Concepts of Manufacturing
The word manufacturing is derived from the Latin “manu factus”, meaning “made by hand”. Modern meaning of the word manufacturing is the process of converting raw materials into products. The manufacturing process involves three important phases: 1) product design, 2) selection of materials, and 3) the selection of various manufacturing production methods and techniques. Any number of process methods may be used by industry. For this reason, 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. The information needed to produce a part in a manufacturing department, most often comes in the form of a working drawing.
Manufacturing Processes
In the actual processing of a part consists of three main stages: 1) ROUGH FORMING 2) Finishing, and 3) Assembly.
Rough Forming – consist of shaping the part by casting, forging, and welding.
Casting
- Sand Casting is made by pouring molten metal into a cavity in damp sand.
Once it cools and is removed from the mold the part is then machined.
- Die Castings are formed by forcing molten metal into cavities between metal dies.
i. This process is much faster than sand casting and is used where rapid production is used.
ii. It also requires little or no machining.
Sand Casting Video 1
Sand Casting Video 2
Die Casting Video 1
Die Casting Video 2
Forging
Drop forging is produced by hammering heated bars of metal between dies.
Press forging is produced by applied by a slowly squeezing action.
***Advantage of forgings over castings is that forgings are much stronger
Forging Process Video 1
Drop Forging Video 2
Press Forging Video 1
Press Forging Video 2
Welding
What is Welding? The process of fusion or joining of two pieces of metal by means of heat.
Usually a part is built up from cut stock forms, assembled, and welded together.