Manufacturing Processes: A Comprehensive Guide, Slides of Engineering Drawing and Graphics

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Engineering 11

Manufacturing

Processes

Select Manufacturing Processes

• Manufacturing process decisions
• Deformation processes
• Casting processes
• Sheet metalworking
• Polymer processing
• Machining
• Finishing
• Assembly
• Material-Compatibilities & Process-Capabilities
• Material costs, Tooling costs, Processing costs

Design for Manuf (DFM) Guidelines

• Keep Functional & Physical Characteristics as

SIMPLE as Possible

• Simple & Sturdy parts are Easier to Make, and

have higher reliability

• Design for the Lowest Cost Production

Method

• Critical for HI-VOLUME Parts

Design for Manuf (DFM) Guidelines

• Design for the Minimum Number for

Processing Steps

• Try ELIMINATE Steps thru Thoughtful Product

Design

• Specify Tolerances NO TIGHTER than

Actually Needed

• OverToleranced Design leads to Increased Cost

thru

• UnNeeded Processing Efforts
• “False Positive” Scrap

Part-Processing Sequence

• Secondary Process  add or remove

geometric features from the basic forms

alter the (“raw”) material’s basic shape or

form. E.g.,

• Machining of a brake drum

casting (flat surfaces)

• Drilling/punching of refrigerator

housings (sheet metal)

• Trimming of

injection molded part “flash”

Part-Processing Sequence

• Tertiary Process  surface treatments. e.g.,
  • Polishing
  • Painting
  • Heat-treating
  • Joining
  • Plating
  • Anodizing
  • Thin Film Coating

Cost Factors

• Influence of Special

Desired Features

• e.g., Threaded Inserts,

DoveTail Grooves

• Materials Availability
• Need for Special Tooling
• PostProcess Finish

Operations

• Special Handling

Equipment

• Special Inspection

Equipment

• Yield
  • i.e., Scrap Rate

Manuf Process Classifications

Extrusion Forging Rolling Bar drawing Wire drawing

Deformation

Centrifugal Die casting Investment Permanent mold Sand casting

Casting

Bending Blanking Drawing Punching Shearing Spinning

Sheet Metal

Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding

Polymer Processes

Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM

Machining

Anodizing Honing Painting Plating Polishing

Finishing

Automated Bonding Brazing Manual Riveting Soldering Welding

Assembly

Manufacturing Processes

Roll To Different Final Shape

slab

bloom

billet

sheet or coil

bar or rod

structural

ingot

Extrusion & Drawing

• Extrusion (^)  Drawing

Ram

OutPut Cross Sections

Extrusion Die

Billet

Pulling force

OutPut Cross Sections

Drawing Die

Billet

Casting Processes

• Sand Casting
• Die Casting
• Investment

(a.k.a. “Lost

Wax”)

Casting 

Machining Processes

Extrusion Forging Rolling Bar drawing Wire drawing

Deformation

Centrifugal Die casting Investment Permanent mold Sand casting

Casting

Bending Blanking Drawing Punching Shearing Spinning

Sheet Metal

Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding

Polymer Processes

Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM

Machining

Anodizing Honing Painting Plating Polishing

Finishing

Automated Bonding Brazing Manual Riveting Soldering Welding

Assembly

Manufacturing Processes

Assembly  Joining

Extrusion Forging Rolling Bar drawing Wire drawing

Deformation

Centrifugal Die casting Investment Permanent mold Sand casting

Casting

Bending Blanking Drawing Punching Shearing Spinning

Sheet Metal

Blow molding Casting Compression molding Extrusion Injection Molding Thermoforming Transfer molding

Polymer Processes

Boring Drilling Facing Grinding Milling Planing Turning Sawing ECM, EDM

Machining

Anodizing Honing Painting Plating Polishing

Finishing

Automated Bonding Brazing Manual Riveting Soldering Welding

Assembly

Manufacturing Processes

Gas Shielded Arc Welding

 MIG (Metal Inert Gas)

• a.k.a., Gas Metal Arc

Welding (GMAW)

• METAL Wire Electrode

CONSUMED

 TIG (Tungsten Inert Gas)

• a.k.a., Gas Tungsten Arc

Welding (GTAW)

• TUNGSTEN Electrode

NOT Consumed