Manufacturing Processes and Design Principles

Non ferrous part

Considered not to contain Iron.

Manufacturing processes

The three main stages are Rough forming, Machining, Assemble final product.

Fillets

Concave metal corner (inside) surfaces which will increase the strength of a corner reducing the possibility of a break.

Rounds

Edges or outside corners that have been rounded to avoid chipping and to avoid sharp edges.

Casting metal process

Forging is not a process for casting metal.

Draft angle

Angle provided to remove a part from a sand casting mold and to help the metal flow into the core.

Joining metal pieces

Process used to join two pieces of metal using heat is known as Welding, Soldering, brazing.

Drop Forging

An operation in which a metal shape is formed by forcing hot metal into an impression (die) and rapidly hammering it into shape.

Press Forging

Process by which metal is heated and shaped by plastic deformation by applying a constant compressive force into a die.

Extrusion

The process in which metal or other material is forced through a series of dies to create a desired shape.

Dial/digital caliper

Versatile tool used to measure inside measurements, outside measurements and depth.

Die casting

Forcing molten metal between dies.

Milling machine

Used to machine a part with a rotating cutter.

Broaching

Using a long cutting tool to shape a hole.

Reaming

Improves hole surface accuracy.

Grinder

Removes metal to a fine and accurate finish.

Boring

Used to produce large holes.

Heat treating

Used to change metal properties.

Lathe

Stock rotates and cutting tool is fed into stock.

Stock Forms

Standard size and shapes of material.

Engineering change order

The method used to record a change to an engineering document.

Traceability

Proper documentation ensures that all changes can be traced back to who made them when and why.

Version Control

Keeping track of revisions prevents confusion over which version is current reducing the risk of using outdated or incorrect information.

Legal and regulatory compliance

Many industries require detailed records of changes to meet legal or safety standards; poor documentation can lead to violations or liability in the event of failure.

Collaboration and communication

Engineering projects often involve multiple team members or departments documenting changes clearly ensures everyone is on the same page and reduces misunderstandings.

Historical reference

Recorded changes provide a history of design decisions and modifications which are useful for future maintenance troubleshooting or upgrades.

Ideas

An integral part in the development of a good design.

Design process

A culmination of ideas, obstacles and innovation explaining basic lean manufacturing principles and concepts and how they impact the design process.