1. Introduction to Manufacturing Processes
Principles Of Engineering
© 2012 Project Lead The Way, Inc.

2. Products and Manufacturing
Introduction to Manufacturing Processes
Products and Manufacturing
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Product Creation Cycle Design → Material Selection → Process Selection → Manufacture → Inspection → Feedback
Typical product cost breakdown
Project Lead The Way, Inc.
Copyright 2009

3. Manufacturing Process
Introduction to Manufacturing Processes
Manufacturing Process
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
A sequence of operations and processes designed to create a specific product
The process of turning materials into a product
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Copyright 2009

4. Engineers in Manufacturing
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Manufacturing Engineer Select and coordinate specific processes and equipment Industrial Engineer Responsible for the manufacturing system design Materials Engineer Develop and select materials based on desired material properties and manufacturing processes
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Copyright 2009

5. Manufacturing System Designs
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Job Shop
Small quantities of products Large variety of products Products move through the shop to various machines General-purpose machines
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6. Manufacturing System Designs
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Flow Shop
Larger quantities of products
Production line
Special purpose machines
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7. Manufacturing System Designs
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Linked-Cell Shop
Manufacturing and subassembly cells connected to final assembly
Lean production system
One piece flow system
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8. Manufacturing System Designs
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Project Shop
Product being manufactured cannot be easily moved during production
Production processes are brought to the product
Examples: Bridges, ships, large airplanes, locomotives, large machinery
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9. Manufacturing System Designs
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Continuous Process Large plants Utilized in the manufacture of liquids, oils, gases, and powders
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10. Manufacturing System Designs
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Lean Manufacturing
100% “good” units flow from process to process
Integrated quality control (IQC)
All employees are inspectors
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11. Basic Manufacturing Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Casting and Foundry Forming or Metalworking Machining Joining and Assembly Rapid Prototyping Other
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Copyright 2009

12. Casting and Foundry Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
In one step raw materials are transformed into a desirable shape
Parts require finishing processes
Excess material is recyclable
Society of Manufacturing Engineers (Producer). (2010). Casting. Available from the Society of Manufacturing Engineers, One SME Drive: Dearborn, Michigan
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13. Introduction to Manufacturing Processes
Basic Casting Process
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
A mold is created – A cavity that holds the molten material in a desired shape until it is solidified
Multiple-use mold Single-use molds
Material is heated to a specified temperature
Molten material is poured into a mold cavity
Molten material solidifies into the shape of the cavity
Casting or mold is removed
Casting is cleaned, finished, and inspected
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14. Forming and Metalworking Processes
Introduction to Manufacturing Processes
Forming and Metalworking Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Utilizes material that has been cast
Modify the shape, size, and physical properties of the material
Hot and cold forming
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15. Forming and Metalworking Processes
Introduction to Manufacturing Processes
Forming and Metalworking Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Rolling – Material passes through a series of rollers, reducing its thickness with each pass
Forging – Material is shaped by the controlled application of force (blacksmith)
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16. Forming and Metalworking Processes
Introduction to Manufacturing Processes
Forming and Metalworking Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Extrusion – Material is compressed and forced through a die to produce a uniformed cross section
Wire, rod, and tube drawing – Material is pulled through a die to produce a uniformed cross section
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17. Forming and Metalworking Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Cold forming and forging – Slugs of material are squeezed into dies
Project Lead The Way, Inc.
Copyright 2009

18. Introduction to Manufacturing Processes
Machining Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Controlled removal of material from a part to create a specific shape or surface finish
Cutting element is used
Movement must exist between the part and cutting element
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Copyright 2009

19. Introduction to Manufacturing Processes
Machining Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Turning Processes
Operations that create cylindrical parts
Work piece rotates as cutting tool is fed into the work
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Copyright 2009

20. Introduction to Manufacturing Processes
Machining Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Turning Processes
Lathes and turning centers
Processes include: Straight, taper, contour turning, facing, forming, necking, parting, boring, threading, and knurling
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Copyright 2009

21. Introduction to Manufacturing Processes
Machining Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Milling Processes
Operations that create flat or curved surfaces by progressively removing material
Cutting tools rotate as the work piece is secured and fed into the tool
Project Lead The Way, Inc.
Copyright 2009

22. Introduction to Manufacturing Processes
Machining Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Milling Processes
Mills – Vertical and horizontal
Processes include: Surfacing, shaping, forming, slotting, T-slotting, angle, straddle, dovetailing, and slab milling
Project Lead The Way, Inc.
Copyright 2009

23. Introduction to Manufacturing Processes
Machining Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Drilling Processes
Operations that create holes
Cutting tools rotate and are fed into nonmoving secured work pieces
Project Lead The Way, Inc.
Copyright 2009

24. Introduction to Manufacturing Processes
Machining Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Drilling Processes
Drilling and boring machines
Processes include: Drilling, counter drilling, step drilling, boring, counter boring, countersinking, reaming, spot facing, and tapping
Project Lead The Way, Inc.
Copyright 2009

25. Introduction to Manufacturing Processes
Machining Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Shearing Processes
Operations that break unwanted material away from the part
A material is placed between a stationary and movable surface. The movable surface (blade, die, or punch) applies a force to the part that shears away the unwanted material.
Project Lead The Way, Inc.
Copyright 2009

