Manufacturing Processes – I Introduction

[Virtual Presenter] This is a training video on manufacturing processes. The presentation will cover the basics of manufacturing, including different techniques and processes commonly used in the industry. As an Assistant Professor in the Mechanical Engineering Department, I am enthusiastic about sharing my expertise and assisting you in gaining a deeper understanding of this subject. So, let's begin our exploration of the world of manufacturing processes together. Let's get started!.

[Audio] This presentation will discuss the course contents of Manufacturing Processes, which covers various techniques used in different industries. These include Sand Casting, Die Casting, Metal Forming, Welding Processes, and Fabrication of Plastics. The first process to be explored is Sand Casting, followed by Die Casting, which is known for its efficiency in producing complex shapes. Metal Forming involves shaping metal with mechanical force, and we will also cover welding processes such as Arc Welding, Gas Welding, and Resistance Welding. Lastly, we will look into the fabrication of plastics, an important aspect in modern manufacturing. This course provides a comprehensive understanding of these processes, their applications, and their pros and cons. We hope this presentation will be informative and beneficial for your knowledge in Manufacturing Processes. Let's move on to the next slide..

[Audio] Today, we will be discussing the manufacturing processes involved in creating metallic and plastic parts. The course is divided into two types of credit hours: 3 for theory and 1 for practical. On this slide, you can see the different CLOs (Course Learning Outcomes) represented by S. No. 2, 3, 4, and 5. Our first CLO focuses on a detailed discussion of the various metal forming processes and their characteristics. The second CLO emphasizes the various manufacturing processes and their output, with a particular focus on sustainable production. We will be implementing the concept of sustainable manufacturing to promote efficiency and eco-friendly production. Following this, we will perform machining operations on a job piece according to guidelines to ensure a safe and efficient manufacturing process. Additionally, we will adhere to the necessary safety protocols outlined in the Health, Safety, and Environment guidelines, in line with our PLO (Program Learning Outcome) to provide a safe working environment. Our PLOs for this course include PLO-1, PLO-2, PLO-7, and PLO-6, encompassing cognitive, psychomotor, and affective skills. The course aims to develop critical thinking, technical expertise, and ethical values in our students. As we continue with our presentation, we encourage you to stay engaged and take notes on the various manufacturing processes being discussed..

[Audio] In this presentation, we will be discussing the fundamentals of manufacturing processes. The main question we will be addressing is: What is manufacturing? Simply put, manufacturing involves using physical and chemical processes to modify materials, their properties, and appearance in order to create parts or products for a specific purpose. This process involves a series of operations, each bringing the material closer to its desired final state. The diagram shows the different components of a manufacturing process, including the starting material, the manufacturing process itself, and the final product. It is important to keep in mind that this process can also generate scrap and waste material. As a professor in the Mechanical Engineering department, it is my duty to educate you on various manufacturing techniques and methods, so that you can become well-versed in this field. Let's now move on to the next slide and continue our exploration of manufacturing processes..

[Audio] We will now shift our focus to slide number five, where we will explore the purpose of manufacturing. Essentially, manufacturing involves transforming raw materials into more valuable items through processing and assembly. This involves various methods to increase the monetary worth of the starting material. The material goes through multiple stages of processing until it becomes a completed, processed part. I am your assistant professor, Erum Khan, for this course in the mechanical engineering department. Let's delve into the world of manufacturing and its different processes on the upcoming slides..

[Audio] We will be discussing the topic of Manufacturing Processes and Production Systems. Manufacturing processes are a crucial component in any manufacturing system. This system consists of men, machine tools, and material-moving systems, all working together to achieve specific production goals. A manufacturing system can be defined as a collection of resources, including people, money, equipment, and supplies, used to fabricate or manufacture products. These systems are organized in a specific sequence to produce components or end products. The production system supports the manufacturing system and includes various functions such as manpower, financial resources, equipment, supplies, market, and management. The production system is responsible for tasks such as scheduling, planning, execution, maintaining quality control, and inventory. Both the manufacturing system and the production system work together to achieve successful and efficient production. It is crucial for these systems to work together to meet market demands and customer expectations. Understanding these concepts is essential for anyone working in the manufacturing industry. This concludes our discussion for slide number six out of twenty-six. Thank you for your attention and stay tuned for more valuable insights in our presentation. This is Erum Khan, Assistant Professor in the Mechanical Engineering Department, signing off..

