Fayoum University, Faculty Of Engineering

Mechanical Engineering Department

Manufacturing Processes I
(MDP 114)
Lecture (1)

Dr. Sabry Said Youssef

Mechanical Engineering Dept.
Faculty of Engineering
Fayoum University
 Course Objective
This course is designed to provide students with a
thorough understanding of the fundamentals of
cutting tools for machining and materials removal.
Turning, boring and related machining processes.
Drilling and related hole making processes. Milling,
broaching, sawing, shaping and planning, and
abrasive machine processes.
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 Course Objective
Also, this course is designed to provide students with
a thorough understanding of the fundamentals of
metal forming. Bulk deformation such as rolling,
forging, extrusion and wire & bar drawing. Sheet
metal working such as bending, deep & cup drawing,
and shearing.

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 Course Outlines
 Introduction to Manufacturing Processes.
 Cutting Tool Materials and Its Characteristics.
 Practical Machining Operations: Turning, Shaping,
Drilling, Milling, Grinding.
 Basic Elements of Machine Tools and Specifications.
 Machining Time.
 Mechanics of Metal Cutting ; Geometry ; Chip
Formation; Wear ; Life; Temperature; Merchant Circle.
 Economics in Cutting Process.
 Metal forming Processes: Rolling, Extrusion, Forging,
drawing, sheet metal working.
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Teaching and Evaluation Methods

 Lectures.

 Exercises and Lab

 Assignments.

 Quizzes.
 Course Assessment
Final Exam 70

Mid Term Exam 20

Assignment 20

Oral/Practical Exam 15

Total Marks 125

References

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Introduction

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 What is Manufacturing?
The word manufacture is derived from two Latin words,

manus (hand) and factus (make); the combination means

made by hand. The English word manufacture is several

centuries old, and ‘‘made by hand’’ accurately described

the manual methods used when the word was first coined

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 What is Manufacturing?
Manufacturing can be defined by two ways, one
technologic and the other economic.
Technologically, manufacturing is the application of
physical and chemical processes to change the geometry,
properties, and/or appearance of a given starting material
to make parts or products; manufacturing also includes
assembly of multiple parts to make products.

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 What is Manufacturing?
Manufacturing can be defined by two ways, one
technologic and the other economic.
Economically, manufacturing is the transformation of
materials into items of greater value by means of one or
more processing and/or assembly operations
The key point is that manufacturing adds value to the
material by changing its shape or properties, or by
combining it with other materials that have been similarly
changed.

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 Materials in Manufacturing
 Most engineering materials can be classified into one of
three basic categories:
1. Metals
2. Ceramics
3. Polymers
4. Composites
 Their chemistries are different, and their mechanical
and physical properties are different.
 These differences affect the manufacturing processes
that can be used to produce products from them.
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Materials in Manufacturing

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 Manufacturing Process
A manufacturing process is a designed procedure that
results in physical and/or chemical changes to a starting
work material with the intention of increasing the value
of that material.
Manufacturing operations can be divided into two basic
types:
1. 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
2. Assembly operations - join two or more components to
create a new entity 14
Manufacturing Process

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 Solidification Processes
 Starting material is heated sufficiently to transform it into

a liquid or highly plastic state

 Casting process at left and casting product at right

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 Particulate Processing
 (1) Starting materials are metal or ceramic powders,

which are (2) pressed and (3) sintered

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 Deformation Processes
 Starting workpart is shaped by application of
forces that exceed the yield strength of the
material
 Examples: (a) forging and (b) extrusion

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 Material Removal Processes
 Excess material removed from the starting piece so what

remains is the desired geometry

 Examples: (a) turning, (b) drilling, and (c) milling

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Material Removal Processes

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 Material Removal Processes
 The material removal processes are a family of shaping
operations in which excess material is removed from a
starting workpart so that what remains is the desired final
geometry.
 Categories:
– Machining – material removal by a sharp cutting
tool, e.g., turning, milling, drilling
– Abrasive processes – material removal by hard,
abrasive particles, e.g., grinding
– Nontraditional processes - various energy forms
other than sharp cutting tool to remove material
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 Material Removal Processes

The family tree

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Material Removal Processes

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Machining types
• Turning

• Drilling

• Milling

• Shaping

• Planning

• Broaching

• Grinding

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Metal Forming Processes

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 Metal forming Processes
The family tree

1. Bulk deformation
– Rolling processes
– Forging processes
– Extrusion processes
– Wire and bar drawing
2. Sheet metalworking
– Bending operations
– Deep or cup drawing
– Shearing processes 26
Machining types
– Rolling

– Forging

– Extrusion

– Wire and bar drawing

– Bending

– Deep or cup drawing

– Shearing

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Thanks

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