26. Introduction to Manufacturing Processes
Machining Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Shearing Processes
Automated hole punch, squaring shear, and rotary cutter
Processes include: Shearing, blanking, cutoff, and parting; punching, perforating, and slotting; notching, lacing, and trimming
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Copyright 2009

27. Abrasive Machining Processes
Introduction to Manufacturing Processes
Machining Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Abrasive Machining Processes
Operations in which small particles of materials (abrasives) remove small chips of material upon contact
Drum, disc, and belt sanders; surface, vertical and horizontal spindle; disc grinders; media blaster; tumblers
Project Lead The Way, Inc.
Copyright 2009

28. Thermal and Chemical Processes
Introduction to Manufacturing Processes
Machining Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Thermal and Chemical Processes
Operations that cut and shape materials through chemical means
No mechanical force is used
Electrical discharge, electrochemical, chemical, laser, electron beam, flame cutting, and plasma-arc cutting
Processes include: Grinding, sawing, cutting, machining, milling, blanking, and etching
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Copyright 2009

29. Heat Treating Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Controlled heating and cooling of a material to alter its properties while maintaining its shape
Properties include: Strength, toughness, machinability, wear resistance, and corrosion resistance
90% of heat treating is preformed on steel and other ferrous metals
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Copyright 2009

30. Heat Treating Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
To aid in the manufacturing process, materials can be treated to be weak and ductile and then can be re-treated to provide high strength.
Can also occur incidentally during the manufacturing process
Project Lead The Way, Inc.
Copyright 2009

31. Joining and Assembly Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Can you think of a product with only one part?
Most products consist of multiple parts that are assembled to form a finished product.
Typical assembly processes include: Mechanical fastening; soldering and brazing, welding; adhesive bonding
Project Lead The Way, Inc.
Copyright 2009

32. Joining and Assembly Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Mechanical Fastening
Use physical force to hold parts together
Mechanical fasteners or part design
Screws, bolts, nails, rivets, cotter pins, retaining clips, and edge design
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Copyright 2009

33. Joining and Assembly Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Welding
Operations that use heat, pressure, or both to permanently join parts
Gas, arc, stud, spot, forge, roll laminating, resistance, and induction welding
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Copyright 2009

34. Joining and Assembly Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Adhesive bonding
Bonding of adjoining surfaces by filling the gap between each surface with a bonding material
Glue, cement, thermoplastic, thermosetting, and elastomers
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35. Joining and Assembly Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Soldering and Brazing
Operation in which metal surfaces are bonded together by an alloy
Heated molten alloy flows between the adjoining surfaces
When the heat is removed, the molten metal solidifies and the metal surfaces are bonded
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Copyright 2009

36. Introduction to Manufacturing Processes
Rapid Prototyping
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Additive process
Parts are produced directly from software applications
Common rapid prototyping systems include: stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), laminated object manufacturing (LOM), digital light processing (DLP)
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Copyright 2009

37. Introduction to Manufacturing Processes
Rapid Prototyping
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Finished parts can be field tested depending upon building material
Created parts can be used to create a mold
Modifications to design can be implemented quickly
Project Lead The Way, Inc.
Copyright 2009

38. Other Manufacturing Processes
Introduction to Manufacturing Processes
Other Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Testing
Transportation
Material handling
Packaging
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Copyright 2009

39. Material-Specific Manufacturing Processes
Introduction to Manufacturing Processes
Material-Specific Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Plastic Processes Ceramic Processes
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Copyright 2009

40. Plastics Manufacturing Processes
Introduction to Manufacturing Processes
Plastics Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Extrusion
A rotating screw forces plastic through a heating chamber and then through a heated die
Produces long plastic parts with uniform cross sections
Project Lead The Way, Inc.
Copyright 2009

41. Plastics Manufacturing Processes
Introduction to Manufacturing Processes
Plastics Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Injection Molding
Heated plastic is forced by a movable plunger through a nozzle and then into a mold. The material fills the mold and then is cooled.
Most widely used high-volume production process
Project Lead The Way, Inc.
Copyright 2009

42. Plastics Manufacturing Processes
Introduction to Manufacturing Processes
Plastics Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Casting
Plastic is melted and poured into a mold – No pressure or fillers are required.
Rotational Molding
A closed mold is filled with a predetermined amount of plastic. The mold is heated, rotated, and then cooled to create a hollow plastic object with uniform wall thickness.
Project Lead The Way, Inc.
Copyright 2009

43. Plastics Manufacturing Processes
Introduction to Manufacturing Processes
Plastics Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Blow Molding
A solid bottom hollow tube is placed between two mold halves and heated. The heated tube is then expanded into the sides of the mold with compressed air.
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Copyright 2009

44. Plastics Manufacturing Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Thermoforming
Plastic sheets are heated over an open mold to a working temperature. Once workable, a vacuum is applied to the mold, forcing the plastic sheet to take the shape of the mold.
Reaction Molding
Liquid reactants are mixed and then pressurized into a mold.
No heat is needed. Curing time is typically less than 1 minute.
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Copyright 2009

45. Ceramic Manufacturing Processes
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Two distinct classes of materials and processes exist.
Glass is heated to a molten state, shaped by viscous flow, and then cooled to produce a solid.
Crystalline Ceramics
Material is shaped and then heated to produce a permanent solid.
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Copyright 2009

46. Manufacturing Importance
Introduction to Manufacturing Processes
Principles Of EngineeringTM
Unit 3 – Lesson 3.2 Material Properties
Typical product cost breakdown
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Copyright 2009