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Manufacturing Processes

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Manufacturing Processes
Manufacturing is a value-addition process by which raw
materials or objects, originally of low value due to
inadequate material properties and poor or irregular
size, shape and finish are converted into high-utility and
high-value products with proper size, form, dimensions
and finish, imparting some functional ability.

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Manufacturing deals primarily with the science,
technology and methods of production of specific
objects effectively and efficiently by -

 Appropriate selection and use of input materials, tools,

machines and environment.
 Proper selection and application of a suitable
manufacturing process and system.
 Improvement of the existing materials and processing
methods and systems.
 Development of new materials, systems, processes and
techniques.
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 All the materials, processes, systems and
techniques must be:

 Technologically acceptable.

 Technically feasible.

 Economically viable.

 Environment friendly.

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Manufacturing technology is continuously and
rapidly advancing to meet the growing demands
for:

 Enhancement of productivity, product quality and

overall economy, especially after liberalization
and for global competitiveness.

 Fabrication of micro-size and ultra-precision

components. [advanced electronics, mechatronics,
computers, medical appliances, etc].

 Processing exotic materials coming up with vast and

rapid progress of science and technology. [aerospace,
nuclear engineering, information technology, etc.] 6
Production Management
 Production management is equally important and is
essentially executed for the management and control
of all the aspects of manufacturing.

 Production management usually refers to proper

planning, coordination and control of all
manufacturing activities to finally get the job done in a
most profitably way by best utilization of the available
resources - man, machine, material and money - with
maximum satisfaction of the customers.
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Production Management

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Production Management
Management helps to select the most appropriate
route, and plan and execute that based on one or more
of the following objectives or criteria:

 Reduction of manufacturing time.

 Increase in productivity.
 Reduction of cost of manufacturing.
 Increase in profit and profit rate.

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Three strategies for increasing
profit in the industry

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Three strategies for increasing
profit in the industry
 Increasing revenue R or selling price by raising quality,
reliability and safety of the product.

 Reducing manufacturing cost C by best utilization of

resources (material, skill, process and system).

 Increasing volume of production (saleable) by creating

or expanding market by adding quality and
aesthetics, improving reliability, trust and post-sell
services, advertisement, etc.
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Broad Classification of
Manufacturing Processes:
Using methods of changing the geometry of bulk
material to produce a mechanical part:

 by putting material together (+)

 by moving material from one region to another (0)

 by removing unnecessary material (-)

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Importance of material removal
 The importance of material removal operations may
be realized by considering the total cost associated
with this activity, including expendable tool cost, labor
cost, and cost of capital investment.

 In the United States, the yearly cost associated with

material removal has been estimated at about 10% of
the gross national product.

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Importance of material removal
There are several reasons for developing a rational
approach to material removal:

 to improve cutting techniques—even minor

improvements in productivity are of major importance
in high volume production.
 to produce products of greater precision and of greater
useful life.
 to increase the rate of production and produce a
greater number and variety of products with the tools
available. 14
Classification of material removal
operations
The entire field of material removal may be divided into
the following categories mainly in terms of the size of
the individual elements removed:

 Cutting (macroscopic chips, in the form of ribbons or

particles, thickness from about 0.025 mm to 2.5 mm)
 Grinding (smaller particles than in cutting, thickness
from 0.0025 mm to 0.25 mm)
 Special techniques (chips of atomic or
submicroscopic size , Associated with mostly NTM like
ECM, EDM, UM, EBM) 15
Machining
Purpose of Machining:

To enable the finished products –

 Meet its functional requirements.

 Provide improved performance. More finished product

performed much better.
 Have longer service life.

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Principle of Machining
 Machining is basically a material removal process.
 The excess material is gradually removed in the form
of chips by the relative motion of the tool and the
workpiece.

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Machining Requirements
Power

Blank
Machine Machining
Product
Tool Process

Fixture

Tools Environment

Correction Analysis
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Definition of Machining
Machining is an essential finishing process by which
jobs of desired dimensions and surface finish are
produced by gradually removing the excess material
from the preformed blank in the form of chips with the
help of cutting tool(s) moved past the work surface(s).

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Definition of Machine Tool
A Machine tool is a non-portable, power operated
and reasonably valued device or system of devices in
which energy is expended to produce jobs of desired
size, shape and surface finish by removing excess
material from the preformed blanks in the form of
chips with the help of cutting tool(s) moved past the
work surfaces.

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Machinability
Machinability simply means ‘ease of machining’, which
is judged by –

 Magnitude of the cutting forces.

 Level of the cutting temperature.
 Wear and life of cutting tools.
 Surface roughness.
 Chip formation.

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Machinability
Improvement of machinability for a given workpiece
requires the following:

 Proper design and preforming of the blank.

