BDA 30502

MANUFACTURING
TECHNOLOGY

Lecturer : Prof. Dr Yusri Bin HjYusof

Room: WFH
Email: yusri@uthm.edu.my
 GOALS

MATLAMAT (GOALS):

This course provide understanding,

exposure and knowledge about important
aspects in the manufacturing
processes and technology and also to
provide better understanding of technical
and economic factors involved in the
manufacturing field.
 HASIL PEMBELAJARAN
(LEARNING OUTCOMES)
At the end of this course, the students will be
able to:

(1) Differentiate manufacturing process based on

theories and applications in the industry. (C4, LO1)
(2) Communicate effectively in solving problems
related to given group project. (P4, LO3)
(3) Identify the appropriate type of processes,
materials and costs to produce a product. (A2, LO7)
 SINOPSIS (SYNOPSIS)

 Introduction to production technology,

Material characteristic and Selection of a
materials, Metal machining process, Casting
process, Metal forming process, Plastic
manufacturing process, Powder metallurgy
process, Joining processes.
 ISI KANDUNGAN (CONTENT)
BAB KANDUNGAN
(CHAPTER) (CONTENTS)

1.0 Introduction to Manufacturing Technology (2hrs)

◦ Understanding of technology
◦ Manufacturing process classification and
◦ Product design and manufacturing

2.0 Material characteristic and selections (2 hrs)

◦ Introduction to materials
◦ Steps in selecting materials
 ISI KANDUNGAN (CONTENT)
BAB KANDUNGAN
(CHAPTER) (CONTENTS)

3.0 Metal machining process (6 hours)

 3.1 Theory of metal machining
 3.2 Machining and machine tool operations

4.0 Metal Casting Process (4 hours)

 4.1 The basic principle of metal casting (fluidity, heating, pouring, solidification, defects)
 4.2 Metal casting process (Sand Casting, Die Casting, Investment Casting)


5.0 Metal Forming Process (4 hours)

 5.1 The basic principles of metal forming
 5.2 Bulk Deformation Processes (Rolling, Forging, Extrusion)
 5.3 Sheet-Metal Working (Cutting, Bending, Drawing)
ISI KANDUNGAN (CONTENT)
6.0 Plastic Manufacturing Process (4 hours)
◦ Introduction to Plastic Manufacturing process
◦ Injection molding (process and equipment, the mold, injection
molding machines, shrinkage)

7.0 Powder Metallurgy Process (2 hours)

◦ Introduction to Powder Metallurgy process
◦ Powder Metallurgy operations

8.0 Joining Process (4 hours)

◦ Basic principle of welding
◦ Welding processes (brazing, soldering and adhesive bonding,
mechanical assembly)
Materials in an Automotive Engine

Figure 1 Section of an automotive engine - the Duratec V-6 - showing

various components and the materials used in making them. Source:
Courtesy of Ford Motor Company. Illustration by David Kimball.
Chapter 1:
Manufacturing Technology
Learning Objectives
The purpose of this chapter is to
discuss in more detail, the tools and
processes technology that is utilised in
the manufacture and assembly of an
product.
By the end of the lesson you should
have an understanding of some of the
processes, techniques and tools used in
the manufacture of the component parts.
 Chapter 2 Revision
 A few questions about the previous chapter.
1. What is meant by the term Homogeneous?
2. Which of the following 3 materials has the
highest Strength to Weight Ratio?
a. High Tensile Steel
b. Aluminium
c. Titanium
3. Name the one of the three types of
Composite Repair?
4. What does the term GLARE stand for?
 What is ‘Man Tech’
Manufacturing technology (or ‘Man Tech’) provides the tooling
required to enable the production of all manufactured goods.

These magnify the effort of individual workers and provide the power
to turn raw materials into finished and functioning products.

Production tools include machine tools and other related equipment

and their accessories and tooling.

◦ Machine tools are non-portable, power-driven manufacturing

machinery and systems used to perform specific.

◦ Computer Aided Design (CAD) and Computer Aided

Manufacturing (CAM) as well as assembly and test systems to
create a subassembly or final product.
Manufacturing Tools & Techniques
For the purposes of this subject,
Manufacturing Technology can be
broken down into the following sub-sets.
◦ Material removal and tooling
◦ Material forming
◦ Additive processes
◦ Controls/Software
◦ Plastics technology
Material Removal and Tooling
The vast majority of tools and techniques
within Manufacturing Technology fall within
‘machining processes’ and perhaps form
the basis of the public perception of
‘Manufacturing’.

