Manufacturing Processes

**MANUFACTURING - Is the economic term for making goods and services available to satisfy human wants.** ***Goods* - are material things that we buy to satisfy our wants, needs or desires.** ***Services* - are nonmaterial things that we buy to satisfy our wants, needs or desires.** **Classificati...

**MANUFACTURING - Is the economic term for making goods and services available to satisfy human wants.** ***Goods* - are material things that we buy to satisfy our wants, needs or desires.** ***Services* - are nonmaterial things that we buy to satisfy our wants, needs or desires.** **Classification of Industries** **Primary industries -- cultivate and exploit natural resources\ Examples: agriculture, mining** 2. **Secondary industries -- convert output of primary industries into products** **Examples: manufacturing, power generation, construction** 3. **Tertiary industries -- service sector** **Examples: banking, education, government, legal services, retail trade, transportation** **Intermittent Production System - Production is performed on a start-and- stop basis, such as for the manufacture of made-to-order products.** **Mass Production - A special type of intermittent production process using standardized methods and single-use machines to produce long runs of standardized items.** **Mass Customization - Designing, producing, and delivering customized products to customers for at or near the cost and convenience of mass-produced items.** **Elements of mass customization:** **Modular product design\ Modular process design\ Agile supply networks** ***Manufacturing -* is the application of physical and chemical processes to alter the geometry, properties, and appearance of a starting material to make parts or products for a given application** **Factors in manufacturing\ Product design\ Materials\ Manufacturing process\ Cost analysis** **Strategies to reduce manufacturing cost\ Lean manufacturing\ Systems approach** **Manufacturing engineer responsibilities - Select and coordinate specific processes and equipment** **Industrial (Manufacturing) engineer - Manufacturing systems layout, time study, cost.** **Materials engineers-\ Specify ideal materials\ Develop new and better materials** **Wire - is made of a single electrical conductor while a cable is a group or bundle of multiple wires inside a common sheathing. Both of them are used for carrying electrical current.** **14-2G: The cable contains [two insulated wires] and a ground wire; individual wire is 14-gauge.** **14-3G: The cable contains [three insulated wires] and a ground wire; individual wires are 14-gauge.** **12-2 w/G: The cable contains two insulated wires [with a ground wire]; individual wires are 12-gauge.** **12-3 w/G: The cable contains three insulated wires with a ground wire; individual wires are 12-gauge.** **600 V: This Cable is rated for a [maximum of 600 volts]; commonly used NM cable for home wiring.** **TYPE NM-B: NM stands for Non-metallic, it is a non-metallic sheathed cable of type-B; this is the commonly used cable for wiring appliances and devices in home.** **The most important label of them is about the insulation or the plastic coating around the conducting wires. Here are some of the common labels written on wires.** - **THHN** - **THWN** - **THW** - **XHHN** ***The meaning of each letter used in the labels above is given below:*** - ***T: Thermoplastic insulation, a fire-resistant material*** - ***H: Heat-resistant; able to withstand temperatures up to 167 F.*** - ***HH: Highly heat-resistant; able to withstand temperatures up to 194 F.*** - ***W: "Wet," or approved for damp and wet locations; this wire is also suitable for dry locations*** - ***X: Insulation made of a synthetic polymer that is flame-retardant*** - ***N: Nylon-coated for resistance to oil and gasoline*** **Service Drop Cable - It is the cable between the utility pole and the consumer's premises or building.** **Communications Cable** **The types of cables and wires that are used for communication or signal transmission purposes are called communication cable** **Coaxial Cable** **Coax or [coaxial cable](https://www.electricaltechnology.org/2015/02/why-coaxial-cables-are-highly-insulated.html) is type of electrical cable made from four layers, forming coaxial shape (having common axis or center).** **Hardline coaxial or mostly known by its trademark name Heliax cable is a thick coaxial cable with its center solid conductor made from copper and the shield made from copper or silver tubing.** **Radiating or leaky coaxial cable is another type of coaxial cable where the shield is deliberately designed in such way to radiate RF waves.** **RG-6 is the most common type of coaxial cable used for signal transmission in residential and commercial applications. It is made from a solid copper wire with plastic** **Triaxial is another type of coaxial cable which includes another layer of insulation and shield over the top of existing shield.** **INSULATION REMOVAL\ The preferred method of removing insulation is with a wire-stripping tool, if available.