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Manufacturing Processes: Theory Of Metal Cutting & Machine Tool

Manufacturing Processes: Theory Of Metal Cutting & Machine Tool
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Dr.SamuelHunt,United Arab Emirates,Teacher
Published Date:21-07-2017
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Manufacturing Processes: Theory Of Metal Cutting & Machine Tool Dr. Dwi Rahdiyanta Jurusan Pendidikan Teknik Mesin FT-UNY Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Introduction to Manufacturing Processes • Definition of Manufacturing • The word manufacturing is derived from Latin: manus = hand, factus = made • Manufacturing is the economic term for making goods and services available to satisfy human wants. • Manufacturing implies creating value to a raw material by applying useful mental and physical labour. • Whether from nature or industry materials cannot be used in their raw forms for any useful purpose. • The materials are then shaped and formed into different useful components through different manufacturing processes to fulfil the needs of day-to-day work. • Manufacturing converts the raw materials to finished products to be used for some purpose. Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Manufacturing Processes • Manufacturing processes is a very fundamental subject since it is of interest not only to mechanical engineers but also to engineers from other discipline of engineering. • There are various manufacturing processes by which a product can be made. • Each process however has its own limitation and restriction and due to this reason a particular process is adopted to certain specific applications. • Thus while a product can be manufactured by two or more processes, the real problem is to select the most economical out of them. • A detailed understanding of various manufacturing processes is thus very essential for every engineer. This helps in designing the proper product required for him. • He would be able to assess the feasibility of manufacturing from his designs. • He may find that there are more than one process is available for manufacturing a particular product and he can make a proper choice of the process which would require lowest manufacturing cost. Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 CLASSIFICATION OF MANUFACTURING PROCESSES Manufacturing processes can be grouped as:  Casting, foundry or moulding processes.  Forming or metal working processes.  Machining (metal removal) processes.  Joining and assembly  Surface treatments (finishing).  Heat treating These groups are not mutually exclusive. For example, some finishing processes involve a small amount of metal removal or metal forming. A laser can be used for joining/metal removal/heat treating. Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 CLASSIFICATION OF MANUFACTURING PROCESSES Casting, foundry or moulding processes • Sand casting • Investment casting • Die casting • Centrifugal Casting • Continuous Casting Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 CLASSIFICATION OF MANUFACTURING PROCESSES Forming or metal working processes • Rolling • Forging • Extrusion • Drawing • Sheet metal works Joining processes • Welding (SMAW, TIG, MIG, PLASMA, LBW, EBW etc.) • Soldering • Brazing • Adhesive bonding • Riveting Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 CLASSIFICATION OF MANUFACTURING PROCESSES Conventional Machining processes • Turning • Milling • Drilling • Shaping • Grinding • Broaching Nonconventional Machining processes • Electro chemical Machining (ECM) • Electro Discharge Machining (EDM) • Wire Electro Discharge Machining(WEDM) • Abrasive Jet Machining (AJM) • Ultrasonic Machining (USM) • Liquid Jet Machining (LJM) • Electron Beam Machining (EBM) • Laser Beam Machining (LBM) • Ion Beam Machining (IBM) • Plasma Arc Machining (PAM) Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Manufacturing Processes and Manufacturing system • Manufacturing system: • A collection of operations and processes used to obtain a desired product(s) or component(s) is called a manufacturing system. • The manufacturing system is therefore the design or arrangement of the manufacturing processes.. • Production system: • A production system includes people, money, equipment, materials and supplies, markets, management and the manufacturing system. Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Production System - The Big Picture Raw materials Manufacturing Manufacturing Finished Process Process product Manufacturing System People, Money, Equipment, Materials and Supplies, Markets, Management Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Application of Manufacturing Processes Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Application of Manufacturing Processes Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Application of Manufacturing Processes Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Application of Manufacturing Processes Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Application of Manufacturing Processes Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Application of Manufacturing Processes (Gears) Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Diagrammatic Representation of Material Removal Operations Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Examples of cutting processes th Source: “ Manufacturing Processes for Engineering Materials”, 4 edition, Kalpakjian, Schmid, Prentice Hall 2003 Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 An Introductory video on Manufacturing Processes Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Machine Tools Machine tools are kind of machines on which metal cutting or metal forming processes are carried out. Material removal is essentially done on machine tools, which may be Lathe, Milling, Drilling, Shaping, Planing, Broaching and Grinding machines. The functions of machine tools are: • holding the workpiece • holding the tool • moving the tool or the work piece or both relative to each other, • supply energy required to cause metal cutting. Every machine tool has a primary cutting tool for metal removal. Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005 Machining Parameters Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005