1. Introduction to Manufacturing Processes
Computer Integrated Manufacturing
© 2013 Project Lead The Way, Inc.

2. Types of Manufacturing Processes
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Types of Manufacturing Processes
Primary Processing
Raw materials to industrial materials
Raw materials are renewable or exhaustible
Secondary Processing
Create final products from primary product
Before a product is manufactured, raw materials must be obtained. Raw materials are natural resources found on or in the earth or seas. They may be renewable or exhaustible. Renewable resources are biological. These include trees, cotton, wool, and animal products such as hides. Exhaustible resources cannot be replaced. Examples include metal ore, petroleum, natural gas, and coal.
Primary processing is the first step in manufacturing. It is the point at which raw materials are changed into useable material. The three major procedures are thermal (heat), chemical, and mechanical. The resulting materials are referred to as industrial materials or standard stock.
Secondary processes take the useable material and use it to create products. Common processes include casting and molding, forming, separating and joining, conditioning, assembling, and finishing.

3. Manufacturing Process Example
Mine Extracting Raw Materials
Secondary Processing to Manufacture A Ladder
Primary Processing to Manufacture Bar Stock

4. Manufacturing Process
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Manufacturing Process
Input Process Output
Feedback
Input: Put into a system in order to receive outputs and achieve goals – People, natural resources, capital, finance, knowledge, energy
Process: Where the actual work is done – Transformation processes; management processes
Transformation Processes – Deal directly with inputs. Use resources to create desired outputs
Management Processes – Used to ensure the effective use of resources. All actions ensure that the transformation acts are efficient and appropriate.
Output: Desired Outputs – May be manufactured products or constructed structures. Other outputs include scrap, pollution, noise, fumes, etc.
Output Objective – Produce the maximum amount of desired output with the minimum amount of undesired output.
Feedback: A system that can use its own information to control itself. If measured output is not what is expected, corrective actions are implemented.
Example: Thermostat – When the temperature is high enough in a room, the thermostat controls the heating and cooling systems in order to maintain the desired results.

5. Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Materials
Ceramics, metals, and plastics are well-suited to manufacturing.
Their properties determine the process for which they are best suited.
Ceramics – Any of various hard, brittle, heat-resistant, and corrosion-resistant materials made by shaping and then firing a nonmetallic mineral, such as clay, at a high temperature.
Metals – Any of a category of electropositive elements that usually have a shiny surface, are generally good conductors of heat and electricity, and can be melted or fused, hammered into thin sheets, or drawn into wires.
Plastics – Materials that undergo a permanent change in shape or size when subjected to a particular amount of stress.
Material properties include:
Mechanical (compression, tension, etc.)
Physical (size, density, etc.)
Thermal (melting and freezing point, etc.)
Chemical (the ability to resist chemical change, such as corrosion)
Electrical/magnetic (conductivity, resistivity, permeability)
Optical (opacity and color)
Acoustical (absorb, transmit, and reflect sound)

6. Materials Organic Materials Inorganic Materials Solid Liquid Gas
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Materials
Organic Materials
Inorganic Materials
Solid
Liquid
Gas
Engineering (Industrial) Materials
Non-Engineering Materials
Organic: Can be traced back to living organisms (or parts of living organisms) – Coal, petroleum, wood, and wool
Inorganic: Nonliving ores and earth elements – Copper, gold, aluminum, glass, and cement
Engineering Materials: Solid structure – Will hold their shape without outside support
Non-Engineering Materials: Gasses and liquids – Must have a container if they are to be contained or held in a particular shape
Metallic: Most widely used group of engineering materials – Pure metals and alloys
Ferrous Metals: Iron is the principal ingredient
Non-Ferrous Metals: Iron is not the principal ingredient
Polymeric: Organic, noncrystalline
Natural: Wood, wool, latex, cotton, silk
Synthetic (plastics): Thermoplastic, thermosetting, elastomer
Thermoplastic: Can be heated and reformed repeatedly
Thermosetts: Once molded, these materials resist heat – Handles of a toaster, iron , kettle
Ceramic: Clays, cements, plaster, glass, abrasives, porcelain
Composites: Combination of two or more materials. Each material retains its original properties in order to overcome the weakness of another.
Polymeric
Metallic
Ceramic