** **Hand Wire Stripper\ The procedure for stripping wire with the hand wire stripper is as follows** **Knife Stripping - A sharp knife may be used to strip the insulation from a conductor. The procedure is much the same as for sharpening a pencil.** **Western Union Splice\ The Western Union splice joins small, solid conductors** **Western union long tie\ A splice which is similar to a western union short tie, only that the number of twist at the center and at both end are more compare to a short tie.** **Britannia\ This splice in applied in both inside and outside the building to big solid wire where twisting is difficult.** **Staggering Splices\ Joining small multiconductor cables often presents a problem. Each conductor must be spliced and taped.** **Fixture Joint\ The fixture joint is used to connect a small-diameter wire, such as in a lighting fixture, to a larger diameter wire used in a branch circuit.** **Plain tap or tee joint\ is mostly used in outside work for joining a tap wire to a through conductor.** **Knotted Tap Joint\ All the splices discussed up to this point are known as [butted] splices. Each was made by joining the free ends of the conductors together.** **Ordinary cross joint\ This is used where two tap conductors are to extend away from the branch conductor in opposite direction.** **SPLICE INSULATION** **The splices we have discussed so far are usually insulated with tape.** **Friction Tape** **Putting rubber tape over the splice means that the insulation has been restored to a great degree.** **Plastic Electrical Tape** **Plastic electrical tape has come into wide use in recent years. It has certain advantages over rubber and friction tape.** **Plasticity** - **It is property of a material which retains the deformation produced under load permanently.** **Ductility** - **It is ability of a material enabling it to be drawn into wire with the application of a tensile force.** **Brittleness** - **It is property of a material opposite to ductility.** **Malleability** - **It is special case of ductility which permits materials to be rolled or hammered into thin sheets.** **Toughness** - **It is property of material to resist fracture due to high impact load like hammer blow.** **Resilience** - **It is property of a material to absorb energy and resist shock and impact load.** **Machinability** **It is property of a material which refers to relative case with which a material can cut** **The Basic Oxygen Furnace (Converter)\ The BOF is a vessel used to convert pig iron, of about 94% Fe and 6% combined impurities such as C, Mn, and Si, into steel with as little as 1% combined impurities.** **Rolling\ A metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness and to make the thickness uniform.** **Hot Rolling: rolling at high temperatures** **Cold Rolling: rolling at room temperature** **Casting\ Molten metal is poured into a mold and cooled to create the desired shape.** **Forming\ Metal is bent, folded, or pressed to create the desired shape.** **Machining\ Metal is cut, drilled, or ground to create the desired shape.** **Joining\ Metal components are welded, soldered, or brazed together to create a larger structure.** **Machining\ A material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains** **Machining: Turning\ A single point cutting tool removes material from a rotating workpiece to generate a cylindrical shape** **Machining: Drilling\ Creates a round hole in a workpart** **Machining: Milling\ Machining operation in which work is fed past a rotating tool with multiple cutting edges** **Joining Processes\ Joining is one of the manufacturing processes by which two or more materials can be permanently or temporarily joined** **Welding\ It is a technique used for joining metallic parts usually through the application of heat.** **Brazing\ Joining metals by the fusion of nonferrous alloys having a melting temperature above 800 degrees Fahrenheit, but below that of the metals being joined.** **Soldering\ A process of joining two or more different types of metals together by melting solder.** **Riveting\ A rivet is a mechanical fastener composed of a head on one end** **Metal Plating\ Metal plating is a method of plating where metals are deposited on the substrates.** **Metal Brushing\ This process gives a special grinding pattern to the surface of workpieces.** **Buffing and Polishing\ Finishing processes that utilize abrasive belts are referred to as polishing, and processes that use cloth wheels with compound applied is buffing.** **Metal Grinding\ Metal grinding is a process that is used extensively in metal fabrication.** **Sandblasting\ Also known as abrasive blasting, sandblasting is a surface finishing process that involves the use of a powered machine** **Powder Coating\ Powder coating is a dry finishing process used to apply a dry coating material.** **Hot Blackening\ Blackening is a finishing\ operation that chemically coats the surface of ferrous materials** **\ **