Manufacturing Processes for Mechanical Systems

Casting

Casting is a process where a liquid material is poured into a mould that contains a hollow cavity of the desired shape, and then allowed to solidify. A range of materials can be cast, including plastics, metals and glass.
Sand casting and die casting are two common types of casting techniques. Sand casting uses sand-based moulds, while die casting involves forcing molten metal under high pressure into a mould cavity.
When casting metals, the process often includes melting the metal, pouring it into the mould, allowing it to cool and solidify, then removing the finished part from the mould.
Cooling rates can affect the structure and properties of the final product; slower rates can make a product more brittle, while rapid rates can make it stronger.

Machining is a manufacturing process that involves cutting away material to shape the desired part. This includes processes such as turning, milling, drilling and grinding.
These processes can create a wide variety of shapes and features, and are used extensively in the creation of complex mechanical systems.
Computer Numerical Control (CNC) machining involves the use of computers to control the machining tools. This allows for a high degree of precision and can produce complex shapes that would be impossible to achieve by hand.
Lathes, mills and grinders are common types of machines used in this process. One must consider the type and strength of the tools, the speed of the cutting, and the coolant/lubrication used to achieve optimal effect.

Joining and assembly processes involve combining parts together to form a product or part of a mechanical system. This can be done through various methods such as welding, soldering, bolting or through the use of adhesives.
Welding is a process where two or more parts are fused together by the use of heat or pressure, often with the addition of a filler material. This process is commonly used for joining metals.
Soldering and brazing are similar to welding, but the materials being joined remain solid while a third, roughly matching metal is melted to form the join.
Other methods of joining parts include mechanical fasteners (like screws, bolts, and rivets), adhesive bonding (using glue or other adhesives), and joining plastics (such as by ultrasonic or vibration welding).

Quality control is an important aspect of manufacturing mechanical systems. This often involves inspections and tests to make sure that the product meets the necessary standards and specifications.
This can be done at various stages of the manufacturing process, from the initial inspection of the raw materials, through to the final inspection of the finished product.
Common techniques include visual inspection, dimensional checking, and testing for required mechanical properties.
Non-destructive testing (NDT) methods are often used to check for faults and defects without damaging the product. Some NDT methods include ultrasonic testing, radiographic testing, and magnetic particle inspection.