Production Technology Lecture Notes PDF

Production Technology Lect. 1: Introduction Associat Prof. Mohamed A. Bhlol  Course Contents Topic 1 Introduction to Production technology 2 Joining Processes and Welding 3 Casting and Pattern making 4 Machining Processes 5...

Production Technology Lect. 1: Introduction Associat Prof. Mohamed A. Bhlol  Course Contents Topic 1 Introduction to Production technology 2 Joining Processes and Welding 3 Casting and Pattern making 4 Machining Processes 5 Material classification and Testing 6 Metal Forming processes 7 Measurement and measurement tools  Evaluation and Grading Mark Attendance 5 Participation 5 Midterm 40 workshop (15) Assessment quiz (5) Written (20) Final-term 50 examination (50%) Total 100  Introduction Topics What is manufacturing process? Classification of manufacturing processes Factors to be considered for selecting a production process Industrial safety and workshop safety  What is manufacturing process? ❑ Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a starting material to make parts or products.  What is manufacturing process? ❑ Manufacturing adds value to the material by changing its shape or properties, or by combining it with other materials (this is done by means of one or more processing and/or assembly operations)  Materials in manufacturing: Most engineering materials can be classified into one of four basic categories: Metals Ceramics Polymers Composites  Classification of manufacturing processes Two basic types of manufacturing processes: ❑ Processing operations ▪ transform a work material from one state of completion to a more advanced state. Operations that change the geometry, properties, or appearance of the starting material. ❑ Assembly operations ▪ join two or more components to create a new product. Classification of manufacturing processes  Classification of manufacturing processes ❑Processing operations Three categories of processing operations: 1) Shaping operations alter the geometry of the starting work material 2) Property-enhancing operations improve physical properties without changing shape. 3) Surface processing operations to clean, treat, coat, or deposit material on exterior surface of the work  Classification of manufacturing processes 1) Shaping processes Material Solidification Particulate Deformation removal processes processes processes processes Ex: Casting Ex: Powder Ex: rolling and Ex: turning metallurgy forging  Classification of manufacturing processes 2) Property-enhancing processes Performed to improve mechanical or physical properties of work material Ex: Heat treatment  Classification of manufacturing processes 3) Surface processing operations Cleaning Surface Coating and treatments thin film remove dirt, oil, and other contaminants deposition from the surface Ex: sand blasting Classification of manufacturing processes Assembly operations Joining Mechanical processes Assembly Ex: Welding Ex: threaded fasteners  Factors to be considered for selecting a production process ❑ shape and size to be produced ❑Quantity to be produced ❑Type of materials ❑Surface finish and dimensional accuracy ❑Quality and property requirements ❑Cost of the product Product Example  Industrial Safety What is Industrial Safety ❑ Industrial safety is primarily a management activity which is concerned with: Reducing Controlling Eliminating hazards from the industries or industrial units.  Industrial Safety Significance of industrial safety: ❑ Industrial causes a great loss to both the employer and employee, that’s it is having importance: Cost of compensation ‫تكلفة التعويض‬ Cost of medical-aid ‫تكلفة االسعافات الطبية‬ Cost of training a new worker ‫تكلفة تدريب عامل جديد‬ Cost of the lost time ‫تكلفة الزمن المفقود‬ Cost of investigation ‫تكلفة التحقيق‬ Cost of supervision and inspections ‫تكلفة االشراف والتفتيش‬ Cost of spoilage of materials ‫تكلفة اتالف المواد‬ Cost of the damage of machinery ‫تكلفة تلف الماكينات‬ Cost of wages payable during injury ‫تكلفة األجور المستحقة أثناء اإلصابة‬ Cost of loss of morale ‫تكلفة فقدان الروح المعنوية‬  Safety in workshop ❑ Working safely is one of the first things a student should learn because the safe way is usually the correct and most efficient way. A person learning to operate machine tools must first learn the safety regulations and safety measures for each tool or machine. ❑ A Safe worker should: 1) Be neat, tidy, and safely dressed for the job he or she is performing. 2) Think safely and work safely at all times. Safety in workshop  Safety in workshop Safety in the Shop Safety in a machine shop may be divided into two categories 1) Those practices which will prevent injury to workers. 2) Those practices which will prevent damage to machines and equipment  Safety in workshop * The aspects of safety in the machine shop ‫جوانب السالمة في الورشة‬  Safety in workshop a) Personal Preparing 1) Always wear approved safety glasses in any area of the machine shop. Several types of eye protection devices are available for use in the machine shop:  Safety in workshop 2. Never wear loose clothing when operating any machine: * Always roll up your sleeves or wear short sleeves. * Clothing should be made of hard, smooth material that will not catch easily in a machine. * Remove a scarf before starting a machine. 3. Remove wrist watches, rings, and bracelets; these can get caught in the machine. 4. Never wear gloves when operating a machine. 5. Long hair must be protected by a hair net because unprotected hair getting caught in a revolving drill. 6. Canvas shoes or open-toed sandals offer no protection to the feet against sharp chips or falling objects. Safety in workshop  Safety in workshop b) Housekeeping The following points should be observed by the operator: 1. Always stop the machine before you attempt to clean it. 2. Always keep the machine and hand tools clean. 3. Use a bench near the machine to place tools and material 4. Keep the floor free from oil and grease. 5. Return bar stock to the storage rack after cutting off the required length. 6. Always remove chips with a brush, never by hand or compressed air  Safety in workshop c) Safe work practices: 1. Do not operate any machine before understanding how to stop it quickly. 2. Always disconnect the power when making repairs to any machine. 3. Be sure the work is clamped securely to a machine table 4. Get first aid immediately for any injury. 5. Before you handle any workpiece, remove all sharp edges. 6. For heavy objects, follow safe lifting practices: a. Assume a squatting position with your knees bent and back straight. b. Grasp the workpiece firmly. c. Lift the object by straightening your legs and keeping your back straight.  Safety in workshop d) Fire Prevention 1. Be sure of the proper procedure before lighting a gas furnace. 2. Know the location and the operation of every fire extinguisher in the shop. 3. Know the location of the nearest fire exit from the building. 4. Know the location of the nearest fire alarm box and its operating procedure. 5. When using a welding or cutting torch, be sure to direct the sparks away from any combustible material. Safety in workshop Thank you