This can range from the simple hand saw

through to laser cutters. The tools and
techniques most likely to be used in the
manufacture of aircraft structures are;
 Cutting
Cutting is the most common material removal and
machining processes.
Cuttingis typically achieved using a cutting blade with
hardened teeth to cut through (or ‘Saw’) the workpiece.
Cutting can also be achieved through the use of a high
velocity jet of ionised gas that conducts electricity. This
technology is referred to as a ‘Plasma Cutter’.
The plasma heats the workpiece, melting material and
allows the operator to produce complex cut-outs.
 Broaching
Broaching uses a toothed tool, to remove material
from the workpiece.
The process is used when precision machining is
required, especially for odd shapes as ‘Broaching’
finishes a surface in a single pass, which makes it
very efficient.
Commonly machined surfaces include circular and
non-circular holes, splines, and flat surfaces.
Typical workpieces include small to medium sized
castings, forgings, screw machine parts, and
stampings.
Even though broaches can be expensive,
broaching is usually favorable to other processes
when used for high-quantity production runs
 Electrical Discharge Machining
Electrical Discharge Machining (EDM) is
also referred to as spark machining, spark
eroding, burning, die sinking or wire erosion
EDM is a manufacturing process whereby the
desired shape of the workpiece, is obtained
using electrical discharges (or sparks).

The material removal from the workpiece

occurs by a series of rapidly recurring current
discharges between two electrodes, separated
by a dielectric liquid and subject to an electric
voltage.
 Material Forming
Not all components can be manufactured
through the use of Material Removal tools &
techniques.
Itis often advantageous to use Material
Forming techniques, where it is easier to
manufacture more complex components
whilst maintaining the material properties.
Material forming techniques include;
 Forging
Forging is the term for shaping metal by using
localised compressive forces.
Cold forging is done at room temperature or near
room temperature, whilst Hot forging is done at a
high temperature, which makes metal easier to
shape and less likely to fracture.
Warm forging is done at an intermediate
temperature between room temperature and hot
forging temperatures. Forged parts can range in
weight from less than a kilogram to 170 metric tons.
Forged parts usually require further processing to
achieve a finished part.
 Casting
Casting is a process by which a liquid material is
poured into a mould, which contains a hollow cavity
of the desired shape, and then allowed to solidify.
The solidified part is known as a casting, which is
ejected or broken out of the mould to complete the
process. Casting materials can be metals or various
cold setting materials that cure after mixing two or
more components together; examples are epoxy,
concrete, plaster and clay.
Castingis most often used for making complex
shapes that would be otherwise difficult or
uneconomical to make by other methods.
 Extrusion
Extrusion is a process used to create objects of a
fixed cross-sectional profile, where the base
material is pushed or drawn through a die of the
desired cross-section.
The two main advantages of this process over
other manufacturing processes are;
◦ Its ability to create very complex cross-sections and
work materials that are brittle, because the material
only encounters compressive and shear stresses.
◦ It also forms finished parts with an excellent surface
finish.
The extrusion process may be continuous or semi-
continuous and can be done with the material hot or
cold.
 Additive Processes
Additive processes, otherwise known as
‘Rapid Prototyping’ is a manufacturing process
for the rapid and flexible production of sample
parts for demonstration, evaluation and/or
testing.
Ittypically uses advanced layer manufacturing
technologies that can quickly generate complex
three dimensional objects direct from computer
based models
Rapid prototyping techniques include;
 Fused Deposition Modelling
Fused Deposition Modelling is a process
which forms three-dimensional objects from
CAD-generated solid or surface models.

The Fused Deposition Modelling patterns

are generally used when an acroylonitrile-
butadiene-styrene thermal plastic part is
required for use in a working prototype.
 Laminated Object Modelling
Laminated Object Modelling is a process
that created models from inexpensive, solid-
sheet materials.

