as the technological considerations of properties and
characteristics of material.
=> The cost and availability of raw and processed material and manufactured components are major concerns in
manufacturing. If raw or processed materials or manufactured components are not commercially available in the
desired shapes, dimensions and quantities, substitutes or additional processing will be required which can contribute to
product cost significantly. For example if we need a bar of certain diameter and it is not available.

Classification of manufacturing processes:

1. Primary manufacturing processes
2. Secondary manufacturing processes
3. Physical processes

1. Various primary manufacturing processes are

a) Casting b) Rolling c) Forging d) Drawing e) Squeezing f) Extruding g) Bending h) Shearing i) Spinning j) Piercing

2. Secondary processes are those processes that are carried out after primary operations. It can be classified into the
following three categories
 a) Machining processes b) Surface finishing processes c) Joining processes.

b) Machining processes :-Turning,Shaping,milling,drilling,grinding,treading,boring,soltting,planning,keyway

cutting, gear cutting, broaching, hobbing, knurling.

c) Surface finishing processes:-Honing,happing,buffing,superfinishing,sandblasting,shotblasting,polishing,

beltgrinding, metalspraying, electroplasting, tumpling, anodizing, phosphating, inorganiccoating, parkeriging, hot
dipping ,galvanizing, electropolishing.
d) Joining processes:- Commonly used metal joining processes are welding, soldering, brazing, rivetting,
screwing, fastening, coupling , pressing, sintering.

3. Physical processes:-These processes affect change in properties. Engineering components subjected to various
operations to provide certain specific properties and structural changes suitable for specific conditions of use.
The various processes used for structural changes on components are annealing, normalizing, hardening,
tempering, patenting, age-hardening, shot-peening, grain refining and homogenizing. The mechanical working of
metal apart from producing changes in shapes also produce structural changes and impart fibrous properties.
In fact cold working is the only process for increasing hardness and strength of non-ferrous materials, shotpeening
imparts fatigue resistance, tempering increases toughness, annealing increases machinability and hardness
increases wear resistance. Physical operations are also carried out to improve magnetic and electrical properties.
Production or manufacturing

Anodizing: Anodizing is an electrolytic passivation process. It is used to increase the thickness of natural oxide layer
on the surface of metal parts. Aluminium is anodized. Titanium, Magnesium, Zn are also anodized.

Parkerising: Parkerising is an electrochemical phosphate conversion coating process, protecting a steel surface from
corrosion and increasing its resistance to wear. This process cannot be used on non-ferrous metals such as aluminium,
brass, copper. It similarly cannot be applied to steel containing large amount of nickel or on stainless steel. Zinc
phosphating results in light to medium grey finish, manganese phosphating produces a medium to dark grey finish. Iron
Phosphating produces black or dark grey finish.

Sherardizing: Sherardizing is a method of galvanizing. It is also called vapour galvanising. Zinc evaporates and
diffuses into metal target object forming Zn-Fe phases by heating the object in an air tight container with Zn powder.
The temperature that the container reaches normally does not exceed the melting point of zinc.

***Factors affecting selection of manufacturing process:

The key factors for selection of manufacturing process for a product are

a) Nature of the product: If the product is discrete in nature then it can be produced by casting, forging,
machining. Example Gear blank, Gear Box, Bearing housing, Machine tool parts etc. produced by casting. If the
product is continuous in nature then it can be produced by drawing or extrusion type of forming processes.
Example seamless pipe, tube, wire

b) Volume of the product: If the volume of the product required is less then manual process or semiautomatic
process is sufficient, otherwise automatic process is opted. Again, when design of the product is changed, new
sample is manufactured by casting for trial which is more economic than produced by machining of old casting.

c) Material required: The process is also selected depending upon the choice of material. If compressive
strength is the main criteria then casting process is opted. If impact strength is the main criteria then product is
manufactured by forming from ductile metals. If the material required is plastic, then injection molding is the
selected process.

d) Part geometry: Depending upon the shape or contour of the product the process is selected. If the surface of
 the work is round, then turning process is applied to get the required shape and size. If surface of the work is
flat, then shaping or milling process is selected to get the desired shape and size. To cut gear teeth milling or
hobbing process is selected.

e) Surface finish: To get the smooth surface of the finished product, the surface finishing processes which are
used are lapping, honing, grinding, tumbling, fettling etc. To protect the surface of the product from atmospheric
contamination or to improve heat resistant feture some sort of coating are applied by nickel or chromium plating,
anodizing, galvanizing, parkerising etc.

f) Precision: To achieve close tolerance of the product dimension, NC or CNC machining process is selected,
otherwise conventional machining processes are selected.

Types of production:

Depending on quantity of production, Production is of three types

1. Job production
2. Batch production
3. Mass production

1. Job production: It comprises of an operator or a group of operators to work upon a single job and complete it
before proceeding to the next similar or different job. The production requirement in the job production system is
extremely low.

2. Batch production: When quantity of produced is less in number say 200 to 800 and similar parts with very little
variation in sizes and shapes are produced, the production is called Batch production.

3. Mass production:itinrolresproductionoflargenumberofidenticalproducts.Alargeamountofinstrumentisinfromed for

special purpose machine tools.

Manufacturing Engineering includes following activity

1. Process planning and process sheet preparation
2. Tool planning
3. Jigs & fixture designing
4. Product simplification andstandardization
5.Inspection & quality control
6.Mechanisation & Automation
a)Fixed automation b) Flexible automation

Reasons why should go for automation

1.Increased production
2. Reduced cost of labour
3. Improved quality
4. Reduced process inventory

5. Reduced mfg time