[Audio] This is the seventh slide of our presentation on Manufacturing Processes. We will be discussing the different types of industries involved in this process. There are three main types of industries in the manufacturing sector: primary, secondary, and tertiary industries. Primary industries involve the cultivation and exploitation of natural resources, such as agriculture, mining, and petroleum, to provide raw materials for production. Secondary industries take these raw materials and convert them into consumer and capital goods, including activities such as manufacturing, construction, and power utilities. Examples of secondary industries include aerospace, automotive, electronics, glass, paper, and textile production. The final type of industry in the manufacturing sector is tertiary industries, which make up the service sector of the economy. These industries provide services such as banking, education, hotels, and healthcare. While they do not directly participate in the manufacturing process, they play a crucial role in supporting and sustaining the overall economy. As an assistant professor in the Mechanical Engineering Department, I have witnessed the importance of all three types of industries in the manufacturing sector. They work together to ensure the availability of raw materials, the production of goods, and the provision of services to consumers. This slide has given a better understanding of the different types of industries involved in the manufacturing process. Stay tuned for more information on Manufacturing Processes..

[Audio] This training video will focus on different manufacturing processes. The products created by manufacturing industries can be categorized into two classes: consumer goods and capital goods. Consumer goods are items that are directly bought by consumers, while capital goods are purchases made by companies for production and service purposes. These goods play a vital role in our daily lives and the functioning of businesses. As a mechanical engineer, it is crucial to have an understanding of manufacturing processes and their impact on the production of these goods. Let's continue with the presentation and learn more about these processes. The rest of the slides will provide more information on this topic..

[Audio] Slide number 9 of our presentation on Manufacturing Processes discusses the key aspect of production - product variety. Product variety refers to the different designs or types of products produced in a manufacturing plant. The level of product variety is an important consideration when analyzing a factory's operations. A high product variety means a large number of product types are made, including different designs, colors, sizes, or completely different products. For example, Pak Suzuki produces various car models such as Liana, Baleno, and Swift, while Unilever offers a diverse product line including brands like Lux, Lifebuoy, and Dove. However, it is important to note that a high product variety typically has an inverse correlation with production quantity. In other words, as product variety increases, the production quantity for each product decreases. This is because the production process becomes more complex and time-consuming, requiring different resources, machines, and methods for each product. For instance, at Pak Suzuki, the production quantity for each car model would be lower compared to a factory that only produces one type of car. The same is true for Unilever, where the production quantity for each brand would be lower due to the diverse range of products. In conclusion, product variety plays a critical role in manufacturing processes as it directly affects a factory's productivity and efficiency. Companies must carefully manage their product variety to ensure optimal output. Our presentation will now continue with slide number 10..

[Audio] In this segment, we will be discussing the various production facilities utilized in the manufacturing industry. The first facility is the Job Shop, which specializes in custom and specialized products, such as space capsules and aircrafts. The equipment used is multi-purpose, with a highly skilled workforce. Moving on, Batch Production is employed for medium quantities of products, where a batch of one product is made before switching to the next item. This allows for efficient production of a variety of products. Mass Production, on the other hand, is used for high quantity production, where the system is dedicated to manufacturing a single item. Each of these facilities offers unique advantages and is chosen based on the type and quantity of products being produced. As a professional in the field, it is imperative to have a thorough understanding of and effectively utilize these facilities for a successful manufacturing process. This concludes our segment on production facilities. We will now move on to the next slide..

