Production Technology - Introduction

Production Technology - Introduction

• The course covers 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.
• The evaluation system includes attendance (5 marks), participation (5 marks), a midterm assessment (40 marks - workshop [15 marks], quiz [5 marks], written [20 marks]), and a final exam (50%).
• The total marks for the course are 100.
• Introduction topics include what manufacturing processes are, their classification, factors to be considered for the selection of a production process, and industrial safety and workshop safety.

What is Manufacturing Process?

• Manufacturing processes involve applying physical and chemical processes to alter the geometry, properties, and/or appearance of a starting material to create parts or products.
• The manufacturing process takes a starting material and transforms it, adding value through changing the shape or properties of the material, or combining it with other materials through processing or assembly operations.

Materials in Manufacturing

• Engineering materials are categorized into metals, ceramics, polymers, and composites.
• Metal-ceramic composites, metal-polymer composites, and ceramic-polymer composites also exist.

Classification of Manufacturing Processes

• Two major 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 make a new product.
• Processing operations are further categorized into shaping, property-enhancing, and surface processing operations.

Shaping Processes

• Examples include casting, powder metallurgy, rolling, and forging, and turning.

Property-Enhancing Processes

• Examples include heat treatment.

Surface Processing Operations

• Examples include cleaning, surface treatments, and coating and thin-film deposition, such as sand blasting.

Assembly Operations

• Joining processes, like welding.
• Mechanical assembly operations, such as using threaded fasteners.

Factors to Consider in Selecting a Production Process

• Shape and size of the product to be made
• Quantity of the product needed
• Type of material
• Surface finish and accuracy needed
• Quality and property requirements
• Cost of the product

Industrial Safety

• Industrial safety is a management activity focused on reducing, controlling, and eliminating hazards in industries.
• Safety involves significant costs for compensation, medical care, worker training, investigation, supervision, material and machinery damage, lost wages due to injuries, and loss of morale.
• Safety in the workshop should be prioritized during operations and machine use.
• Workers need to wear appropriate personal protective equipment (PPE), including safety glasses, be neat and tidy in clothing, and work safely at all times.
• Housekeeping includes stopping machinery before cleaning, keeping machines and tools clean, keeping floors free of oil and grease, returning equipment to the correct storage location, and careful removal of metal chips or debris.
• Safe work practices include understanding how to stop machines quickly, disconnecting power before repairs, securely clamping work pieces, removing sharp edges from workpieces, and using proper lifting techniques for heavy objects.
• Fire prevention is crucial, including proper furnace procedures, knowing the location and operation of fire extinguishers, understanding fire exits and alarm systems, and directing sparks away from flammable materials.

Safety in Workshop - Additional Points

• Personal Preparing: Always wear appropriate safety glasses, and use available eye protection devices. Avoid loose clothing, and wear tight-fitting, non-flammable clothes.
• Housekeeping: Stop equipment before cleaning, keep machines clean, use benches for materials, keep the floor clear of grease and oil, and return equipment to its proper place.
• Safe Work Practices: Do not operate machines or tools before understanding their functions and stopping capabilities. Disconnect power during repairs. Secure workpieces to the machine. Remove sharp edges from work pieces. Use correct lifting techniques for heavy items.
• Fire Prevention: Use correct procedures before igniting gas-powered equipment. Know the location and use of fire extinguishers. Be familiar with fire exits and alarm locations. Guide sparks away from combustible materials.

This quiz introduces you to the fundamental concepts of production technology, including various manufacturing processes, joining methods, and material classifications. Dive into topics such as industrial safety, measurement tools, and the detailed structure of the evaluation system for the course.