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Introduction to Manufacturing Processes
© 2013 Project Lead The Way, Inc.Computer Integrated Manufacturing
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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
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Manufacturing Process Example
Mine Extracting Raw Materials
Primary Processing to Manufacture Bar Stock
Secondary Processing to Manufacture A Ladder
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Manufacturing Process
Input Process Output
Feedback
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• Ceramics, metals, and plastics are well-suited to manufacturing.
• Their properties determine the process for which they are best suited.
Materials
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Materials
Organic Materials
Inorganic Materials
Solid Liquid Gas
Engineering (Industrial) Materials
Non-Engineering Materials
Polymeric Metallic
Ceramic
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Composite Video
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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
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Casting and Molding
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Casting and Molding Videos
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Separating• Involves the removal of material• Also referred to as the subtractive process• Includes two types of processes
– Chip Forming– Non-Chip Forming
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Separating Videos
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• Also referred to as the additive process
• Materials added in layers to build a finished part
• Examples– Welding– Gluing– Soldering– Prototyping
Joining
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• Uses force to cause a material to permanently take a shape
• Changes some of the material properties
Forming
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Forming Videos
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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
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Finishing: Deburring• Methods include filing, scraping, and
trimming• Considerations include actual
requirements regarding work piece specifications, production quantities, and cost
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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
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• Involves a material being applied to a work piece
• May be mechanical, electrolytic, or conversion
Finishing: Coating
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Finishing: Assembling• Involves putting parts together• May be temporary or permanent• Includes bonding and mechanical
fastening
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• Refers to changing the physical or mechanical properties of a material
• Includes thermal, chemical, and mechanical
Finishing: Conditioning
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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
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ReferencesWikipedia (2010). Weipa bauxite mine. Retrieved from
http://office.microsoft.com/en-us/clipart/default.aspx