gtu b. e. mech sem v mp ii topic 1 introduction 3hrs

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Manufacturing Processes - II

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Page 1: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes - II

Page 2: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes – II Structure & Syllabus:

GUJARAT TECHNOLOGICAL UNIVERSITYGUJARAT TECHNOLOGICAL UNIVERSITY

DEGREE IN MECHANICAL ENGINEERINGDEGREE IN MECHANICAL ENGINEERING

PROPOSED TEACHING SCHEMEPROPOSED TEACHING SCHEME

Semester - VSemester - V

Page 3: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

GUJARAT TECHNOLOGICAL UNIVERSITYB. E. SEMESTER: V

MECHANICAL ENGINEERINGSubject Name: Manufacturing Processes - II

Page 4: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes – II Syllabus

Page 5: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes – II Syllabus BooksTerm Work:Term Work:

The term work shall be based on the topics mentioned above.The term work shall be based on the topics mentioned above.

Practical / Oral:Practical / Oral:

The candidate shall be examined on the basis of term-work.The candidate shall be examined on the basis of term-work.

Reference Books:Reference Books:

1. Production technology, by R.K. Jain, Khanna publishers.1. Production technology, by R.K. Jain, Khanna publishers.

2. Production Technology by P.C. Sharma S Chand & Co Ltd.2. Production Technology by P.C. Sharma S Chand & Co Ltd.

3. Manufacturing Technology Vol-II, By P.N. Rao, Tata McGraw 3. Manufacturing Technology Vol-II, By P.N. Rao, Tata McGraw Hill.Hill.

4. Manufacturing Engg. & Technology By S. Kalpakajain, 4. Manufacturing Engg. & Technology By S. Kalpakajain, PHI/Pearson.PHI/Pearson.

5. Welding technology, by O. P. Khanna, Dhanpat Rai publishers.5. Welding technology, by O. P. Khanna, Dhanpat Rai publishers.

Page 6: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Introduction to Manufacturing:

• Importance of manufacturing, Importance of manufacturing,

• Economic and technological definition of manufacturing, Economic and technological definition of manufacturing,

• Classification of manufacturing processes, Classification of manufacturing processes,

• Selection of Manufacturing process.Selection of Manufacturing process.

Page 7: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing definition & importance:DefinitionDefinition

Manufacturing includes all steps necessary to convert raw Manufacturing includes all steps necessary to convert raw materials, components, or parts into finished goods that meet materials, components, or parts into finished goods that meet a customer's expectations or specifications. Manufacturing a customer's expectations or specifications. Manufacturing commonly employs a man-machine setup with division of commonly employs a man-machine setup with division of labor in a large scale production.labor in a large scale production.

Manufacturing (from Latin manu factura , "making by hand") is Manufacturing (from Latin manu factura , "making by hand") is the use of tools and labor to make things for use or sale. the use of tools and labor to make things for use or sale.

The term may refer to a range of human activity, from The term may refer to a range of human activity, from handicraft to high tech, but is most commonly applied to handicraft to high tech, but is most commonly applied to industrial production, in which raw materials are transformed industrial production, in which raw materials are transformed into finished goods on a large scale.into finished goods on a large scale.

Page 8: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing definition & importance (Cont..):

Manufacturing takes place under all types of economic Manufacturing takes place under all types of economic systems. systems.

• In a free market economy, manufacturing is usually directed In a free market economy, manufacturing is usually directed toward the mass production of products for sale to consumers toward the mass production of products for sale to consumers at a profit. at a profit.

• In a collectivist economy, manufacturing is more frequently In a collectivist economy, manufacturing is more frequently directed by the state to supply a centrally planned economy. directed by the state to supply a centrally planned economy.

• In free market economies, manufacturing occurs under some In free market economies, manufacturing occurs under some degree of government regulation.degree of government regulation.

EconomicsEconomics is the social science that is concerned with  is the social science that is concerned with the production, distribution, consumption of goods and  the production, distribution, consumption of goods and  services. services. 

Page 9: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing definition & importance (Cont..):

The importance of manufacturing in Indian economy:The importance of manufacturing in Indian economy:

Production of goods in large quantities after processing Production of goods in large quantities after processing from raw materials to more valuable products is called from raw materials to more valuable products is called manufacturing. For example: paper is manufactured manufacturing. For example: paper is manufactured from wood, sugar from sugarcane, iron and steel from iron from wood, sugar from sugarcane, iron and steel from iron ore and aluminum from bauxite. ore and aluminum from bauxite.

i. Manufacturing industries help in modernizing agriculture, i. Manufacturing industries help in modernizing agriculture, which forms the backbone of our economy.which forms the backbone of our economy.

ii. Manufacturing industries also reduce the heavy dependence ii. Manufacturing industries also reduce the heavy dependence of people on agricultural income by providing them jobs in of people on agricultural income by providing them jobs in secondary and tertiary sectors.secondary and tertiary sectors.

iii. Industrial development is a precondition for eradication of iii. Industrial development is a precondition for eradication of unemployment and poverty from our country.unemployment and poverty from our country.