7. Composite Video Presentation Name Course Name
Unit # – Lesson #.# – Lesson Name
Composite Video
Play video: Composites

8. Selecting Materials Internal Structure Types of atoms
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Selecting Materials
Internal
Structure
Types of atoms
Bonds between atoms
Molecular
structure
Property
Physical
Mechanical
Chemical
Thermal
Electrical – Magnetic
Acoustical
Optical
Conditions
Chemicals
Radiation
Mechanical Loads
Thermal
Electromagnetic Fields
Sonic Forces
Physical: Density, porosity, moisture content, surface texture
Mechanical: Type of bonding, number and types of imperfections in the material, strength, plasticity, ductility, elasticity, hardness

9. Casting and Molding Presentation Name Course Name
Unit # – Lesson #.# – Lesson Name
Casting and Molding
Molding is the process of manufacturing by shaping pliable raw material using a rigid frame or model called a mold. Plastics are a popular type of material used in this process.
Casting is a manufacturing process by which a molten material such as metal or plastic is introduced into a mold, allowed to solidify within the mold, and then ejected or broken out to make a fabricated part.
Here we have an artist’s rendition of an injection molding machine. On the right is a robot assisting with sand casting.

10. Casting and Molding Videos
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Casting and Molding Videos
Play videos: Casting, Die Casting, Plastic Injection Molding

11. Separating Involves the removal of material
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Separating
Involves the removal of material
Also referred to as the subtractive process
Includes two types of processes
Chip Forming
Non-Chip Forming
The separating process is one of the oldest processes.
Chip forming subtractive processes are a type of separation process where a chip is formed. Good examples of this include cutting with a saw, drilling with a drill, or machining with a mill or lathe.
Non-chip forming processes are a type of separation process where no chips are produced. Good examples of this would be stamping or shearing.
Some processes use an electric arc to cut material. One such example is EDM (electrical discharge machining), which is used to cut holes in metal.

12. Separating Videos Presentation Name Course Name
Unit # – Lesson #.# – Lesson Name
Separating Videos
Play video: Laser cutting, Oxy-Fuel Cutting, and Waterjet Cutting

13. Joining Also referred to as the additive process
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Joining
Also referred to as the additive process
Materials added in layers to build a finished part
Examples
Welding
Gluing
Soldering
Prototyping
The joining process may also include newer processes of join such as rapid prototyping, which might be in the form of Stereolithography (STL), Laminated Object Manufacturing (LOM), Selective Laser Sintering (SLS), 3-D Printing, and Fused Deposition Modeling (FDM).
Stereolithography is a rapid prototyping process that fabricates a part layer-wise by hardening a photopolymer with a guided laser beam.

14. Forming Uses force to cause a material to permanently take a shape
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Forming
Uses force to cause a material to permanently take a shape
Changes some of the material properties
The properties of the product do not change. For example, a metal handle on a shovel may be bent to make the handle more ergonomic. Bends may also be added to strengthen a shape.

15. Forming Videos Presentation Name Course Name
Unit # – Lesson #.# – Lesson Name
Forming Videos
Play video: Forging, Metal Extrusion, Plastic Extrusion, Stamping Dies, and Hydroforming.

16. Finishing May be completed before or after assembly
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Finishing
May be completed before or after assembly
Used primarily to protect a product from various conditions
Also used to enhance a product’s appearance
Finishing includes such processes as deburring, cleaning, coating, electro plating, painting, and assembly.

17. Finishing: Deburring Methods include filing, scraping, and trimming
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Finishing: Deburring
Methods include filing, scraping, and trimming
Considerations include actual requirements regarding work piece specifications, production quantities, and cost
This slide provides images of some common burr locations found after machining and some hand deburring tools.

18. Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Finishing: Cleaning
Involves the process of removing unwanted material from work pieces
Techniques include
Alkaline cleaning
Electrolytic cleaning
Solvent cleaning
Vapor degreasing
Acid cleaning
Abrasive blasting
Abrasive wheels
Cleaning is typically performed in preparation for further processing. The unwanted material may be soil, grime, grease, scale, stains, blemishes, or corrosive deposits.
Alkaline cleaning – Employs alkaline solutions; parts are soaked or sprayed to promote cleaning.
Electrolytic cleaning – Parts are soaked in an alkaline solution and a current is passed through it, effectively cleaning the surface.
Solvent cleaning – Parts are soaked or sprayed with a solvent that removes oils and greases.
Vapor degreasing – Solvent cleaning with the vapors from a boiling solvent solution.
Acid cleaning – An acid solution employed to dislodge solid dirt deposits from metal surfaces.
Abrasive blasting – Abrasive particles propelled by compressed air or water at a work piece to dislodge undesirable matter.
Abrasive wheels – A wheel made up of abrasive-covered cloth that is spun over a surface to clean.

19. Finishing: Coating Involves a material being applied to a work piece
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Finishing: Coating
Involves a material being applied to a work piece
May be mechanical, electrolytic, or conversion
This material will protect the work piece from atmospheric elements which would cause corrosion or some other form of surface deterioration.
Mechanical coatings (organic coatings) applied by brushing, spraying, dipping, and flowing include:
Paints
Varnishes and enamels
Lacquers
Electrolytic coatings (also organic) applied by use of electrical energy:
Powder coating
Electroplating
Conversion coatings (inorganic coatings) applied by chemical reaction include:
Phosphate coating
Chromate coating
Oxide coating
Anodizing

20. Finishing: Assembling
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Finishing: Assembling
Involves putting parts together
May be temporary or permanent
Includes bonding and mechanical fastening
This PVC-pipe dog agility jump uses mechanical fastening. Mechanical fastening might be temporary, as in the case of the dog jump, so that it can be changed. In this example, the size of the dog using the jump will determine how high to set the jump. Mechanical fastening can also be permanent. If, for example, you have a large dog and you want the jump to stay at a certain height, it can be held together with screws.
When using bonding, the bonding agent (glue or some other substance) must be considered. The two major bonding methods include cohesive (heat welding and/or pressure welding) and adhesion (includes solvent bonding, brazing and soldering, and adhesives). In addition, the method used to create the bond and the type of joint that will be used must be taken into consideration.

21. Finishing: Conditioning
Presentation Name
Course Name
Unit # – Lesson #.# – Lesson Name
Finishing: Conditioning
Refers to changing the physical or mechanical properties of a material
Includes thermal, chemical, and mechanical
Heat, mechanical force, or chemical action is used to change the internal properties of a material.
An example of thermal conditioning is air drying lumber to make it suitable for construction applications. Lumber intended for interior uses is kiln dried, another thermal conditioning process. Ceramics are created using a thermal process called firing. The tires pictured were conditioned using a thermal process called vulcanization.
Cement is an example of chemical conditioning. Water is added to the powder so that the chemical process may begin. Tanning of animal hides is also a chemical conditioning process.
Mechanical conditioning occurs when physical force is used to modify the internal structure. This is achieved through pounding, squeezing, or even by spraying shot against a part.

22. References
Custompart.net. (2008). Tutorials. Retrieved from Microsoft, Inc. (2008). Clip art. Retrieved from Society of Manufacturing Engineers (Producer). (2010). Forging. Available from the Society of Manufacturing Engineers, One SME Drive: Dearborn, Michigan The ABB Group. (2008). Photo gallery. Retrieved from Wikipedia (2010). Assorted bar stock for metalworking. Retrieved from

23. References
Wikipedia (2010). Weipa bauxite mine. Retrieved from