03/06/2024

Manufacturing Course: IPE 3205 Theory

Course Title: Manufacturing Processes II
Processes II 3.00 credits; 3 Hrs/week

Class Schedule (weekly)

Saturday Time: 9.00 – 9.50 AM
Tuesday Time: 2.00 – 2.50 PM
Thursday Time: 9.00 – 9.50 AM

Room 412 (C)

Course Teacher Term Tests

Term Test # 1, at 13th Class
Dr. M. Abu Hayat Mithu Term Test # 2, at 25th Class
Professor
Email: mithu-ipe@sust.edu
mithuipe@gmail.com Department of Industrial & Production Engineering
Shahjalal University of Science and Technology (SUST)
Sylhet, Bangladesh

Course Content: Manufacturing Processes II

IPE 317 Manufacturing Processes II
 Bulk deformation processes: Forging; open, close, coining, Extrusion;
Hot and cold extrusion process; Rolling; Sheet metal working:
Shearing and forming, Bending, Bulging, Breaking, Explosive forming.

 Non-traditional machining process: Electro-discharge, electrochemical,

LASER beam, electron beam, and abrasive jet machining;

 Nonconventional joining processes: LASER, Electron Beam,

Submerged Arc welding;

 Plastic products manufacturing processes: Injection molding,

compression molding, blow molding, vacuum forming and hand lay-up.
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Reference Books

Students are advised to collect Textbooks as given in the Reference Section, or to

collect the lecture outlines, multimedia presentation. In exception, the course
teacher will provide the necessary article, or reference pages.
1. Mikell P. Groover, Fundamentals of 4. Fritz Klocke (Translated by Aaron
Modern Manufacturing Materials, Kuchle), Manufacturing Processes 1
Processes, and Systems, (Cutting) Springer

Wiley & Sons, Inc.

2. Serope Kalpakjian and Stevan R. 5. Hassan El-Hofy, Advanced

Schmid, Manufacturing Engineering Machining Processes
and Technology, Prentice Hall Nontraditional and Hybrid
Machining Processes McGraw Hill

3. J.T. Black and Ronald A. Kohser,

6. P.N. Rao, Manufacturing
DeGarmo’s Materials and Processes in
Technology Metal Cutting
Manufacturing, Wiley and Sons
and Machine Tools, vol 2
Tata McGraw Hill

Why do we study MP II

Manufacturing processes are at the core of converting raw materials

into finished products. It helps understanding how goods are produced,
from the initial stages of material selection to the final assembly.

Conventional techniques: provides insights into conventional techniques

It allows students to specialize in specific areas of manufacturing, such

as metalworking, plastics processing, or advanced manufacturing….
Solving complex problems related to process, efficiency improvement,
highly valued in the manufacturing industry.
Courses include laboratory sessions or hands-on projects, allowing
students to gain practical experience with advanced manufacturing
equipment and techniques.
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Lecture Outcomes
At the end of this lecture, student will be able to:
 recognize and understand a broad range of manufacturing processes used in
the industry;
 learn about common bulk metal deformation processes, sheet metal forming,
important non-traditional processes, and plastic fabrication processes.

What is Manufacturing ?

The word ‘manufacture’ is derived Manufacturing can be separated into

from two Latin words, ‘manus’ two subjects:
(meaning hand) and ‘factus’ 1. human’s discovery and invention
(meaning make). of materials and processes to
make things, and
The combined meaning is 2. development of the systems of
made by hand. production.

Manufacturing
In modern context, manufacturing can be defined two
ways,

1. Technologic manufacturing – the application of

physical and chemical processes to alter the
geometry, properties, and/or appearance of a given
starting material to make parts or products, and

2. economic manufacturing - the transformation of

materials into items of greater value by means of
one or more processing and/or assembly
operations
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Manufacturing

Manufacturing redefined
Manufacturing, a branch of industry which accounts for the application of tools
and a processing medium to the transformation of raw materials into finished
goods for sale.
Manufacturing can be defined as the transformation of raw materials into useful
products through the use of the easiest and least expensive method.

