Lecture 1

01NLEJM
Manufacturing processes
(MECHANICAL ENGINEERING- Torino)
PROF.SSA MANUELA DE MADDIS
Department of Management and Production Engineering (DIGEP)
+39 011 0907234

manuela.demaddis@polito.it
Assistants : Prof. F. Lombardi, Ing. J.Sauza.
30/09/2015
Manufacturing Processes
manuela.demadis@polito.it
Lectures/Practical lectures
Thursday 10:00-13:00 classroom 17 A/ Laib 3B
Friday 10:00-13:00 classroom 6N
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Didactic Portal
- any changes on lectures timetable and classroom
-didactic material
-information about the exams
All information about the course are on the website
https://didattica.polito.it/pls/portal30/sviluppo.guide.visualizza?p_cod_ins=01NLEJM&p_a_acc=2015
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Exams information
DURATION
MIN 1,5 h/MAX 2 h
Compulsory written examination
The written exam will concern all course programme
and will be made up of theoretical questions and practical exercises
Rules and regulations
The students are allowed to use a personal formulary (a single A4 page) where
they can note formulas which they are unable to remember.
They cannot use any material (e.g. books or any other type of materials)
The students are permitted to use a simple calculator (i.e. not scientific), but
cannot use any other electronic device such as mobile phones or notebooks.
The overbooking students can attend the course but are not allowed to the exam
till they will not be regularly registered.
Unless they have a official justification released by Politecnico di Torino
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During the lesson will be registered the signatures of

the present students.
The Student which attend at least 70% of the course lessons may present a
report ( not compulsory) on a topic, of them choice, explained during the
course to get a vote between 0-3 that they can sum to the written exam
result.
Exemples:
Compulsory written result: 15; report result 1. Not pass exam
Compulsory written result: 15: report result 3. Pass exam with 18
Compulsory written result: 30; report result 3. Pass exam with 30L
The report have to contain only material used during the course ( slide of the
professor - exercise carried out during the laib - book suggested from the
professor) not information taken from internet or other source. The report
should be an, ordered and good structured, word file on a theoretical subject
of the course program with the explanation of the relative exercises. The
relative exercises have to be soved also in a added .xls file.
You can work in a team maximum of 3 students. Each group have to chose a
different topics.
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At the end of each lesson only one group can

reserve the topic explained during the lesson. The
team will have to upload the report on the
didactical portal in the session elaborati within
2 weeks.
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Course programme
?
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Manufacturing
Manufacturing is the use of machines, tools and labor to
produce goods for use or sale. The term may refer to a range
of human activity, from handcraft to high tech, but is most
commonly applied to industriasl production, in which raw
materials are transformed into finished goods on a large
scale
Process
A particular course of action intended to achieve a result.
Systematic series of mechanized or chemical operations that
are performed in order to produce or manufacture something
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TRANSFORMATIONS
What do we intend as transformations?
Def. :The variation in time of one or more properties of the
part obtained by suitable elementary processes.
Parts property)
Final state
Transformations
trajectory
i
Starting state
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t (time)
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Examples:
Shape and size transformation (macrogeometry

of the part);
Transformation of the surface finish of a part

surface (macrogeometry of the part);
Transformation of mechanical characteristics

(hardness, max load);
Transformation of state, of temperature.
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WHAT DO WE NEED TO CARRY OUT A TRANSFORMATION?
Factors that contribute to a transformation

Material
Energy
Information
Resources
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M1
MATERIAL
M2
Material
Raw /
Semimanufactured
Trasformazione
Transformation
Material
Semimanufactured /
Finished
Further Materials
Chips/Scraps/wastes
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M2
M1
Raw/Semimanufac
tured
Start product on which we want to operate the

transformation
Further
Materials
Materials that may be called for the correct

execution of the transformation (Ex. Coolants);
Materials that can be added to the raw part
during the transformation.
Semimanufactured /
Finished
Product obtained after the transformation.
Chips
Material into excess presents in the raw and

exported during the transformation.
Scraps
Product finished / Semimanufactured which does

not respect the specifications.
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M1
M2
State of the Material