Page 10: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing definition & importance (Cont..):The importance of manufacturing in Indian economy (Cont..):The importance of manufacturing in Indian economy (Cont..):

iv. It brings down regional disparities by establishing iv. It brings down regional disparities by establishing industries in tribal and backward areas.industries in tribal and backward areas.

v. Export of manufactured goods expands trade & commerce, v. Export of manufactured goods expands trade & commerce, and brings in much needed foreign exchange.and brings in much needed foreign exchange.

vi. Countries that transform their raw materials into a wide vi. Countries that transform their raw materials into a wide variety of furnished goods of higher value are prosperous.variety of furnished goods of higher value are prosperous.

vii. Industry sector contributes 27 % of GDP out of it vii. Industry sector contributes 27 % of GDP out of it manufacturing accounts for 17 %.manufacturing accounts for 17 %.

Page 11: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes Structure:

• In industrial production, many different processes or In industrial production, many different processes or manufacturing methods are used. manufacturing methods are used.

• To be able to select the technically and economically best To be able to select the technically and economically best manufacturing sequence for a product, it is necessary to manufacturing sequence for a product, it is necessary to have a have a broad fundamental knowledge of the possibilities broad fundamental knowledge of the possibilities and limitations of the various manufacturing processes, and limitations of the various manufacturing processes, including work materials used and geometries, surface including work materials used and geometries, surface finishes & tolerances required. finishes & tolerances required.

Here, the individual processes are not considered in detail, Here, the individual processes are not considered in detail, but a general picture of the common structure on which all but a general picture of the common structure on which all processes are based is introduced. processes are based is introduced.

Page 12: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes Structure:

The term process can in general be defined as a change in The term process can in general be defined as a change in the properties of an object, including geometry, hardness, the properties of an object, including geometry, hardness, state, information content (form data), and so on. state, information content (form data), and so on.

To produce any change in property, three essential agents To produce any change in property, three essential agents must be available: (1) material, (2) energy, and (3) must be available: (1) material, (2) energy, and (3) information. information.

Depending on the main purpose of the process, it is either a Depending on the main purpose of the process, it is either a material process, an energy process, or an information material process, an energy process, or an information process. process.

In this topic, only material processes will be considered, In this topic, only material processes will be considered, especially those producing geometrical changes or changes especially those producing geometrical changes or changes in material properties, or both. in material properties, or both.

Page 13: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes Structure:

The general process model can be illustrated as shown in The general process model can be illustrated as shown in Fig. The model shows that a material process can be Fig. The model shows that a material process can be described by the associated flow system: material flow, described by the associated flow system: material flow, energy flow, and information flow. energy flow, and information flow.

Figure: The general process model. (i) indicates inputs and (o) outputs. Figure: The general process model. (i) indicates inputs and (o) outputs.

Material flow can be divided into three main types, as shown in Fig. Material flow can be divided into three main types, as shown in Fig. in next slide.in next slide.

• • Through flow, corresponding to mass-conserving processes. Through flow, corresponding to mass-conserving processes.

• • Diverging flow, corresponding to mass-reducing processes. Diverging flow, corresponding to mass-reducing processes.

• • Converging flow, corresponding to assembly or joining processes. Converging flow, corresponding to assembly or joining processes.

Page 14: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes Structure: Material Flow Material Flow

FIGURE : The three main types of FIGURE : The three main types of material flow: material flow:

(a) mass-conserving processes (dM = 0); (a) mass-conserving processes (dM = 0);

(b) mass-reducing processes (dM < 0); (b) mass-reducing processes (dM < 0);

(c) assembly or mass-increasing processes (c) assembly or mass-increasing processes (dM > 0). (dM > 0).

Here M means mass of material, i: input, and Here M means mass of material, i: input, and o: output. o: output.

The numbers 1 and 2 refer to the number of The numbers 1 and 2 refer to the number of material elements. material elements.

Depending on the process, Auxiliary flow of Depending on the process, Auxiliary flow of material may be necessary, e.g. Lubricants, material may be necessary, e.g. Lubricants, cooling fluids, filler metals, flux. cooling fluids, filler metals, flux.

Page 15: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes Structure:

If the processes are evaluated:If the processes are evaluated:• Most processes aiming to at a change in materials properties is Most processes aiming to at a change in materials properties is

without change in geometry are without change in geometry are mass conserving ones. mass conserving ones.