[Audio] Slide number 11 out of 26 in the MANUFACTURING PROCESSES - I presentation discusses the various materials used in manufacturing. These materials are categorized into four main groups: metals, ceramics, polymers, and composites. Each group has its own unique properties and characteristics that influence the manufacturing process. Metals are widely used in manufacturing due to their strength, durability, and ability to withstand high temperatures. Examples of commonly used metals in manufacturing include steel, aluminum, and iron. Ceramics are known for their high resistance to heat, corrosion, and wear. They are often used in products that require high strength and hardness, such as construction materials and turbine blades. Polymers are lightweight and flexible, making them suitable for a wide range of products. They can be found in items such as plastic bottles and car parts, and are used in processes like injection molding and extrusion. Composites combine two or more of the aforementioned materials, such as metal-ceramic, ceramic-polymer, and metal-polymer composites. These combinations create stronger and more versatile products. The differences in chemical, mechanical, and physical properties of these materials have a significant impact on the manufacturing process. The choice of material dictates the type of process used to produce a product, and it is important to understand these differences in order to achieve the desired result. In future slides, we will further explore the specific techniques and methods used for each of these materials in the manufacturing process. Thank you for attending this informative presentation and stay tuned for more insights in the coming slides..

[Audio] We will now discuss the different materials used in manufacturing processes. Metals, such as alloys made up of two or more elements, are commonly used. Non-ferrous metals like Y A1, Cu, and Ni are known for their durability and resistance to corrosion. Ferrous metals like steel and cast iron, containing carbon and other elements, are widely used in industrial tools and equipment production. Ceramics, consisting of metallic or semi-metallic elements and non-metallic elements, can be categorized as crystalline or glass. Examples of ceramics used in manufacturing include clay for building materials, silica for glass production, and carbides like silicon and nitrides for cutting tools. These materials are essential for grinding abrasives in manufacturing. Thank you for listening and we hope you have gained a better understanding of the materials involved in manufacturing processes..

[Audio] In this slide, we will be discussing the different types of materials used in manufacturing, specifically focusing on polymers. Polymers are compounds formed of repeating structural units, making them suitable for use in a variety of manufacturing processes. There are three main types of polymers: thermoplastics, thermosetting, and elastomers. Thermoplastics can be melted and reshaped without any change in their molecular structure, allowing them to be used in a wide range of applications. Some common thermoplastics include polyethylene, polystyrene, and polyvinylchloride. On the other hand, thermosetting polymers chemically transform into a rigid structure upon cooling, offering high strength and durability. Examples of thermosetting polymers include phenolics, amino resins, and epoxies. Elastomers, on the other hand, exhibit elastic behavior and are ideal for applications that require flexibility. Common examples include rubber and polyurethane. As a manufacturing professional, it is important to understand the properties and applications of each type of polymer in order to select the most suitable material for your specific manufacturing process. We will continue discussing other materials in the next slide.".

[Audio] In this training video on manufacturing processes, we will be discussing the use of composites. Composites are made up of two or more phases that are processed separately and then bonded together to achieve superior properties. These composites come in both natural and synthetic forms, such as wood and metal matrix composites, ceramic matrix composites, and polymer matrix composites. Other common composites in manufacturing include fiberglass, fiber reinforced plastic, and tungsten carbide in a cobalt-binder for cemented carbide cutting tools. As we have seen, composites offer a wide range of possibilities in manufacturing and greatly enhance the properties of the materials used. Stay tuned for the rest of our presentation on manufacturing processes..

[Audio] Slide number 15 of our presentation on Manufacturing Processes will cover the important properties of materials commonly used in the industry. We will discuss mechanical properties such as strength, toughness, ductility, brittleness, hardness, elasticity, plasticity, fatigue, and creep. Strength refers to a material's ability to withstand external forces without breaking or deforming, while toughness is the ability to resist fracture or deformation under extreme conditions. Ductility measures a material's ability to be stretched without breaking, and brittleness refers to its tendency to fracture under stress. We will also discuss the behavior of materials under loading, including tension, compression, bending, torsion, and shear. Tension is the force that pulls a material apart, while compression squeezes it together. Bending is the deformation caused by a force applied perpendicular to the material's axis, while torsion is twisting and shear is stress from opposing parallel forces. Next, we will explore the physical properties of materials, such as density, specific heat, thermal expansion, thermal conductivity, melting point, and electrical and magnetic properties. Density is the measure of a material's mass per unit volume, while specific heat is the energy required to raise its temperature. Thermal expansion is the tendency for a material to contract or expand with temperature changes, and thermal conductivity is its ability to transfer heat. Melting point is the temperature at which a material changes from a solid to a liquid state, and electrical and magnetic properties refer to its conduction of electricity and response to magnetic fields. Lastly, we will discuss the chemical properties of materials, which include oxidation, corrosion, degradation, toxicity, and flammability. Oxidation is the reaction with oxygen that can cause breakdown or deterioration of a material, while corrosion is its degradation due to the environment. Degradation is the breakdown of a material..

