Production Engineering (1) Chapter 1 Eng121

Production Engineering (1)

(Eng121)

Books;
Mikell P. Groover, Fundamentals of Modern Manufacturing, 4th Ed.,
John Wiley & Sons, Inc., 2010.

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Production Engineering (1) Chapter 1 Eng121

Table of contents
Chapter 1: Introduction to manufacturing
Chapter 2: Fundamentals of metal cutting
Chapter 3: Turning and related operations
Chapter 4: Shaping and planning operations
Chapter 5: Drilling and related operations
Chapter 6: Milling and related operations
Chapter 7: Grinding and related operations
Chapter 8: Broaching operations
Chapter 9: Numerical Control Machine
Chapter 10: Joining Processes
Grading:
Final exam: 40% Midterm Exam.(s) 20%
Sheets 25% Att. + Project + reports 15%

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Production Engineering (1) Chapter 1 Eng121

Chapter 1
Introduction of Manufacturing
The manufacturing can be defined;
• Technically as; the application of physical, chemical and/or assembly
processes to alter the geometry, properties and/or appearance of a given
starting material to produce the final parts or product, fig. 1(a).
• Economically as; the transformation of materials into items of greater value by
means of one or more manufacturing processing, fig. 1(b).

(a) Technically definition (b) Economically definition

Fig.1 Manufacturing definitions.

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Production Engineering (1) Chapter 1 Eng121

Materials in Manufacturing
Engineering materials can be classified into three basic categories; metals, and
non-metals, fig.2. Another classification is given in fig. 3.
Ferrous Metals
Wrought iron
(contains iron)
Metals Cast iron
Non-Ferrous Metals
and alloys (contains no Steels
iron) Alloy Steels
Engineering
Materials Synthetic materials
Thermosetting plastics
(plastics)
Non-Metals Thermoplastics
Natural materials (rubber,
glass, wood, emery,
ceramics, diamonds, oil, etc.)
Fig.2 Classification of Engineering Materials

Fig.3 The basic Categories of Materials

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Production Engineering (1) Chapter 1 Eng121

Manufacturing processes
Manufacturing operations can be divided into two basic types; processing
operations and assembly operations, fig.4.

Fig. 4
Manufacturing
process
classification.

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Production Engineering (1) Chapter 1 Eng121

The different manufacturing processing operations are shown in figures 5 to 9.

While fig. 10 shows a different manufactured parts.

Fig. 6 Particulate Fig. 7 Deformation processes.

Fig. 5 Solidification processes. processes.

Fig. 8 Metal removing processes.

Fig. 9 Welding processes.

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Production Engineering (1) Chapter 1 Eng121

Fig. 9 Manufactured parts examples.

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Production Engineering (1) Chapter 1 Eng121

Experimental Work
• Cutting motions (note cutting motions of different metal cutting machine tools)
• Types of chips (turn different workpiece materials; with different cutting conditions
and tool geometry, find out the different types of chip and show the role of chip
breaker).
• Holding devices in the lathe (discuss holding time and machining accuracy for most
holding devices).
• Turning tapper with lathe (discuss the different ways to machine tapper in lathe).
• Turning threads in the lathe machine (note pitch and shape).
• Types of holes machined with drilling and how to make internal thread for these
holes (manually and with machine tool).
• Machining the products with milling machines.
• How to cut gears in the milling machine (the use of index device and index plates).
• Grinding machining to finish the products.
• Surface roughness measuring (show the effect of cutting condition in the roughness
parameters).

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Production Engineering (1) Chapter 1 Eng121

Project
Select a product and write down a process sheet to produce it

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