Introduction to Manufacturing Processes and Materials

Robert Creese

• Publisher: CRC Press
• Year: 2017
• Topic: Technology & Engineering
• eBook ISBN:
  9781351990707
• Subtopic: Project Management
• Index: Technology & Engineering

The first manufacturing book to examine time-based break-even analysis, this landmark reference/text applies cost analysis to a variety of industrial processes, employing a new, problem-based approach to manufacturing procedures, materials, and management. An Introduction to Manufacturing Processes and Materials integrates analysis of material costs and process costs, yielding a realistic, effective approach to planning and executing efficient manufacturing schemes. It discusses tool engineering, particularly in terms of cost for press work, forming dies, and casting patterns, process parameters such as gating and riser design for casting, feeds, and more.

III
MANUFACTURING PROCESSES

7 Manufacturing Processes Overview

7.1 General Process Overview

Manufacturing processing is the procedure by which materials are formed into the desired shapes. Figure 7.1 indicates the typical forms and shaping operations for the basic materials, such as metals, polymers, ceramics, and wood. Materials are formed into preliminary shapes, near net shapes, and then the final shaping and finishing operations are performed. Final treatments for material property improvement or surface improvement and assembly operations are the final stages in the manufacturing process.

Shaping processes can be classified into two main categories: primary shaping processes and secondary processing. The primary shaping processes form the overall shape of the product or of the components that will be joined to form the final product shape. The most common primary shaping processes are casting, bulk deformation processes such as forging and extrusion, sheet metal working, and machining. Other primary shaping processes include powder metallurgy and slush casting; these are sometimes included as casting or forging processes. One process, machining, is also frequently used as a secondary step for the other primary shaping processes. Thus, machining is used to improve the basic shape produced by casting or deformation processing as well as to produce the basic shape. Machining is the only process considered to be both a primary shaping process and a secondary shaping process.

The purpose of the secondary processing is to provide the final shape surfaces to meet some of the product requirements such as surface or dimensional tolerances. There frequently are several secondary shaping processes necessary to meet the product specifications. The emphasis of this chapter is to present an overview of the basic manufacturing processes. The following chapters will discuss the process selection basics and the basic manufacturing processes in more detail. For optimal product design, the optimal primary shaping and secondary processing operations must be selected together and not independently. Table 7.1 indicates the general focus of primary shaping processes and secondary finishing operations.

Figure 7.1 Manufacturing processing overview.

Table 7.1 Primary Component Processing Operations and Secondary Processing Operations

Primary operations		Secondary operations
Primary shape formation	Primary shape completion	Assembly/joining	Finishing
Casting (liquid metals and semisolid polymers)	Machining (component to final shape)	Fasteners	Tolerance requirements
Powder processing (metals/ceramics in powder form)		Adhesives	Corrosion protection
Deformation processing (metals in bulk or sheet form)		Welding	Decorative painting & plating
Machining (chip/chipless)			Packaging

The selection of the primary shaping process is critical in controlling overall product costs. The shaping process selection is dependent upon the material and the product design. Both the shaping process and the material affect the product design, and this makes manufacturing so difficult to optimize. The primary manufacturing processes considered are casting, deformation processing (both bulk deformation and sheet metal deformation), machining (both chip generating processes and chipless processes), and powder processing. The discussion of the processes will emphasize metal materials, because most processes have been applied to metals, but similar an...

Table of contents

• Cover
• Half Title
• Title Page
• Copyright Page
• Table of Contents
• Preface
• I Manufacturing Management and Overview
• II Material and Design Considerations in Manufacturing
• III Manufacturing Processes
• IV Manufacturing Support Functions
• Index