The process is similar to that of

Sterolithography in that it slices a three-
dimensional electronic file from the computer
to the Laminated Object Modelling machine to
produce parts for use in visualisation models,
casting patterns and designs.
 Selective Laser Sintering
Selective Laser Sintering is a flexible
technology that uses a CO2 laser beam to
fuse (sinter) layers of nylon, metal or
trueform powdered materials into a three-
dimensional model.
This is a leading rapid prototyping
technology as it provides more choices of
materials for flexibility and has more
applications than the other technologies.
 Stereolithography
Stereolithography is a manufacturing
technology where the layers are formed
using a laser to cure the surface of a
bath of photo-sensitive polymer resin in
The process takes a CAD design and
producesorder
a to produce
solid the desired shape.
three-dimensional
prototype model using a combination of
laser, photochemistry, optical scanning and
computer software technology.
Controls/Software
A feature of modern manufacturing
technology, computer software has
improved not only the accuracy of the
design process, but also the material
output.
Often, the more complex machining
operations with tight engineering
tolerances can only be achieved using
tooling controlled by computer.
Typical processes encountered include;
 Computer Aided Design
Computer-aided design (CAD) is the use of
computer technology for the design of objects, real
or virtual.

As in the manual drafting of technical and

engineering drawings, the output of CAD must also
convey symbolic information such as materials,
processes, dimensions, and tolerances.

 CAD may be used to design

curves and figures in two-
dimensional space or curves,
surfaces and solids in three-
dimensional objects.
 Computer Aided Manufacturing
Computer-aided manufacturing (CAM) is the
use of software tools in the manufacture of product
components.
It’s
primary purpose is to create a faster production
process and components with more precise
dimensions and material consistency, which in
some cases, uses only the required amount of raw
material (thus minimizing waste), while
simultaneously reducing energy consumption.
With CAM it is possible to manufacture physical
models using CAD programmes, creating real life
versions of components designed within a software
package.
Computer Integrated Manufacturing
Computer-Integrated Manufacturing (CIM)
is a closed-loop method of manufacturing in
which the entire production process is
controlled by computer.
The traditional separated process methods
are joined through a computer by CIM.
This integration allows the processes to
exchange information with each other to
initiate actions. Through this, integration the
manufacturing can be faster and with fewer
errors.
The main advantage is the ability to create
automated manufacturing processes.
 Numerical Control
Numerical Control refers to the automation of
machine tools that are operated by means of
predetermined programmed commands, as opposed to
manually controlled via handwheels or levers.
This can be found in the following forms;
◦ Computer Numerical Control (CNC): Control of the
machine tools is performed by a software programme
executed by a computer.
◦ Direct Numerical Control: Control of a number of CNC
machines by a large centralised host computer.
◦ Distributed Numerical Control: Hierarchical control of all
machine tools controlled by a central plant computer,
where the controllers are themselves CNC units.
 Injection Moulding
Injection Moulding is a manufacturing
process for producing parts from both
thermoplastic and thermosetting plastic
materials.

Materialis fed into a heated barrel, mixed,

and forced into a mould cavity where it cools
and hardens to the configuration of the
mould cavity.
 Die
Within the context of Plastics Technology,
the term die, mould and tool are sometimes
considered the same.

This is considered true in that they have a

female or negative cabity through, or into,
which the molten plastic moves under heat
and pressure.
 Plastics Extrusion
Plastics extrusion is a high volume
manufacturing process in which raw plastic
material (often in bead form) is melted and
forced through a die to form a single
continuous profile.

The process is similar to that of Metal

Extrustion.
 Thermoforming
Thermoforming is a manufacturing process
where a plastic sheet is heated to a pliable forming
temperature, formed to a specific shape in a mould,
and trimmed to create a usable product.

The plastic sheet is heated to a high-enough

temperature, so that it can be stretched into or onto
a mould using a vacuum and cooled to a finished
shape.
Curing
Curing is the process that refers to the
toughening or hardening of a polymer
material by cross-linking of polymer chains,
brought about by the use of chemical
additives, ultraviolet radiation, electron
beam or heat.
In rubber, the curing process is also called
vulcanization.
With composite materials, the final
process involves curing the assembly using
heat in an ‘Auto-clave’ or large oven.
Conclusions
Manufacturing Technology covers a wide
variety of tools, techniques and processes
– all utilised to transform raw materials into
finished products.
Although not all tools, techniques and
processes applicable to airframe
manufacturing have been covered within
this chapter, you should now be familiar
with the basics of manufacturing
technology.
Any Questions ?
 Questions
 Here are some questions for you!

1. What does the acronym CNC stand for?

2. What is an ‘Additive Process’?

3. Name the 5 Manufacturing Technology

sub-groupings?
THANK YOU