Introduction to Manufacturing Processes

© 2013 Project Lead The Way, Inc.Computer Integrated Manufacturing

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

Manufacturing Process Example

Mine Extracting Raw Materials

Primary Processing to Manufacture Bar Stock

Secondary Processing to Manufacture A Ladder

Manufacturing Process

Input Process Output

Feedback

• Ceramics, metals, and plastics are well-suited to manufacturing.

• Their properties determine the process for which they are best suited.

Materials

Materials

Organic Materials

Inorganic Materials

Solid Liquid Gas

Engineering (Industrial) Materials

Non-Engineering Materials

Polymeric Metallic

Ceramic

Composite Video

Selecting Materials

InternalStructure

Types of atoms

Bonds between atoms

Molecularstructure

Property

Physical

Mechanical

Chemical

Thermal

Electrical – Magnetic

Acoustical

Optical

Conditions

ChemicalsRadiation

Mechanical Loads

Thermal

Electromagnetic Fields

Sonic Forces

Casting and Molding

Casting and Molding Videos

Separating• Involves the removal of material• Also referred to as the subtractive process• Includes two types of processes

– Chip Forming– Non-Chip Forming

Separating Videos

• Also referred to as the additive process

• Materials added in layers to build a finished part

• Examples– Welding– Gluing– Soldering– Prototyping

Joining

• Uses force to cause a material to permanently take a shape

• Changes some of the material properties

Forming

Forming Videos

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: Deburring• Methods include filing, scraping, and

trimming• Considerations include actual

requirements regarding work piece specifications, production quantities, and cost

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

• Involves a material being applied to a work piece

• May be mechanical, electrolytic, or conversion

Finishing: Coating

Finishing: Assembling• Involves putting parts together• May be temporary or permanent• Includes bonding and mechanical

fastening

• Refers to changing the physical or mechanical properties of a material

• Includes thermal, chemical, and mechanical

Finishing: Conditioning

ReferencesCustompart.net. (2008). Tutorials. Retrieved from

http://www.custompartnet.com/wu/InjectionMolding

Microsoft, Inc. (2008). Clip art. Retrieved from http://office.microsoft.com/en-us/clipart/default.aspx

Society of Manufacturing Engineers (Producer). (2010). Forging. Available from the Society of Manufacturing Engineers, One SME Drive: Dearborn, Michigan 48121.

The ABB Group. (2008). Photo gallery. Retrieved from http://www.abb.com

Wikipedia (2010). Assorted bar stock for metalworking. Retrieved from http://office.microsoft.com/en-us/clipart/default.aspx

ReferencesWikipedia (2010). Weipa bauxite mine. Retrieved from

http://office.microsoft.com/en-us/clipart/default.aspx