[Audio] This presentation discusses the importance of processing operations in manufacturing and their role in achieving the desired final product. These operations involve various techniques and methods to alter the initial work material and improve its physical properties. There are three main categories of processing operations: shape-producing, property-enhancing, and surface processing. Shape-producing processes involve changing the geometry of the material, while property-enhancing processes focus on improving its physical properties without altering its shape. Surface processing involves cleaning, treating, coating, or depositing material onto the exterior surface of the work. These operations are crucial in controlling and manipulating the material to meet required standards and produce high-quality products. In the next slide, we will discuss the different types of shape-producing processes in more detail..

[Audio] In this section of our presentation on manufacturing processes, we will be discussing shape producing processes. These processes play a crucial role in the production of various metal products used in our daily lives. The first category is casting processes, also known as solidification processes. These processes involve pouring heated liquid into a mold cavity, where it solidifies to take on the shape of the mold and create the desired product. There are various types of casting processes, all following a similar basic procedure of pouring the molten metal into a mold, filling the mold cavity, and then removing the part by separating along the mold's parting line. The mold is typically made of sand, and the final product will be trimmed to give a clean finish. This is known as solid casting, one of the most common casting processes. With a better understanding of casting processes, we will now move on to the other three categories of shape producing processes. Stay tuned for the next slide as we continue our discussion..

[Audio] The following presentation will focus on casting processes or solidification processes. These processes involve transforming liquid materials into solid objects. There are various methods used in this type of manufacturing, with three main types being expendable mold, multiple-use mold, and fabrication of plastics. Expendable mold casting is cost-effective and suitable for small-scale productions, as it is used for one-time use and then discarded. Casting involves pouring molten material into a mold and allowing it to solidify, making it suitable for producing complex shapes and commonly used in foundries for metal objects. The multiple-use mold, as the name suggests, can be used multiple times and is commonly used in mass production. Sand casting involves pouring molten metal into a sand mold and allows for larger and more intricate designs. Die casting, on the other hand, involves injecting molten metal into a metal mold under high pressure to produce high-quality and precise metal parts. Casting processes can also be used for plastic fabrication, allowing for the production of a wide range of plastic products. As we have seen, casting processes offer a variety of methods for transforming liquid materials into solid objects, making it an essential part of the manufacturing process..

[Audio] Today we will be discussing slide number 19, titled 'Shape Producing Processes - Four Main Categories,' which introduces us to the first category, deformation processes. These processes use the ductility or plasticity of certain materials, primarily metals, to achieve the desired shape through the use of tools and dies that apply external forces. Examples of deformation processes include chamber, ram, extruded cross section, forging, and trimming of excess material. In the accompanying diagram, a starting billet is placed in the die and an external force is applied to shape it. This process may involve trimming excess material, seen in the 'flash' area. This concludes our discussion of slide number 19..

[Audio] Slide number 20 discusses deformation processes in the manufacturing industry, which involve changing the shape and size of materials through the application of external force. There are two main types of deformation processes: hot forming and cold forming. Hot forming involves heating the material to a high temperature, making it more malleable, while cold forming is done at room temperature for a stronger and more precise end product. Common techniques include rolling, forging, extrusion, wire drawing, and sheet metal forming, which are used to create various products such as pipes, cylinders, and sheets. As an Assistant Professor in the Mechanical Engineering Department, I have extensive knowledge on these processes and their applications in the industry. The next slide will delve further into each technique and its advantages in the manufacturing process. Let's continue our exploration of manufacturing processes..

[Audio] In this slide, we will be discussing the first category of Shape Producing Processes, Material Removal Processes. These processes involve removing excess material from a solid workpiece to achieve the desired geometry. Material Removal Processes are one of the four main categories of Shape Producing Processes. Turning is one example of a Material Removal Process, where a rotating tool is used to remove excess material and create a specific shape on the workpiece. Another example is drilling, where a rotating drill bit creates a hole in the workpiece. Milling is also a Material Removal Process, where a rotating cutter is used to shape the workpiece by removing material. In this process, the workpiece is fed into the rotating cutter. A single point cutting tool is commonly used in Material Removal Processes, such as turning and milling. This concludes our discussion on Material Removal Processes, the first category in Shape Producing Processes. Stay tuned for our next slide on the second category, Deformation Processes..