Solid
Compact
Granular
Liquid
Gaseous
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M2
M1
Transfomations involve a mass variation M of the

finished/semimanufactured product (M2) with respect
to the mass of the raw/semimanufactured part of the
beginning (M1).
Three possible cases:
M = M2 - M1 < 0
M = M2 - M1 = 0
M = M2 - M1 > 0
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M2
M1
M = M2 - M1 < 0
M1
Raw
After transformation the mass of the

finished part is smaller than that of the
beginning.
Transformation
M2 < M1
Semimanufactured/
Finished
M Chips = - M
Further Materials
(coolants)
Chips / Scraps
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M2
M1
M = M2 - M1 = 0
M1
The transformation leaves

unchanged the parts mass.
Trasformazione
Raw
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M2 = M1
Semimanufactured/Fini
shed
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M2
M1
M = M2 - M1 > 0
The transformation involves an increase

of the mass of the final part, because it is
the output of the assembly of more parts.
M1a
Part a
M1b
Part b
Transformation
Trasformazione
M2 = M1a + M1b + M1c

Semimanufactured /
Finished
M1c
Part c
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Material
Energy
Information
Resources
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M2
M1
Energy
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ENERGY
Trasformazione
Transformation
Energy
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Heat
E2
E1
Transformations are operated thanks to

an exchange of energy;
The energy exchanged may be of
various type:
Mechanical;
Thermal;
Chemical
..
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E2
E1
Mechanical Energy
The exchange of energy occurs by means of
forces that perform mechanical work;
Examples:
Bending
Turning
Shaving
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E2
E1
Thermal Energy
The exchange of energy occurs estabilishing
a suitable temperature difference between
parts.
Examples
Melting butter in a pot;
Melting metal;
Solidification of an ice rock.
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E2
E1
Chemical Energy
The exchange of energy occurs by means of

chemical reactions.
Examples:
Elimination of stains through detergent.
Deposition of CVD coatings.
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TRANSFORMATIONS
Transformation
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TRANSFORMATIONS
Transformations are realized through

elementary processes (processing);
These elementary processes may be
classified by type of energy used.
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Elementary processes which use mechanical

energy
Elastic deformation (ex.: to pull an elastic,to
compress a spring);
Plastic deformation (Ex.: to fold a plate, coining
a coin);
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Break
(Ex.:to break a glass plate);
Mixing
(Ex.: to mix powders)
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Elementary processes that use

thermal energy
Heating/Cooling
(Ex. To heat a component to stretch it or cool it to
contract it - Coupling forced)
Melting
(Ex. To melt tin to assembly a component
Welding)
Solidification
(Ex. To solidify steel melted in a form Foundry
Processes).
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thermal energy
Evaporation
- (Ex. Drying of a green mold)
Condensation
- (Ex. To condense vapours of metals on a surface)
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chemical energy
Solution (Ex. Solution of zinc in copper to obtain
brass);
Combustion (Ex. Combustion of hydrocarbons)
Diffusion (Ex. Atoms of carbon penetrate by
diffusion in the steels structure changing
properties - Cementation).
Hardening (Ex. Hardening of the cement).
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Material
Energy
Information
Resources
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Information
INFORMATION
Information
Technolocal
Managerial
Information
Transformation
Feedback from
the process
Feedback
from the part
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Information
Transformations, to be activated, need

suitable information of two types:
Technoloical Information:
List of types of instruments needed to execute the trasformation
(machines, tools, fixtures).
Trajectory of the process.
Managerial Information:
When to execute the trasformation
Which part is to be transformed (among possible alternatives).
What specific instruments to use (among possible alternatives).
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Material
Energy
Information
Resources
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RESOURCES
Resources
Transformation
Resources
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Resources
Any trasformation needs suitable resources.

