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Manufacturing is the process of producing a solid product of definite size and shape from a given material taken in three possible states: in solid state - e.g. Forging,rolling, extrusion, drawing etc. In liquid or semi-liquid state - casting, injection moulding etc.
Manufacturing is the process of producing a solid product of definite size and shape from a given material taken in three possible states: in solid state - e.g. Forging,rolling, extrusion, drawing etc. In liquid or semi-liquid state - casting, injection moulding etc.
Manufacturing is the process of producing a solid product of definite size and shape from a given material taken in three possible states: in solid state - e.g. Forging,rolling, extrusion, drawing etc. In liquid or semi-liquid state - casting, injection moulding etc.
manufacturing) 2.What it comprises of 3.What are the various steps in manufacturing 4.Major manufacturing processes 5.Examples 8 M are inputs for any manufacturing process 1.Men 2.Material 3.Machines 4.Money 5.Method 6.Market 7.Management 8.Message
1.Products 2.Services and 3.scart Need of customer- main driving force behind the concept of manufacturing How to know the need? 1.Historical data 2.Market research 3.Simulation 4.Sales forecasting
Marketing dept. Marketing research people questionaires Unbiased data. Simulate it Generate data Biased data Refine data Simulate it. Generate data manufacturing Design engg. HRM production scheduling Inventory control Quality control Need of customer
Feasibility study needs converted to specification
Design concept formulation
Model formulation
Analysis of model If found correct
Process planning
.process planning 1.Production planning 2.Design and procurement of new tools 3.Order material 4.NC, CNC, DNC programming
Production
Quality control
Packaging Shipping Marketing (a) Shaping or forming Manufacturing : a solid product of definite size and shape from a given material taken in three possible states: in solid state e.g. forging ,rolling, extrusion, drawing etc. in liquid or semi-liquid state e.g. casting, injection moulding etc. in powder form e.g. powder metallurgical process. (b) Joining process Welding, brazing, soldering etc. (c) Removal process Machining (Traditional or Non- traditional) (d)metal melting : casting
Mechanical machining :AJM,USM,WJM,AWJM etc. Thermal machining : LBM, PAM, PAC, EBM, W-EDM etc. Chemical and electrochemical machining : ECM, Electro- chemical deburring, Electro- chemical grinding etc. Direct use of energy : LBM, EDM, Electro-chemical machining etc. Fusion welding Chemical: thermit welding Electrical : arc welding Solid state welding Electrical: resistance welding Chemical:explosion welding Mechanical:friction welding Expendable mould casting: sand casting, ceramic shell casting etc. Permanent mould casting: slush casting, pressure casting,die casting,squeeze casting etc.
. Machine Tools produce desired geometrical surfaces on solid bodies (preformed blanks) Characteristics of machine tools: . 1.Devices for firmly holding the tool and work 2.Drives for providing power and motions to the tool and work 3. Kinematic system to transmit motion and power from the sources to the tool-work 4.Automation and control systems 5. Structural body Process of removal of material by a cutting tool to get the desired dimensions and in process generating a new surface Concepts: 1.Generatrix and directrix concept 2.Tool work motions 3.Machine tool drives 4.Mechanism of chip formation
Key principles: 1.Generatrix 2.Directrix 3.Principle of Generation of flat surface . Principle of generation of cylindrical surfaces Long straight cylindrical surfaces Cylindrical surface of short length Form cylindrical surface . Principle : On a flat plain a straight line called Generatrix (G) is traversed in a perpendicular direction called Directrix (D) resulting a flat surface . The lines representing the Generatrix and Directrix are obtained by the motions of the tool-tip (point) relative to the work surface Types of relative motions: Formative motions 1. Cutting motion (CM) 2. Feed motion (FM) Auxiliary motions Indexing motion .
Generatrix (G) Cutting motion (CM) Work (W) Directrix (D) Feed motion (FM) Tool (T) Generatrix : provided by the cutting motion imparted . to the cutting tool Directrix : provided by the feed motion of the work. . G CM T . D FM W .
.: Tracing (Tr) .continuous line is attained as a trace of path of a moving point . Forming (F) .Generatrix is simply the profile of the cutting edge Tangent Tracing (TTr) .Directrix is taken as the tangent to the series of paths traced by the cutting edges . Generation (G): G or D is obtained as an envelope being tangent to the instantaneous positions of a line or surface which is rolling on another surface .. Gear generation by hobbing is an example of generation A long straight cylindrical surface : is obtained by a circle (G) being traversed in the direction (D) parallel to the axis A cylindrical surface of short length : is obtained by traversing a straight line (G) along a circular path (D
Form cylindrical surfaces : by rotating a curved line (G) in a circular path (D) 1.Material ahead of tool undergoes plastic deformation 2.Crack formation in deforming zone 3.Small lump of material moves up the rake face 4.Crack propagation (either in interior or towards the surface) 5.fracture Favourable conditions: 1.Ductile material 2.High speed 3.Low feed and depth of cut 4.High back rake angle
Favourable conditions: 1.Brittle materials 2.Low speed 3.High speed and depth of cut 4.Low back rake angle chips with Built up edge Favourable conditions: 1. Ductile material 2. Low speed 3. High feed and depth of cut
.Stepped drives : 1.very common in conventional . machine tools . 2. discrete number of speeds and feeds are available 3.preferably in G.P. (Geometric Progression) series 4.Attained by using gear boxes or pulleys + power pulleys stepless drives: 1.common in modern CNC machine tools 2.enable optimum selection and 3.flexibly automatic control of the speeds and feeds. 4. attained usually by : (a) Variable speed AC or DC motors (b) Stepper or servomotors (c) Hydraulic power pack