Manufacturing processes (e.g., cutting, forming, joining, etc.)

Manufacturing processes (e.g., cutting, forming, joining, etc.)

Manufacturing Processes

  • Cutting: This process involves removing unwanted material from the raw stock to get the desired shape. Methods include sawing, drilling, milling, turning and grinding. High-speed steel or carbide-tipped tools are often used.

  • Forming: Here, raw material is shaped without adding or removing material. Forming methods include bending, drawing, pressing and rolling. Materials used can be sheet metal, wire or tubing.

  • Casting: This is the process of pouring a liquid material into a mould that contains a hollow cavity of the desired shape. Once solid, it’s removed or ejected from the mould.

  • Joining: This process chemically or mechanically fuses two or more parts together. Common methods are welding, soldering, fastening (which uses methods like screws, bolts, or rivets), and adhesive bonding.

Variables in Manufacturing Processes

  • Feed rate: The speed at which the tool or workpiece is moved, this impacts the final surface finish of the component.

  • Cutting speed: Refers to the speed at which the cutting tool moves relative to the workpiece, affecting the manufacturing time and quality of the cut.

  • Depth of cut: This is the distance that the cutting tool penetrates into the workpiece, impacting the material removal rate.

Safety Considerations

  • Protection: Always wear appropriate safety gear. This can include safety glasses, gloves, aprons, and safety footwear.

  • Maintain equipment: Regularly inspect and maintain all machinery and tools for any faults or wear.

  • Training: Ensure you are fully trained on the operation of each piece of equipment before you use it. Never exceed machine operating limits.

Environmental Considerations

  • Energy consumption: Consider the amount of energy a manufacturing process consumes when choosing a method.

  • Material waste: Plan to minimise material waste. Materials that cannot be prevented can often be recycled or reused.

  • Chemical waste: Some manufacturing processes generate harmful chemical waste. Consider how this waste will be managed, and, where possible, try to substitute dangerous substances with more benign ones.

Quality Control and Inspection

  • Inspection techniques: Regular inspections ensure all products meet the required specifications. Techniques include visual inspection, Non-Destructive Testing (NDT), and coordinate measuring machines (CMM).

  • Quality control tools: These include control charts, cause-and-effect diagrams, check sheets, Pareto diagrams, histograms, scatter diagrams, and flow/process charts.

  • Tolerance: This is the acceptable amount a part can deviate from the specified dimension. Both oversizing and undersizing can lead to part failure in an assembly or operational problems in the final product.