Manufacturing Processes

What you'll learn

• Classify manufacturing processes into their families, relate production volume to layout, and select processes using requirements screening and fixed-plus-variable cost models with breakeven quantities.
• Describe sand, investment, die and other casting processes, explain solidification structures, apply Chvorinov's rule to size risers, and identify the causes and remedies of casting defects.
• Estimate forces and power in rolling, forging and extrusion using true strain and flow stress, and explain how hot and cold working and grain flow affect part properties.
• Calculate blanking forces, flat lengths with bend allowance, springback and drawing ratios, and choose suitable sheet forming processes and dies.
• Analyze orthogonal cutting with chip ratio, shear angle and Merchant's model, estimate cutting power from specific energy, and apply Taylor's tool life equation.
• Plan turning, milling and drilling operations, calculate machining time and cost per part, find minimum-cost and maximum-production cutting speeds, and read basic CNC programs.
• Specify and predict surface roughness, choose grinding wheels and conditions that avoid burn, and explain finishing processes and surface integrity, including shot peening.
• Compare arc and other welding processes, calculate heat input and carbon equivalent, explain weld zones, hydrogen cracking and distortion, and describe procedure qualification and inspection.
• Design bolted joints with controlled preload and tightening torque, and choose rivets, press fits, brazing, soldering, adhesives and sealants for suitable applications.
• Describe extrusion, injection molding and other polymer processes, estimate clamp force and cooling time, apply molded part design rules, and outline composite manufacturing methods.
• Explain the additive manufacturing process families, estimate build time and cost for powder bed fusion, and judge when additive manufacturing is the right choice.
• Apply measurement principles, control charts and capability indices, build manufacturing cost estimates, and use lean methods such as takt time, flow, pull and OEE in a production launch plan.