• • The energy flow associated with a process can be characterized The energy flow associated with a process can be characterized as energy supply, energy transmission to work piece as energy supply, energy transmission to work piece

• • Information flow includes shape and property information. A Information flow includes shape and property information. A certain geometry for a certain material can be characterized as certain geometry for a certain material can be characterized as shape information for the material. shape information for the material.

• • In a geometry-changing process, shape-change information is In a geometry-changing process, shape-change information is impressed on the material so that the final shape information is impressed on the material so that the final shape information is equal to the SUM of the initial shape info and the shape-change equal to the SUM of the initial shape info and the shape-change info impressed by the process. info impressed by the process.

Page 16: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes Structure: • The shape-change information is created by an The shape-change information is created by an

INTERACTION between tool/ die and a pattern of INTERACTION between tool/ die and a pattern of MOVEMENT for work material and the tool/die. MOVEMENT for work material and the tool/die.

• • This means that a geometry-changing process is characterized by This means that a geometry-changing process is characterized by a material flow on which, by means of an energy flow, the a material flow on which, by means of an energy flow, the shape-change info corresponding to the info flow is impressed. shape-change info corresponding to the info flow is impressed.

• • Impressing a change in geometry on material can be carried out Impressing a change in geometry on material can be carried out in one or more steps: in one or more steps:

• • Io = Ii + ΔIp1 + Δ Ip2 +………+ Δ Ipn where Io: desired Io = Ii + ΔIp1 + Δ Ip2 +………+ Δ Ipn where Io: desired geometry; Ii: initial shape info; and ΔIpn is the shape change geometry; Ii: initial shape info; and ΔIpn is the shape change info for single process. info for single process.

••

Page 17: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes Structure:

• Similarly, the property info flow, hardness, strength, Similarly, the property info flow, hardness, strength, involves the sum of the properties of the initial material and involves the sum of the properties of the initial material and the changes in properties produced by various processes. the changes in properties produced by various processes.

• • The proper interaction between these 3 fundamental flow The proper interaction between these 3 fundamental flow systems, yielding to the desired component, is governed by systems, yielding to the desired component, is governed by the the control info, which includes knowledge of forces, control info, which includes knowledge of forces, power, friction and lubrication, cutting data, etc.. power, friction and lubrication, cutting data, etc..

• • A complete model of manufacturing process is shown in A complete model of manufacturing process is shown in figure. figure.

Page 18: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Manufacturing Processes Structure:

Material ProcessMaterial Process

Figure: Complete model of a material Process. Figure: Complete model of a material Process.

Page 19: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

The Morphological Structure of Material Processes:

The Morphological structure of material processes is the form & The Morphological structure of material processes is the form & structure of material processes. structure of material processes.

• All manufacturing processes can be All manufacturing processes can be described by a general described by a general morphological model built up from few fundamental morphological model built up from few fundamental elements related to the 3 flow systems. elements related to the 3 flow systems.

• • By combining these elements, a process morphology is By combining these elements, a process morphology is obtained from which all manufacturing processes can be obtained from which all manufacturing processes can be deduced. deduced.

••

Page 20: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

The Morphological Structure of Material Processes:

Each of these elements can have different “values”, as in fig. 1.4. by Each of these elements can have different “values”, as in fig. 1.4. by choosing a value from each column the fundamental basis for a choosing a value from each column the fundamental basis for a material process is obtained. material process is obtained.

Some of the combinations are physically impossible but, in general, Some of the combinations are physically impossible but, in general, the model contains all the basic ingredients necessary to establish a the model contains all the basic ingredients necessary to establish a process. process.

Page 21: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

The Morphological Structure of Material Processes:

The fundamental elements in this morphological model The fundamental elements in this morphological model are: are:

• • Material flow: Material flow: - basic process - state of material - type of - basic process - state of material - type of flow [process type] flow [process type]

• • Energy flow: Energy flow: - tool/die [energy supply, transfer medium] - - tool/die [energy supply, transfer medium] - equipment [energy characteristics, type of energy] equipment [energy characteristics, type of energy]

• • Information flow: Information flow: - - surface creation principles - pattern of movement for material & tool/die]

Page 22: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

The Morphological Structure of Material Processes:

Page 23: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Basic Processes:

Basic processes are defined as those processes that create changes in the geometry and/or the properties of the materials. The basic processes are characterized by the nature of their interaction with the material.

Page 24: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Basic Processes (Cont..):Schematic illustration of the Material Flow System Schematic illustration of the Material Flow System

Page 25: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Basic Processes (Cont..):A manufacturing process normally consists of a series of basic A manufacturing process normally consists of a series of basic processes, which constitute the structure of the material flow. processes, which constitute the structure of the material flow.

