Introduction to Production Technology

Production Technology Introduction

• This lecture introduces Production Technology.
• The course will cover various topics, including Introduction to Production Technology, Joining Processes and Welding, Casting and Pattern Making, Machining Processes, Material Classification and Testing, Metal Forming Processes, and Measurement and Measurement Tools.

Course Contents

• The course will cover seven topics.
• The first topic is Introduction to Production Technology.
• The second topic is Joining Processes and Welding.
• The third topic is Casting and Pattern making.
• The fourth topic is Machining Processes.
• The fifth topic is Material classification and Testing.
• The sixth topic is Metal Forming processes.
• The seventh topic is Measurement and measurement tools.

Evaluation and Grading

• Attendance is worth 5 marks.
• Participation is worth 5 marks.
• The midterm assessment is worth 40 marks, which includes a workshop (15 marks), a quiz (5 marks), and a written exam (20 marks).
• The final exam is worth 50% of the total grade.
• The total grade is 100 marks.

Introduction Topics

• The topics for this lecture are:
• What is a manufacturing process?
• Classification of manufacturing processes
• Factors to be considered for selecting a production process
• Industrial safety and workshop safety

What is Manufacturing Process?

• The application of physical and chemical processes alters the starting material's geometry, properties, or appearance to create parts or products.
• These processes include machinery, tooling, power, and labor.
• Scrap and waste result from the manufacturing process.
• Manufacturing adds value to the material by changing its shape or properties, or combining it with other materials.
• This is done through processing and/or assembly operations.
• The manufacturing process increases the cost of the material from $$ to $$-$$$.

Materials in Manufacturing

• Most engineering materials can be categorized into four basic groups: metals, ceramics, polymers, and composites.
• These materials can be combined to form metal-ceramic, metal-polymer, and ceramic-polymer composites.

Classification of Manufacturing Processes

• Manufacturing processes are broadly classified into two main types: processing operations and assembly operations.
• Processing operations transform a work material from one state to a more advanced one, altering its geometry, properties, or appearance.
• Assembly operations join two or more components to create a new product.
• In terms of processing, there are three subsets: shaping processes, property-enhancing processes, and surface processing operations.

Shaping Processes

• Solidification processes (e.g., casting)
• Particulate processes (e.g., powder metallurgy)
• Deformation processes (e.g., rolling, forging)
• Material removal processes (e.g., turning)

Property-enhancing Processes

• Heat treatment is used to improve the mechanical or physical properties of the work material.

Surface processing operations

• Cleaning
• Surface treatments
• Coating and thin-film deposition (e.g., sand blasting)

Assembly operations

• Joining processes (e.g., welding)
• Mechanical assembly (e.g., threaded fasteners)

Factors for Selecting a Production Process

• Shape and size
• Quantity to be produced
• Type of materials
• Surface finish and dimensional accuracy
• Quality and property requirements
• Cost of the product

Product Example

• Examples of different manufacturing processes used in a car body build.
• Includes: Bonding of the windshield, Fasteners, Bolted engine assembly, Soldered electrical circuitry, Brazed joint for emission control, Adhesively bonded fabric, Spot-welded car body, Mechanical fastening of body trim, Welded pipes for exhaust system, Seamed body components, Seam-welded muffler.

Industrial Safety

• Primary a management activity concerned with reducing, controlling, and eliminating hazards in industries and industrial units.
• Significance of industrial safety means high importance due to losses to both employers and employees.
• Losses include costs of compensation, medical aid, training new workers, lost time, investigation, supervision, material spoilage, and machinery damage, wages payable during injury, and loss of morale.

Safety in Workshop

• Working safely is crucial for efficiency and safety.

• Machine operation requires learning and adhering to safety standards and regulations for each tool or machine.

• Employees should be: neat, tidy, and properly dressed for their assigned jobs.

• Employees need to think and work safely at all times.

• Includes: proper use of personal protective equipment (PPE), housekeeping practices, and fire prevention procedures:

• Safety in the machine shop, Safety in the shop, Types of safety precautions to be taken in the workshop, Aspects of safety in the workshop.

• PPE (Personal Protective Equipment), such as safety glasses, face shields, gloves, and appropriate clothing, is essential.

• Housekeeping practices like keeping machines and tools clean, keeping the floor clean, organizing materials, organizing bar stock, and using brushes to clear chips are critical to safety..

• Safe work practices: stop machines before cleaning, disconnect power for repairs, ensure secure workpiece clamping, deal with injuries immediately, remove sharp edges on workpieces, follow proper lifting procedures for heavy items.

• Fire prevention: understand gas furnace procedures, familiarise with fire extinguishers, know fire exit locations and alarm box operations, direct welding/cutting torch sparks away from flammables.