Different Types of Production Processes
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The document outlines various production processes, detailing primary and secondary methods, including metalworking, casting, machining, and joining techniques such as welding, soldering, and brazing. It discusses fundamental processes like shaping, forming, and finishing, while providing examples of traditional and nontraditional machining methods. Additionally, it cites educational references to support the insights presented.
Different Types of Production Processes
- 1. DIFFERENTTYPES OF PRODUCTION PROCESSES AND SCOPE OF APPLICATIONS By Group F Taufiq Rahman Reg no: 2013334039 Saif Istiaqe Reg no: 2013334040
- 2. PRESENTED TO Engr Dr Mohammad Iqbal Mr Md Rezaul Hasan Shumon Professor Assistant Professor Department of Industrial and Department of Industrial and Production Engineering Production Engineering Shahjalal University of Science Shahjalal University of Science andTechnology andTechnology
- 3. WHAT ARE PRODUCTION PROCESSES? • Production Processes were accomplished primitively in ancient times. Weapons were sharpened by stones having grinding properties; first cutting- tools were held in the working position by hand, later they were secured to a handle by withes or animal sinews. An achievement of that time was the application of a rotating stone the prototype of the modern tool grinder. Later, rotary motion was employed to make ceramic ware, and still later for producing round articles of wood, bone and, finally, of metals. Along with devices for transmitting motion to the cutting tool, mechanisms were used for driving the material being worked.The prototype of the primitive lathe was the bow which rotated the work by means of the bow string, the flint tool being held by hand.The simplest type of turning lathe thus got developed gradually.
- 4. Primary Processes • MetalWorking • Metal Casting Secondary Processes • Chiseling, Filing, Scraping • Traditional machining processes such as turning, shaping, drilling, milling etc. • Nontraditional machining processes such as ultrasonic, electrical discharge, electro- chemical, laser etc. • Surface finishing processes such as abrasive belt grinding, barrel tumbling, polishing, anodizing etc. • Metal joining processes such as welding, brazing, soldering, riveting, screw fastening, adhesive joining etc.
- 5. SHAPING PROCESSES : CASTING (FOR METALS) AND MOLDING (FOR PLASTICS) Casting and molding processes start with a work material heated to a fluid or semifluid state.The process consists of: (1) pouring the fluid into a mold cavity and (2)allowing the fluid to solidify, after which the solid part is removed from the mold.
- 6. PARTICULATE PROCESSING In particulate processing, the starting materials are powders of metals or ceramics. Although these two materials are quite different, the processes to shape them in particulate processing are quite similar.The common technique involves pressing and sintering, illustrated in the figure below, in which the powders are first squeezed into a die cavity under high pressure and then heated to bond the individual particles together. Particulate processing: 1) the starting material is powder; the usual process consists of (2) pressing and (3) sintering.
- 7. DEFORMATION PROCESSES (FORGING & EXTRUSION) Some common deformation processes: (a) forging, in which two halves of a die squeeze the work part, causing it to assume the shape of the die cavity; and (b) extrusion, in which a billet is forced to flow through a die orifice, thus taking the cross-sectional shape of the orifice.
- 8. MACHINING (Material Removal Process) Milling Turning Drilling Boring Reaming Shaping Planning Finishing Machining is any of various processes in which a piece of raw material is cut into a desired final shape and size by a controlled material-removal process
- 9. MILLING • A machining operation in which workpiece is fed against a rotating tool with multiple cutting edges Milling Operation Face Milling Peripheral Milling The cutting action occurs primarily at the end corners of the milling cutter. In peripheral milling, the cutting action occurs primarily along the circumference of the cutter
- 10. Face Milling Peripheral Milling
- 11. Turning is a machining process in which a cutting tool, typically a non-rotary tool bit, describes a helical toolpath by moving more or less linearly while the workpiece rotates. TURNING OPERATION Turning Operations TaperedTurning Hard turning Facing Parting Grooving Boring Knurling Reaming Threading
- 12. TAPER/ CONTOURTURNING A taper is defined as a uniform increase or decrease in diameter of a cylindrical workpiece measured along its length. Taper turning is a process of producing a conical surface by gradual reduction in diameter from a cylindrical workpiece. A taper is generally turned by feeding the tool at an angle to the axis of rotation of the workpiece. The angle formed by the path of the tool with the axis of the workpiece should correspond to the half taper angle.
- 13. FACING Facing in the context of turning work involves moving the cutting tool at right angles to the axis of rotation of the rotating workpiece.This can be performed by the operation of the cross-slide, if one is fitted, as distinct from the longitudinal feed (turning). It is frequently the first operation performed in the production of the workpiece, and often the last— hence the phrase "ending up".
- 14. GROOVING Grooving is like parting, except that grooves are cut to a specific depth instead of severing a completed/part- complete component from the stock. Grooving can be performed on internal and external surfaces, as well as on the face of the part (face grooving or trepanning). External grooving Face grooving
- 15. • It is an operation of making a round hole in a workpiece usually by means of a rotating tool (drill bit) that has two or more cutting edges. DRILLING OPERATION A Bench Drilling Machine is most commonly used for drilling operations
- 16. BORING OPERATION It is an operation of enlarging of a hole already made in a work piece. How the process works: -A boring tool or a bit (single point cutting tool) mounted on a rigid bar is held in the tool post and fed into the work by hand or power in the similar way as for turning.