 Proper planning and scheduling of the machining
operations.
 Appropriate selection of cutting tools - type, material
and geometry.
 Optimum selection of the values of the process
parameters - cutting velocity, feed and depth of cut.
 Proper selection and application of environment or
cutting fluid for cooling and lubrication at the cutting
zone. 22
Basic functions of Machine Tools
Machine tools produced geometrical surfaces –

 Flat Surfaces

 Cylindrical surfaces

 Contour surfaces

Note: Production of such surfaces in machine tools

needs appropriate relative positioning and motions of
the cutting tool and the workpiece.
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Major functional components of
Machine Tools
 Device(s) for holding job and tool.

 Drive(s) for providing power and motion.

 Kinematic system(s) to transmit motion and power to

the tool and the job.

 Automation and control system.

 Strong and rigid structure/body.

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Machine tools produce geometrical surfaces with
the help of -

 Tool-work
 Tool-work motion
 Generatrix (G) and Directrix (D)

Note: In geometry, a Generatrix or generator is a point,

curve or surface that when moved generates a new shape.
The path of the genratrix motion is called a Directrix.
Both the Generatrix and Directrix are vectors.

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Generation of flat surfaces

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Generation of cylindrical surfaces

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Generation of formed surfaces

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Tool-work motion in machine tools
 Formative motions, namely
(a) Cutting motion (CM).
(b) Feed motion (FM).

 Auxiliary motions, such as

(a) Indexing motion of work or tool.
(b) Additional feed motion as in gear shaping machine.
(c) Relieving motion as in relieving lathe, gear shaper, etc

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 Connection with Generatrix and Directrix with
Tool-Work motion:

Sources of G
Work-piece
operation

Motions
M/cing

Tool or
G or D
Sl. No.

and D
Illustration

Straight G CM W Tr
1 plain
turning D FM T Tr

G CM W Tr
Taper
2
turning
D FM T Tr

G CM W Tr
3 Facing
D FM T Tr

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 Connection with Generatrix and Directrix with
Tool-Work motion:

Sources of G
Work-piece
operation

Motions
M/cing

Tool or
G or D
Sl. No.

and D
Illustration

G CM W Tr
Straight
4
boring
D FM T Tr

G CM W Tr
Taper
5
boring
D FM T Tr

G CM T Tr
6 Shaping
D FM W Tr

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 Connection with Generatrix and Directrix with
Tool-Work motion:

Sources of G
Work-piece
operation

Motions
M/cing

Tool or
G or D
Sl. No.

and D
Illustration

G CM W Tr
7 Planing
D FM T Tr

G CM T Tr
8 Drilling
D FM T Tr

Vertical G CM T Tr
9 Jig
Boring D FM T Tr

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Sources of Generatrix and Directrix
The Generatrix and Directrix can be obtained in four
ways:

 Tracing (Tr): Here the continuous line is attained as a

trace or path of a moving point.

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Sources of Generatrix and Directrix
 Forming (F): Here the Generatrix is simply the profile
or form of the cutting edge.

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Sources of Generatrix and Directrix
 Tangent Tracing (TTr): Here the Directrix is taken as
the tangent to the series of paths traced by the
cutting edges as in milling.

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Sources of Generatrix and Directrix
 Generation (G): Here the Generatrix or Directrix is
obtained as an envelope being tangent to the
instantaneous positions of a line or surface which is
rolling on another surface. Gear teeth generation
by hobbing or gear shaping is an example.

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Machine tool drives
Machine tool drives may be one of the following types:

 Electro-mechanical type drives: These are more

common where main source(s) is an electrical
motor(s) from which power and motions are
transmitted to the tool and work through several
mechanisms.
 Electro-hydraulic type drives: They are common
where power and motions are derived from electrical
motor(s) and transmitted through several hydraulic
systems.
 Combination of electro-mechanical and electro-
hydraulic drives. 37
The relative advantages of hydraulic drive are:
1. Smooth operation.
2. Precision (stepless) speed control.
3. Less jerk, vibration and noise.
4. Hardly needs separate lubrication.
5. Lesser wear and tear.
6. Easier connections by flexible tubings.
Limitations of hydraulic drive are:
1. Needs more floor space.
2. Chances of leakage of fluid, which not only causes
inconveniences and hazards but also affects feed rate
control.
3. More difficulties in repair and maintenance. 38
Machine tool drives, in terms of tool–work motions, are
further classified as:
1. stepped drive 2. stepless drives.

The types of electric motors, which are generally used for

electro-mechanical drives in machine tools, are as follows:
1. For stepped drives
(a) induction motors having only one or two fixed speeds.
2. For stepless drives
(a) variable speed induction motor with frequency converter.
(b) DC motors.
(c) Ward–Leonard system of motor–generator–motor set.
3. For NC and CNC machines
(a) stepper motor.
(b) AC and DC servo motors. 39
References:
 Chattopadhyay, A.B., 2011. Machining and machine
tools (With CD). John Wiley & Sons.
 Shaw, M.C. and Cookson, J.O., 2005. Metal cutting
principles (Vol. 2, No. 3). New York: Oxford university
press.
 https://nptel.ac.in/

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