16-01-2015

INTRODUCTION TO
MANUFACTURING AND
METAL CUTTING

PROFESSOR (DR.) VINAY SHARMA,

DEPARTMENT OF PRODUCTION ENGINEERING
BIRLA INSTITUTE OF TECHNOLOGY, MESRA, RANCHI,
JHARKHAND- 835215
email: vinay1970@gmail.com

INTRODUCTION TO MANUFACTURING

Manufacturing describes the entire sequence of events from the time the raw material is
brought into the production system until it is changed into the desired characteristics of a
product.
There are several methods of changing the geometry of bulk material to produce a
mechanical part:
• By putting material together (+); Performed on the atomic, micro, or macro scales. E.g.
electroplating, electroforming (at atomic level);
• By moving material from one region to another (0); Rolling; Forging and extrusion
• By Melting the material and giving it desired shape; casting
• By converting the material into powder and than giving it desired shape; powder
metallurgy
• By removing unnecessary material (-); Metal cutting
• Rapid Prototyping/ layered manufacturing

DR. VINAY SHARMA , PROFESSOR & HEAD, PRODUCTION ENGINEERING, BIT MESRA RANCHI-835215 2

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MANUFACTURING PROCESS CLASSIFICATION

MANUFACTURING PROCESS CAN ALSO BE CLASSIFIED AS:

A. CONSTANT MASS OPERATIONS

• Casting, rolling, extrusion, wire drawing, forging, etc.

CASTING ROLLING EXTRUSION

DR. VINAY SHARMA , PROFESSOR & HEAD, PRODUCTION ENGINEERING, BIT MESRA RANCHI-835215 3

MANUFACTURING PROCESS CLASSIFICATION

B. MATERIAL ADDITION OPERATIONS – BOTTOM UP APPROACH

• Bolting, riveting , keying, welding, rapid prototyping, etc.

DR. VINAY SHARMA , PROFESSOR & HEAD, PRODUCTION ENGINEERING, BIT MESRA RANCHI-835215 4

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MACHINING

C. MATERIAL REMOVAL OPERATIONS (SURPLUS MATERIALS REMOVED) –

TOP DOWN APPROACH

• Machining, finishing, etc.

DR. VINAY SHARMA , PROFESSOR & HEAD, PRODUCTION ENGINEERING, BIT MESRA RANCHI-835215 5

DR. VINAY SHARMA , PROFESSOR & HEAD, PRODUCTION ENGINEERING, BIT MESRA RANCHI-835215 6

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METAL CUTTING:

Machining is a process designed to change the size, shape, and surface of a material through
removal of materials that could be achieved by

Conventional Machining:
straining the material to
fracture

Non conventional Machining:

Using energy to machine material
(Thermal, Chemical, or
Mechanical)

Hybrid Machining:
combination of the above

DR. VINAY SHARMA , PROFESSOR & HEAD, PRODUCTION ENGINEERING, BIT MESRA RANCHI-835215 7

METAL CUTTING:

the machining process has the following characteristics:

• They improve the dimensional accuracy and tolerances of the components produced by
other processes.
• Internal and external surface features which are difficult or not possible to be produced by
other processes, can be produced by machining processes.
• Specified surface characteristics or texture can be achieved on a part or whole of the
component.
• It may be economical to produce a component by machining process.

DR. VINAY SHARMA , PROFESSOR & HEAD, PRODUCTION ENGINEERING, BIT MESRA RANCHI-835215 8