- 17. It is a process of sizing and finishing a hole already made by a drill. • A multi-point cutting tool with straight cutting edges used to size or smooth holes. • A reamer follows the original hole and cannot shift its center. REAMING OPERATION
- 18. • It is a process of producing small straight, flat surfaces: horizontal, vertical, or inclined. • Workpiece is rigidly held in a vice or clamped directly on the table. • A single point cutting tool is held in the tool holder, which is mounted on the ram. • The ram reciprocates and thus cutting tool held in tool holder moves forward and backward over the workpiece. • Tool performs the cutting operation during its forward stroke. • The backward stroke remains idle and no cutting takes place during this stroke. • Both the forward and backward strokes form one working cycle of the shaper. • The feed is given to the workpiece after one working cycle, and • he depth of cut is adjusted by moving the tool downward towards the workpiece. • The time taken during the idle stroke is less as compared to forward cutting stroke. • This is obtained by quick return mechanism. SHAPING OPERATION How the process works
- 19. PLANNING OPERATION -A shock initiated machining process, -Low cutting speed due to start-and-stop motion, and -Used to produce straight, flat surfaces on the workpiece -Parts are too large and heavy to be accommodated on the shaping machine table. Planning is similar to shaping. It is a
- 20. THREADING An operation of cutting threads or helical grooves of specific shape (V or square) on the external cylindrical surface of the job. How the process works: The job is held in between centers or in a chuck and the single point cutting tool (thread cutting tool) is held on tool post. To make or cut threads: The cutting tool is brought to the start of job and a small depth of cut is given to cutting tool using cross slide. The cutting tool must travel a distance equal to the pitch of the thread to be cut (in mm) as the work piece completes a revolution.
- 21. KNURLING Knurling is the cutting of a serrated pattern onto the surface of a part to use as a hand grip using a special purpose knurling tool.
- 22. FINISHING PROCESS • Surface finishing processes can be categorized by how they affect the workpiece: • Removing or reshaping finishing • Adding or altering finishing Surface Finishing Methods Wet Process Methods Electrical Methods Non Electrical Methods Dry Process Methods Mechanical Methods InVaccum Coating Methods Diffusion Coating Methods Others
- 23. JOINING PROCESSES: WELDING Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. Photo: Working on welding projects
- 24. Some of the best known welding methods include: Shielded Metal Arc Welding (SMAW) - also known as "stick welding", uses an electrode that has flux, the protectant for the puddle, around it. The electrode holder holds the electrode as it slowly melts away. Slag protects the weld puddle from the outside world. Gas Tungsten Arc Welding (GTAW) – also known as TIG (tungsten, inert gas), uses a non-consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by an inert shielding gas such as Argon or Helium. Gas Metal Arc Welding (GMAW) – commonly termed MIG (metal, inert gas), uses a wire feeding gun that feedswire at an adjustable speed and sprays an argon-based shielding gas or a mix of argon and carbon dioxide (CO2) over the weld puddle to protect it from the outside world. Flux-Cored Arc Welding (FCAW) – almost identical to MIG welding except it uses a special tubular wire filled with flux; it can be used with or without shielding gas, depending on the filler. Submerged Arc Welding (SAW) - uses an automatically fed consumable electrode and a blanket of granular fusible flux. The molten weld and the arc zone are protected from atmospheric contamination by being "submerged" under the flux blanket. Electroslag Welding (ESW) - a highly productive, single pass welding process for thick (greater than 1 in/25 mm up to about 12 in/300 mm) materials in a vertical or close to vertical position.
- 25. JOINING PROCESSES: SOLDERING Soldering is a process in which two or more metal items are joined together by melting and flowing a filler metal (solder) into the joint, the filler metal having a lower melting point than the adjoining metal. Soldering differs from welding in that soldering does not involve melting the work pieces. In brazing, the filler metal melts at a higher temperature, but the work piece metal does not melt. In the past, nearly all solders contained lead, but environmental concerns have increasingly dictated use of lead-free alloys for electronics and plumbing purposes. Desoldering a contact from a wire
- 26. JOINING PROCESSES: BRAZING Brazing is a metal-joining process whereby a filler metal is heated above melting point and distributed between two or more close-fitting parts by capillary action. The filler metal is brought slightly above its melting (liquidus) temperature while protected by a suitable atmosphere, usually a flux. It then flows over the base metal (known as wetting) and is then cooled to join the workpieces together. It is similar to soldering, except the temperatures used to melt the filler metal are higher for brazing. Working on projects which need brazing
- 27. References • Fundamentals of Modern Manufacturing: Materials, Processes, and Systems by Mikell P. Groover • Lecture: Manufacturing Process -1 by Dr Mohammad Muhshin Aziz Khan • ProductionTechnology by O P Khanna • http://en.wikipedia.org/wiki/List_of_manufacturing_processes • Manufacturing Engineering &Technology by S.Kalpakjian and S.A.Schmidt • Introduction to Basic Manufacturing Process andWorkshopTechnology by Rajender Singh • Images taken from www.custompartnet.com and google image search