Machine
It supplies the energy needed

for the transformation and carries out
the trajectory of process.
Tool
It allows to transfer the energy

from the machine to the
raw/semimanufactured part.
Fixtures
It allows the raw /semimanufactured

part to be integrated in the machine.
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TECHNOLOGICAL
TRANSFORMATION SYSTEM
Together with the raw/semimanufactured part the
resources allow to define the technological
transformation system.
This is therefore composed of:
Raw/Semimanufactured part
Machine
Fixtures
Tool
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Example of of a technological transformation system
To break a coconut
Stone
(Tool)
Coconut
Man
(Machine)
(Raw material)
Hand
(Fixture)
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Example of technological transformation system
Drilling of a part
Drilling Press
(Machine)
Drill
(Tool)
Part
(Raw/Semimanufactured part)
Work table
Clamps
(Fixture)
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Example of technological transformation system
Mold Polishing
Robot
(Machine)
Abrasive Brush.
(Tool)
Stamp
(Semimanufactured part)
Work Table
Clamps.
(Fixture)
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CLOSED TECHNOLOGICAL
CLOSED SYSTEM:
The force loop
closes inside the
machines structure
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OPEN TECHNOLOGICAL
OPEN SYSTEM:
The force loop is
external to the
machines structure
and closes with the
ground.
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Example of closed technological transformation system.

MACHINING CENTRE FOR BURRS REMOVAL.
Tool
Machine
Raw part
Fixture
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Example of open technological transformation system.

ANTHROPOMORPHIC ROBOT FOR TRIMMING
Tool
Machine
Raw part
Fixture
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Example of open loop techological transformation system.
Welding
Robot
tagliolaser3d_2.mov
Laser cutting Robot

WJ cutting
Robot
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Sequence of processes ( trasformations) that
modify the shape, size, surface conditions
of single parts
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Theory of transformations. Introduction on manufacturing processes ( Prof. De

Maddis)
Mechanical fundamentals ( Prof. F. Lombardi)
Mechanical behavior , testing and manufacturing properties of materials (F.
Lombardi)
Deformation Processes ( Prof. Lombardi/ De Maddis)
Solidification processes ( Prof. ssa De Maddis)
Material removal Processes ( Prof. De Maddis)
Computer Numerical Control ( Ing. Sauza)
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Manufacturing
Processes
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Books:
Manufacturin Engineering and Technology
Kalpakjian_Schmid
Pearson
Fundamentals od Modern Manufacturing

Mikell P. Groover
John Wiley & sons, inc.
Mechanical Metallurgy
George E. Dieter
Mc Graw - Hill Book Company
.
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Deformation
processes
Q-Form
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Deformation processes
1. Bulk deformation
Rolling
Forging
Extrusion
Wire and bar drawing
2. Sheet metalworking
Bending
Deep drawing
Cutting
Miscellaneous processes
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Solidification Processes
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Casting
Mold
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Cast metal
Blank
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56
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Second industrial
revolution 1947
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Material removal processes

Turning
Milling
Drilling
Broaching
Grinding
Ecm
Awjc
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CNC simulator
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Some Fusion Welding Processes
Arc welding (AW) melting of the metals is accomplished by electric

arc
Resistance welding (RW) - melting is accomplished by heat from
resistance to an electrical current between faying surfaces held
together under pressure
Oxyfuel gas welding (OFW) - melting is accomplished by an oxyfuel
gas such as acetylene
Some Solid State Welding Processes
Diffusion welding (DFW) coalescence is by solid state

fusion between two surfaces held together under
pressure at elevated temperature
Friction welding (FRW) - coalescence by heat of friction
between two surfaces
Ultrasonic welding (USW) - coalescence by ultrasonic
oscillating motion in a direction parallel to contacting
surfaces of two parts held together under pressure
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PROCESS SELECTION
Each process have certain attributes: the materials it
can handle, the shapes it can make, their size,
precision, and an optimum batch size (the number of
units that it can make economically).
Manufacturing Process
Case study
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Scales in Manufacturing
Illustration of the range of

common sizes of parts and the
capabilities of manufacturing
processes in producing these
parts.
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PRECISION OF THE
TRANSFORMATIONS
Ideal transformation :
the starting and final states are

defined in deterministic manner.
Parts properties)
Final State
Transformations
trajectory
i
Starting State
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76
( time)
REAL TRANSFORMATIONS
All real transformations are affected by phenomena that arent
controllable (disturbances) and that modify the final result.
(Parts properties)
f2
f1
Final State 2
Variability of
the results
Final State 1
f3
Finale State 3
i
Starting State
t (time)
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Even if, with suitable techniques, the features of the input materials of a
transformation may be controlled (acceptance control), nevertheless, generally,
the starting state of the transformation isnt precisely known.
This makes more uncertain the final result.
Parts properties)
Variability of the
starting state
Variability
of the
result
i2
Starting State 2
i1
Starting State 1
t(time)
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Every transformation is subjected to disturbances of different origin

