Basic Machine Basic Machine ProcessesProcessesCompetency D403.00Competency D403.00

Identify the basic Identify the basic concepts of the concepts of the

manufacturing processes.manufacturing processes.

Basic Machine ProcessesBasic Machine Processes

Objective D403.01Objective D403.01

Explain the concepts Explain the concepts of the of the

manufacturing manufacturing process.process.

ManufacturingManufacturing Arrived from the Latin word

“manu factus”, meaning “made by hand”.

Manufacturing is the process of converting raw materials into products.

WHY STUDYWHY STUDYMANUFACTURING PROCESSES?MANUFACTURING PROCESSES?

The designer and the drafter must have a working knowledge of the various processes that could produce a part in order to: lower cost and reduce production time.

Three Phases Of The Three Phases Of The

Manufacturing ProcessManufacturing Process

1. Product design.

2. Selection of materials.

3. Selection of production methods and techniques.

The information needed to produce a part, most often comes in the form of a:

Working Drawing

Three Main Stages Of The Three Main Stages Of The Production Of A Machined Part Production Of A Machined Part

Rough FormingCasting, Forging, Welding

FinishingDrilling, machining, surfacing

AssemblingThe assembly of parts

The Casting Process

First a pattern is made. Then a cavity is made by placing a pattern in wet

sand. Next molten metal is poured into the cavity of damp

sand.

The Casting Process

The rough casting is now ready for the machine shop. Holes are then bored and reamed. Top and bottom surfaces are machined Smaller holes will be drilled and counterbored. All corners on cast parts are fillets and rounds.

Rough

Casting

Machined

Finish

Forging Process

Forging is produced by using heavy mechanical presses or hammering heated bars of metal between dies.

Advantages of forging over sand casting are that forged parts are much stronger and less brittle.

Welding

Welding is the fusion or joining of two pieces of metal by means of heat, with or without the application of pressure.

Cast

Welded

ManufacturingManufacturing MaterialsMaterialsFall into three general categories:

1. Metal2. Plastic3. Inorganic materials

Metals are classified as:Metals are classified as:

Ferrous - contain iron and steel.

Nonferrous - do not have iron content (such as copper and aluminum).

Alloys - mixture of two or more metals.

Inorganic Materials Include:Inorganic Materials Include:

• Carbon and graphite - have low tensile strength (ability to be stretched).

• Ceramics are clay and glass materials. (resistant to heat, chemicals, & corrosion).

Heat-Treating:Heat-Treating:

Annealing – is the process generally used to soften metal by heating followed by slow cooling.

Hardening – requires heating and then rapid cooling in oil or water.

Plastics ProcessingThe plastics industry represents one of the major manufacturing segments.

Thermoplastic – becoming or remaining soft and moldable when subjected to heat.

Thermosetting – becoming permanently hard and unmoldable when once subjected to heat.

Typical Plastic Processing Operations Include:

Extrusion Blow Molding Injection Molding Thermoforming

ExtrudingExtruding

The process of producing shapes by forcing hot metal through a die that has and opening of the desired shape.

Blow Molding

Used in the production of bottles, automotive ductwork, hollow toy components, and door panels.

Injection Molding

Used to manufacture products such as housings for electronic implements, automotive components, food storage containers, and components for medical applications.

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Thermoforming

Used in the manufacturing of thin-walled packages for the food industry.

Manufactured primarily by injection molding.

CAD in Manufacturing

The process of developing a design drawing on a CAD system and producing it on a computerized machine is called CAD/CAM.

The process of converting the CAD drawing into a preprogrammed, coded instructions is called Computer Numerical Control (CNC).

The advantages of the (CNC) is, better production and control, increased productivity, decreased labor and lower production costs.

The Machinist Steel Ruler

Commonly used measuring tool for getting rough measurements on a part.

The smallest division on the fractional scale is 1/64” (.016).

Vernier CaliperVernier Caliper

Precise measuring.

Decimal, fractional, or metric.

Often used by drafters to record dimensions from a machined prototype or part.

6” Dial Caliper

Inside Inside

Outside

DepthStep

4-way Measurement

4-way Measurement

6” Dial Caliper – Three Scales

METRIC (mm)

DECIMAL (.XX)

FRACTIONAL (1/64”)