Basic Machine

Processes
Competency D403.00
Identify the basic
concepts of the
manufacturing processes.
 Basic Machine Processes

Objective D403.01
Explain the concepts
of the
manufacturing
process.
 Manufacturing
 Arrived from the Latin word
“manu factus”, meaning “made
by hand”.
 Manufacturing is the process of
converting raw materials into
products.
 WHY STUDY
MANUFACTURING PROCESSES?

The designer and the drafter

must have a working knowledge
of the various processes that
could produce a part in order to:
lower cost and reduce
production time.
 Three Phases Of The
Manufacturing Process
1. Product design.
2. Selection of materials.
3. Selection of production
methods and techniques.
The information needed to produce a
part, most often comes in the form of a:

Working Drawing
 Three Main Stages Of The
Production Of A Machined Part

Rough Forming
Casting, Forging, Welding

Finishing
Drilling, machining, surfacing

Assembling
The assembly of parts
 The Casting Process

 First a pattern is made.

 Then a cavity is made by placing a pattern in wet
sand.
 Next molten metal is poured into the cavity of damp
sand.
 The Casting Process
Rough Machined
Casting Finish

 The rough casting is now ready for the machine shop.

 Holes are then bored and reamed.
 Top and bottom surfaces are machined
 Smaller holes will be drilled and counterbored.
 All corners on cast parts are fillets and rounds.
 Forging Process

 Forging is produced by using heavy mechanical

presses or hammering heated bars of metal
between dies.
 Advantages of forging over sand casting are that
forged parts are much stronger and less brittle.
 Welding
Welded

Cast

Welding is the fusion or joining of

two pieces of metal by means of
heat, with or without the application
of pressure.
 Manufacturing Materials
Fall into three general categories:

1. Metal
2. Plastic
3. Inorganic materials
 Metals are classified as:
 Ferrous - contain iron and steel.

 Nonferrous - do not have iron content

(such as copper and aluminum).

 Alloys - mixture of two or more metals.

Inorganic Materials Include:
• Carbon and graphite - have low
tensile strength (ability to be
stretched).

• Ceramics are clay and glass

materials. (resistant to heat,
chemicals, & corrosion).
 Heat-Treating:
 Annealing – is the process generally used
to soften metal by heating followed by slow
cooling.

 Hardening – requires heating and then

rapid cooling in oil or water.
 Plastics Processing
The plastics industry represents one of the
major manufacturing segments.

 Thermosetting – becoming permanently

hard and unmoldable when once
subjected to heat.

 Thermoplastic – becoming or remaining soft

and moldable when subjected to heat.
Typical Plastic Processing Operations Include:

 Extrusion
 Blow Molding
 Injection Molding
 Thermoforming
 Extruding

The process of producing

shapes by forcing hot metal
through a die that has and
opening of the desired shape.
 Blow Molding

Used in the production of

bottles, automotive ductwork,
hollow toy components, and
door panels.
 Injection Molding
.
   
 

Used to manufacture products such

as housings for electronic
implements, automotive components,
food storage containers, and
components for medical applications.
 Thermoforming

 Used in the manufacturing of thin-walled

packages for the food industry.
 Manufactured primarily by injection molding.
 CAD in Manufacturing

 The process of developing a design drawing on a

CAD system and producing it on a computerized
machine is called CAD/CAM.
 The process of converting the CAD drawing into a
preprogrammed, coded instructions is called
Computer Numerical Control (CNC).
 The advantages of the (CNC) is, better production and
control, increased productivity, decreased labor and
lower production costs.
 The Machinist Steel Ruler

 Commonly used measuring tool for getting

rough measurements on a part.
 The smallest division on the fractional
scale is 1/64” (.016).
Vernier Caliper

 Precise measuring.
 Decimal, fractional, or
metric.
 Often used by drafters
to record dimensions
from a machined
prototype or part.
 6” Dial Caliper
Step
Inside Inside Depth

4-way
4-way
Outside
Measurement
Measurement
6” Dial Caliper – Three Scales
METRIC
(mm)

FRACTIONAL DECIMAL
(1/64”) (.XX)