Information
Disturbances
Troules
Technological
Managerial
Material
Material
Raw/
Semimanufactured
Further Materials
Energy
Disturbances
Transformation
Semimanufactu
red/Finished
chips/scraps
Energy
Heat
Disturbances
Information
Resources
Machines
Tools
Fixtures
Feedback from the process

Feedback from the part
Disturbances
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REAL
TRANSFORMATIONS
The variability of the final state depends on many
different causes (Disturbances) that contribute to
determine the variability of the output and cannot be
eliminated.
The process may be also subjected to variations that are
caused by specific reasons which may be identified and
eliminated:
Wear/breakage of tools
Wear/breakage machines mechanical components.
Introduction of inexpert operators.
..
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Example: operator replacement
Introduction of an
inexpert operator
The variability of the output increases due to the presence of an inexpert

operator. In this case there is an assignable cause and the variability of the
output may be and must be reduced (replacing the operator, through suitable
education courses, through more clear instructions, etc)
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Example: Tool Wear
Tool
Wear
Tool
Wear
Due to tool wear the average value of the dimensions produced increases
continuously. In this case there is an assignable cause which may be and
must be removed (for example replacing or reconditioning the tool, adjusting
its trajectory to take into account progressive wear).
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How to consider Disturbances?

The presence of Disturbances implies that the output of the
transformation will never be the same, but it will vary inside an
interval of possible values.
Disturbances due to assignable causes must be identified and
eliminated (control charts).
Once eliminated the Disturbances due by assignable causes,
the problem is to ensure that possible outputs of a
transformation are contained inside a tolerance interval defined
during the design phase (specifications).
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Variability of output and tolerances (capability)
OK
Parts property)
Variability
of the result
Starting state 2
Variability of
starting state
i2
i1
Starting state 1
t (time)
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Tolerance
interval
Variability of the output and tolerances (capability)
NO !!!!
Parts property)
Variability of
the result
Variability
of the
output
Starting state 2
Variability of
starting state
i2
i1
Starting state 1
t
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(time)
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REDUCTION OF OUTPUTS VARIABILITY
When the variability of the output is higher than the

specified tolerance we may:
Improve the process
Change the process
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Example of process improvement
DRILLING
Specification:
Obtain a blind hole with axis laying at d=10 mm from a reference
surface.
The specified tolerance for this dimension is + 0.1 mm.
We need to determine the process which allows to realize this hole,
with the specified tolerance.
d = 10 + 0.1
Unit: mm
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INTERVAL OF SPECIFIED TOLERANCE
d(mm)
Position of hole axis)
10 + 0.1
Tolerance
interval
10 - 0.1
t (time)
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1st CASE
Drilling with standard drill
Helicoidal drill
Variability of holes position : + 0.18 mm

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Drilling with standard drill
NO !!!!
d(mm)
Position of holes axis)
10 + 0.18
10 + 0.1
Variability
of result
Tolerance
interval
10 - 0.1
10 - 0.18
t (time)
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2nd CASE
Drilling after a center drilling
1.
Center drill
2. Standard drill
Position variability of the axis: + 0.1 mm

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Drilling with center drill
d(mm)
LIMIT SITUATION
Position of holes axis)
10 + 0.1
Variability
of result
Tolerance
Interval
10 - 0.1
t (time)
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3 rd CASE
Drilling with a guide bushing after center drilling
1. Center drill
2. Standard
chisel drill with
guide bushing
Variability of holes position: + 0.05 mm

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Drilling with a guide bushing after center drilling
d(mm)
Posiotion of holes axis)
OK
10 + 0.1
10 + 0.05
Variability
of result
Tolerance
interval
10 - 0.05
10 - 0.1
t (time)
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CHOICE OF PRODUCTION PROCESS
Technical practicability
Economical practicability
Production Process
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TECHNICAL PRACTICABILITY OF THE

