mata kuliah Proses Produksi with Dr.Eng.Ir. RUDI SUHRADI RACHMAT, M.Eng

Basic Manufacturing Processes

  • Casting and Foundry
  • Forming or Metalworking
  • Machining
  • Joining and Assembly
  • Rapid Prototyping
  • Other
  1. Casting and Foundry Processes

In one step raw materials are transformed into a desirable shape

Parts require finishing processes

Excess material is recyclable

Basic Casting Process

A mold is created – A cavity that holds the molten material in a desired shape until it is solidified

Multiple-use mold
Single-use molds

Material is heated to a specified temperature

Molten material is poured into a mold cavity

Molten material solidifies into the shape of the cavity

Casting or mold is removed

Casting is cleaned, finished, and inspected

  1. Forming and Metalworking Processes

Utilizes material that has been cast

Modify the shape, size, and physical properties of the material

Hot and cold forming

Rolling – Material passes through a series of rollers, reducing its thickness with each pass

Forging – Material is shaped by the controlled application of force (blacksmith)

Extrusion – Material is compressed and forced through a die to produce a uniformed cross section

Wire, rod, and tube drawing – Material is pulled through a die to produce a uniformed cross section

Cold forming and forging – Slugs of material are squeezed into dies

  1. machining processes

Controlled removal of material from a part to create a specific shape or surface finish

Cutting element is used

Movement must exist between the part and cutting element

Turning Processes

Lathes and turning centers

Processes include: Straight, taper, contour turning, facing, forming, necking, parting, boring, threading, and knurling

Milling Processes

Operations that create flat or curved surfaces by progressively removing material

Cutting tools rotate as the work piece is secured and fed into the tool

Mills – Vertical and horizontal

Processes include: Surfacing, shaping, forming, slotting, T-slotting, angle, straddle, dovetailing, and slab milling

Drilling Processes

Operations that create holes

Cutting tools rotate and are fed into nonmoving secured work pieces

Drilling and boring machines

Processes include: Drilling, counter drilling, step drilling, boring, counter boring, countersinking, reaming, spot facing, and tapping

shearing processes

Operations that break unwanted material away from the part

A material is placed between a stationary and movable surface. The movable surface (blade, die, or punch) applies a force to the part that  shears away the unwanted material.

Abrasive Machining Processes

Operations in which small particles of materials (abrasives) remove small chips of material upon contact

Drum, disc, and belt sanders; surface, vertical and horizontal spindle; disc grinders; media blaster; tumblers

Thermal and Chemical Processes

Operations that cut and shape materials through chemical means

No mechanical force is used

Electrical discharge, electrochemical, chemical, laser, electron beam, flame cutting, and plasma-arc cutting

Processes include: Grinding, sawing, cutting, machining, milling, blanking, and etching

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