Introduction

1. Introduction Manufacturing is the act of making a products by hand or machine from raw materials. It seems to be a fundamental human activity, and like design, is an integral part of the rise of civilization. Selecting of appropriate materials and manufacturing processes is a critical part of the design process. In particular, the manufacturing process must be economical and capable of producing the geometric surfaces (see below) and other features embodied in the design.

2. Process Classification • There are seven fundamental classifications for manufacturing processes • Molding or casting • Forming and shearing • Machining (material removal, includes chip-making process, chipless processes, and heat cutting) • Heat treatment • Finishing (painting, anti-corrosion coatings, etc.) • Assembly • Inspection • Molding • Molding is usually used for plastics, casting for metals. There are eight major molding processes • Hot compression molding • Transfer molding • Injection molding • Extrusion • Laminating • Vacuum forming • Cold molding

3. Molding Casting

6. Forming Operations

7. Molding Processes (1)

8. Molding Processes (2)

9. Sand Casting Techniques for Producing Various Shapes

10. Design for Efficient Sand Casting

11. Other Casting Processes

12. Common Forming and Shearing Processes

13. Extrusion Processes

14. Hot Forming Processes - Forging

15. Other Hot Forming Processes - Forging

16. Basic Machining Processes • Machining • Physical removal of unwanted material in the form of chips (usually), leaving a part with the desired geometry and surface finish. • Can produce complex shapes, very good dimensional control, and good surface finishes. • Tends to be wasteful of material, and expensive in terms of labor and capital.

17. Operations and Machines for Machining Internal Cylindrical Surfaces

18. Operations and Machines for Machining Flat Surfaces

19. Operations and Machines for Machining External Cylindrical Surfaces