Raw Materials- Transformation Outputs

 Men  Shape  Finish Goods
 Machine  Size  Service
 Material  Forms  Waste
 Methods  Add  Scrap
 Money  Remove

Feed back

What Engineers Do?

Functions of manufacturing engineers are: Process Design and

Development
• to design the product and the process
Process Optimization
• to determine and define the equipment, tools, and processes
required to convert the design of the desired product in an Quality Assurance
efficient manner;
Cost Analysis and Cost
• to find out the most appropriate, optimal combination of Reduction
machinery, materials and methods needed to achieve
Equipment Selection
economical and trouble-free production. and Maintenance

A manufacturing engineer must have a strong theoretical and Continuous Improvement

practical knowledge:
Supply Chain
• in materials and up-to-date machinery, Collaboration
• to develop analytical solutions and alternatives,
Safety and Compliance
• managerial skill to solve open ended problems.
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Whom to concern?
Manufacturing processes concerned to science and technology of manufacturing
products effectively, efficiently, economically and environment-friendly through:

• application of any existing manufacturing process and system,

• proper selection of input materials, tools, machines and environments,

• improvement of the existing materials and processes, and

• development of new materials, systems, processes and techniques.

Therefore, all manufacturing processes, systems, techniques have to be:

• Technologically acceptable • Economically viable

• Technically feasible • Eco-friendly

Trends of MPs
New trends of manufacturing

Macro Meso Micro Nano

Unit: meter Unit: millimeter Unit: micrometer Unit: nanometer
• Bridges • Crank-shaft • Integrated circuit • Viruses
• Airplanes • Cam/ jig • Micro-gears • Nanofilter
• Statue • Drill bit • Needle • Cell apparatus
• Cars • Machine-gears • Mirco-grippers • Transistors
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Trends of MPs
Have you seen???
Manufacturing processes

Traditional Nontraditional
Chemical
Mechanical
Electrical
Thermal

Manufacturing processes

Traditional Nontraditional
Chemical
Mechanical
Electrical
Thermal
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Classification of MPs
In manufacturing, the terms ‘top-down approach’ and ‘bottom-up approach’ refer to
two different strategies or methodologies for organizing and implementing production
processes. Here's a breakdown of each approach:

Top down Approach Bottom up Approach

» etch away material to make the » moving atoms around to create
products products

process is designed and organized

from the top level, and then
breaking them down into more
detailed plans and tasks.

starting from the lower levels, and

gradually building up to higher-level
processes and decisions.

Classification of MPs
Casting and
Manufacturing operations can be divided into two basic types: molding

(1) Processing operations, and (2) Assembly operations. Shaping

Particulate
processing
process
Deformation
process
Processing operations- transforms a work material
Material
from one state of completion to a more advanced Processing Property removal
enhancing Heat treatment
operations
state that is closer to the final desired product. process

Cleaning and
surface
treatment
Surface
processing
operations Coating and
Manufacturing deposition
processes process

Assembly operation- joins two or more components Welding

Permanent
to create a new entity, called an assembly, joining
Brazing &
soldering
process
subassembly, or some other specific terms. Assembly Adhesive
operations bonding
Thread
fasteners
Mechanical
fastening Permanent
fastening
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Shaping and forming processes are fundamental techniques

used in manufacturing to transform raw materials into finished
products by altering their shape, size, or properties.
• Forging • Extrusion • Stamping • Rolling • Forming

Property-enhancing processes are techniques used to alter the

mechanical, physical, and/or chemical properties of metal
components or materials. These processes are often employed to
increase strength, hardness, durability, corrosion resistance, and
other desirable characteristics.

Surface processing operations are a diverse set of techniques used

to modify the surface of materials, typically to improve their
properties or prepare them for specific applications. These
operations can involve physical, chemical, or mechanical methods.

Material Removal Processes

A family of shaping operations, the common feature of
which is removal of material from a starting workpart
so the remaining part has the desired geometry.

 Machining – material removal by a sharp cutting tool, Traditional

e.g., turning, milling, drilling, etc.

 Abrasive processes – material removal by hard,

abrasive particles, e.g., grinding, polishing etc.
Abrasive process

 Nontraditional processes - various energy forms other

than sharp cutting tool to remove material