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3. What is manufacturing?manufacturing can be defined as a material that go through a processto produce a product. Theinitial process consist of raw material that will be altered by physical or chemical process thatwill be give output of desired output or product.5.

difficulties encountered at the manufacturing stage must be conveyed to the designers formodification in design, if any. The two-way communication between design andmanufacturing can help to improve the quality of the productto a great extent, asdifferent issues such as practical difficulties, achievable tolerances and processcapabilities will beaddressed.Performance of the manufactured productThe product must function as per the expectations of the end customer. The two waycommunication betweendesigners and customer is the key to have a high quality product.Manufacturing Process Selection CriteriaThe following points need to be considered before the actual manufacturing of aproduct.

Material selection including and considering all the environmental and recyclingaspects

Selection of processing methods such as metal casting, metal forming, sheet metalworking, powder metallurgy,machining, joining, finishing etc.

Shape and appearance of the final product

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Dimensional tolerance and surface finish aspects of the final product

Economics of tooling

Design requirements Functional requirements of the product

Production quantity required

Safety and environmental concerns

CostProduct design is the most important parameter amongst all the parameters of themanufacturing system. Asquality is imbibed at each stage in the product, if the producthas not been designed right at the first stage, nosubsequent operation or steps can bringback the quality into the product. Hence, the material and manufacturing

process selection and all associated concerns such as availability, environmental considerations,recycling etc must be takencare of right at the product design and development stage. Asfar as the manufacturing process is concerned, it must beeconomical and capable of producing the geometric surfaces and other features which are embodied in the designof the product.Manufacturing Processes Classification

There are six basic / fundamental classifications of manufacturing processes.1. Metal casting or Molding: expendable mold and permanent mold2. Metal Forming and Shearing: rolling, forging, extrusion, drawing, sheetforming, powder metallurgy3. Material Removal Processes / Machining Processes: turning,

boring,drilling, milling, planing, shaping, broaching, grinding, ultrasonic machining,chemical machining, electricaldischarge machining (EDM), Abrasive flowmachining (AFM), abrasive jet machining (AJM),electrochemicalmachining, high-energy beam machining, laser beam machining (LBM) etc.4.

Joining: welding, brazing, soldering, diffusion bonding, adhesive bonding,mechanical joining, plasma arc, plasma MIG, projection welding, ultrasonic,electron beam welding, laser welding etc.5. Finishing (painting, anti-corrosion coatings, etc.)6.

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Rapid Manufacturing: stereo-lithography, selective laser sintering, fuseddeposition modeling, three dimensional printing, laminated objectmanufacturing, laser engineered net shapin

It does not further used for the others production. For example burger, shirt, laptop, tv, mobile phone and others.Capital goods are the goods which purchased by other companies for use to a new production.Capital goods would consist of items such as industrial buildings, equipment, andheavymachinery

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TUTORIAL 3

1) Sketch and describe procedure for open-die and close-die forging process.2) Describe preforming operation of edging and fullering.3) Describe the difficulties involved in defining the term forgeability precisely.4) What is the purpose of a dummy block in extrusion?5) Describe the process of indirect extrusion.6) Describe three extrusion defects and suggest suitable method to prevent them from occur.7) Sketch and describe the process of injection and blow molding. Describe characteristics for

bothprocesses.8) Describe two type of mold in injection molding process.9)

What is prototype? Describe the advantages of Rapid Prototyping.10) Describe with aid of sketching the process of SLA, FDM and 3D Printing. Compare the startingmaterialfor all the processes.11) Describe discontinuities that usually develop in welding process. Describe the testing techniquesfor critical applications for welded structure.12) Discuss the advantages and disadvantages for adhesive bonding, mechanical fastening andwelding.13)

Describe three types of adhesives.14) Describe design guidelines for mechanical fastening.

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