[Audio] This training video will discuss material removal processes in manufacturing. These processes use mechanical techniques to shape and finish a workpiece. The traditional method is mechanical machining, which involves cutting and shaping with tools like a lathe or drill. Nontraditional methods include electrical discharge machining, laser beam machining, and chemical etching for more complex shapes and difficult materials. Mechanical machining is used for common products such as gears and holes. Chemical techniques, like etching and electro-polishing, are used for precise and intricate parts like microelectronics. Nontraditional methods, such as EDM and laser beam machining, are used for hard and delicate materials. Material removal processes are crucial in manufacturing and play a vital role in creating products. Thank you for watching and stay tuned for more slides in this presentation..

[Audio] Slide number 23 of our presentation focuses on the four main categories of shape producing processes in manufacturing. These processes are used to create a specific shape or form for products. One category is consolidation or assembly, which involves joining separate parts together to form a new entity. There are various types of assembly operations, such as joining processes and mechanical assembly. Joining processes create permanent joints using methods like welding, brazing, soldering, riveting, and adhesive bonding - commonly used for strong and durable joints. Mechanical assembly, on the other hand, uses mechanical methods such as screws, bolts, nuts, threaded fasteners, press fitting, expansion, and shrink fits. This type of assembly is often used when parts need to be easily disassembled and reassembled. In summary, consolidation or assembly processes play a crucial role in creating desired product shapes. Thank you for listening, and let's continue to our next slide..

[Audio] Today, we will discuss assembly operations, which are a crucial aspect of the manufacturing process. These operations involve joining different parts together through processes such as welding, brazing, soldering, consolidation, and riveting. Each method has its own techniques and benefits, and it is important to choose the right one for the specific application. There are also other methods, such as adhesive bonding and mechanical joining, which use pressure or interference to create a secure bond. Fusion welding, on the other hand, involves melting and fusing two pieces of metal together without a separate filler metal. As we have seen, there are various joining methods used in manufacturing, and it is important to understand their differences and choose the appropriate one. I hope this overview of assembly operations has been helpful, and I look forward to discussing the remaining two slides with you..

[Audio] Slide number 25 of our presentation focuses on property-enhancing processes and their significance in the manufacturing industry. These processes aim to improve the mechanical or physical properties of the work material, without changing its shape intentionally. Examples include heat treatment of metals and glasses, as well as sintering of powdered metals and ceramics. These processes are essential for enhancing the strength, durability, and overall quality of the final product. As an Mechanical Engineering assistant professor, I have witnessed the positive impact of these processes in the manufacturing world. They not only enhance material properties, but also contribute to efficient and cost-effective production. In conclusion, property-enhancing processes are vital for achieving high quality and reliable products, and can lead to success in the competitive market of manufacturing..

[Audio] This is the final slide, number 26, of our presentation on manufacturing processes. In this section, we will be discussing surface processing, which is an important step in creating high-quality end products. Surface processing is a crucial part of the manufacturing process as it prepares the workpart's surface for further processing. There are three main categories of surface processing: cleaning, surface treatment, and coating and thin film deposition. To begin, cleaning involves using chemical and mechanical methods to remove dirt, oil, and other contaminants from the surface. This is essential in ensuring the quality and integrity of the final product. Next, surface treatments use mechanical methods like sand blasting and physical processes like diffusion to enhance the surface of the workpart, resulting in improved mechanical properties and a desirable surface finish. Lastly, coating and thin film deposition involve applying a layer of material to the surface of the workpart, such as electroplating, painting, and chemical vapor deposition. These methods can improve the surface properties and protect against corrosion and wear. As we come to the end of our presentation, I, Erum Khan, Assistant Professor in the Mechanical Engineering Department, would like to thank you for your attention. I hope this presentation has given you valuable insights into the world of manufacturing processes. Thank you for listening..