PROCESS
The process that makes the part must guarantee:
Technical Specifications of the part indicated in the

technical design (tolerances, roughness, etc.);
Required amount (production capability) ;
The respect of environmental laws;
The respect of safety lows.
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ECONOMICAL PRACTICABILITY OF THE

PROCESS
Besides technical practicability of the production process we

need to verify also its economical practicability.
This means that the costs associated to the process must be

sustainable with respect to the income derived by the use of its
production capability.
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ECONOMICAL PRACTICABILITY OF THE

PROCESS
The production activity must guarantee to the firm a profit in
monetary terms.
. In first approximation, neglecting financial proceeds (ordinary and
extraordinary), the profit derives by the difference between the
productions value and productions cost.
PROFIT = PRODUCTIONS VALUE PRODUCTIONS COST
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PRODUCTIONS VALUE
Manufacturing add value to the materials as they become discrete
products and are marked .
Monetary value:
Use value reflecting the function of the product
Prestige value reflecting the attractiveness of the product that

make its ownership desiderable
" Value engineering" conducts a value anlysis jointly to designers,

manufacturing engineers, and quality-control, purchasing, markeing
personnel and managers to obtain the maximum performance per unit
cost
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PRODUCTIONS COST
Material cost ( type material, processing history, size, shape, surface
characteristics)
Tooling cost (tools, dies,molds,patterns, fixtures required to manufacturing a

product)
Fixed costs ( electric poer, fuel, taxes, rent etc)

Capital costs
(Machinery, tooling, equipment, investiment in building, land)
Direct-labot Costs (labor rate * amount of time that the worker spends
producing the particular part)
Indirect-labor Costs (supervision, maintenance, quality control, repai,

research, sales activities etc)
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CHOICE OF PRODUCTION PROCESS
Technical practicability
Economical practicability
Production Process
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101
chap 1and chap 40
Manufacturing Engineering and Technology

Kalpakjian
30/09/2015
102

Lecture 1

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Lecture 1

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01NLEJM

+39 011 0907234

Assistants : Prof. F. Lombardi, Ing. J.Sauza.

During the lesson will be registered the signatures of

At the end of each lesson only one group can

Shape and size transformation (macrogeometry

Transformation of the surface finish of a part

Transformation of mechanical characteristics

Transformation of state, of temperature.

WHAT DO WE NEED TO CARRY OUT A TRANSFORMATION?

Factors that contribute to a transformation

Start product on which we want to operate the

Materials that may be called for the correct

Product obtained after the transformation.

Material into excess presents in the raw and

Product finished / Semimanufactured which does

State of the Material

Transfomations involve a mass variation M of the

After transformation the mass of the

The transformation leaves

The transformation involves an increase

M2 = M1a + M1b + M1c

Factors that contribute to a transformation

Transformations are operated thanks to

The exchange of energy occurs by means of

Transformations are realized through

Elementary processes which use mechanical

(Ex.:to break a glass plate);

(Ex.: to mix powders)

Elementary processes that use

Elementary processes that use

Elementary processes that use

Factors that contribute to a transformation

Transformations, to be activated, need

Factors that contribute to a transformation

Any trasformation needs suitable resources.

It supplies the energy needed

It allows to transfer the energy

It allows the raw /semimanufactured

Example of of a technological transformation system

Example of technological transformation system

Example of technological transformation system

Example of closed technological transformation system.

Example of open technological transformation system.

Example of open loop techological transformation system.

Laser cutting Robot

Theory of transformations. Introduction on manufacturing processes ( Prof. De

Fundamentals od Modern Manufacturing

Material removal processes

Some Fusion Welding Processes

Arc welding (AW) melting of the metals is accomplished by electric

Diffusion welding (DFW) coalescence is by solid state

Illustration of the range of

the starting and final states are

Every transformation is subjected to disturbances of different origin

Feedback from the process

The variability of the output increases due to the presence of an inexpert

How to consider Disturbances?

Variability of output and tolerances (capability)

Variability of the output and tolerances (capability)

REDUCTION OF OUTPUTS VARIABILITY

When the variability of the output is higher than the

Example of process improvement

INTERVAL OF SPECIFIED TOLERANCE