Any series of basic processes can be divided into three typical Any series of basic processes can be divided into three typical phases: phases:

Phase 1, which consists of the basic processes that bring the Phase 1, which consists of the basic processes that bring the material into a suitable state-geometry and/or properties material into a suitable state-geometry and/or properties (heating, melting, sawing, cropping, etc. i-for the primary (heating, melting, sawing, cropping, etc. i-for the primary change in geometry and/or properties. change in geometry and/or properties.

Phase 2, which consists of the basic processes that create the Phase 2, which consists of the basic processes that create the desired geometry and/or change in properties.desired geometry and/or change in properties.

Phase 3, which consists of the basic processes that bring the Phase 3, which consists of the basic processes that bring the component into the specified end state (solidification, cooling, component into the specified end state (solidification, cooling, deburring, etc.) deburring, etc.)

Page 26: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Basic Processes (Cont..):

• This division is illustrated in Fig. shown in earlier slide, This division is illustrated in Fig. shown in earlier slide, where the basic processes associated with phase 2 are called where the basic processes associated with phase 2 are called the primary basic processes (according to the primary goal).the primary basic processes (according to the primary goal).

• The basic processes associated with phases 1 and 3 are The basic processes associated with phases 1 and 3 are called secondary basic processes. The structure shown in called secondary basic processes. The structure shown in Fig. shown in earlier slide is very useful when analyzing Fig. shown in earlier slide is very useful when analyzing and designing manufacturing processes. and designing manufacturing processes.

• • The bThe basic processes can be divided into three main asic processes can be divided into three main categories, as shown in Table [next slide]. categories, as shown in Table [next slide].

• Each of these categories is characterized by the nature of the Each of these categories is characterized by the nature of the interaction with the work material. interaction with the work material.

Page 27: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Basic Processes (Cont..):

• When the main objective for a process has been established, When the main objective for a process has been established, relevant series of primary and secondary basic processes relevant series of primary and secondary basic processes can be found. can be found. Here the actual type of material has a Here the actual type of material has a significant influence, since the materials react differently significant influence, since the materials react differently when subjected to mechanical, thermal, or chemical actions. when subjected to mechanical, thermal, or chemical actions.

• • If only processes aiming at geometrical changes are If only processes aiming at geometrical changes are considered, the number of possible primary basic processes considered, the number of possible primary basic processes (phase 2 in Fig. in previous slide) is reduced to those shown (phase 2 in Fig. in previous slide) is reduced to those shown in Table [second table]. in Table [second table].

• • It is the primary basic process and the way in which it is It is the primary basic process and the way in which it is established that determines the types and number of established that determines the types and number of secondary basic processes required. secondary basic processes required.

Page 28: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Main categories of basic processes:

Page 29: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Primary Basic Processes used in Material Processes that change Geometry:

• Selection of flow or process type depends on the requirements of material, geometry, surface, tolerance, number, price and other factors.

Page 30: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Classification of technological Material Processes used in Shaping Materials:

Page 31: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Examples of Manufacturing Processes:

Page 32: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Examples of Manufacturing Processes:

Page 33: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Summary of Classification of Manufacturing Processes:

1. Classification as per the main purpose of the process: 1. Classification as per the main purpose of the process:

AA material process, material process,

An energy process, or An energy process, or

An information process. An information process.

2. Classification as per the mass modifying process:2. Classification as per the mass modifying process:

Mass-conserving processes (dM = 0)Mass-conserving processes (dM = 0)

Mass-reducing processes (dM < 0)Mass-reducing processes (dM < 0)

Assembly or mass-increasing processes (dM > 0). Assembly or mass-increasing processes (dM > 0).

Page 34: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Summary of Classification of Manufacturing Processes:

3. Classification as 3. Classification as characterized by the nature of their interaction with the material.

Basic pre-processing processes (Secondary processes)

Basic primary processes

Basic post-processes (Secondary processes).

4. Classification as per the flow system:4. Classification as per the flow system:

Material flow type processes, Material flow type processes,

Energy flow type processes, Energy flow type processes,

Information flow type processes. Information flow type processes.

Page 35: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Summary of Classification of Manufacturing Processes:

5. Classification as per category of basic processes:5. Classification as per category of basic processes:

Mechanical basic processes,Mechanical basic processes,

Thermal basic processes,Thermal basic processes,

Chemical basic processes.Chemical basic processes.

Page 36: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs
Page 37: GTU B. E. Mech Sem v MP II Topic 1 Introduction 3Hrs

Topic 1 Completed

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