Manufacturing Processes

Manufacturing Processes: Definition

General concept:
• A sequence of operations designed to increase the value of an entity. Passenger car, film,
software, rice, etc.

Engineering concept:
• It is defined as the interrelated activities to convert raw input materials into a useful product
to fulfill a societal need, involving 7 M’s (Man, Material, Money, Machine, Method, Market,
Meaningful data), output having acceptable quality and cost.
 Functions of Manufacturing Process
•It is a transformation process.
•Change the properties (physical/chemical) of the work material
•Change the geometry (shape and size) of the work piece.
•Change the appearance of the work piece.
•Produce desired quality (dimensional accuracy and surface finish) at affordable cost.

Value added
Transformation Desired Quality and
Product cost with a societal
Process
need
Machine
Method
Market
Material
Money

Scrap and
Man

Information waste
 Selection of a Manufacturing Process
1. Understand Function/Geometry Recognize requisite Properties
Functional requirements of product Geometry of input raw material and output product
2. Properties Make out required Material(s)
Properties: mechanical, electrical, thermal, magnetic, optical, deteriorative.
3. Material Identify optimum Processing
Material: structure, composition.

• Processing: changes structure and overall shape

• Material and Geometry compatibility
• Other considerations ( Time, availability, skill, law……..)
 Classifications:
1. Casting Processes – Sand Casting, Permanent mold casting, die casting, Centrifugal casting

2. Primary metal working processes – Rolling, forging, extrusion, wire drawing

3. Machining Processes – Turning, drilling, milling, grinding

4. Joining processes – Welding, brazing, soldering

5. Shearing and Sheet metal forming processes – Punching, blanking, drawing, bending, forming

6. Processes for changing physical properties of the materials – Hardening, Tempering, Annealing,
Surface Hardening.

7. Surface finishing processes – Lapping, honing, superfinishing

 Casting
• Casting is the most primitive & most popular means of producing the
desired shape to raw materials.
• In casting process, material in a liquid or semi-liquid form is poured or
forced to flow into a previously made mold or cavity where it solidify &
take the shape & size of the mold.
• The term casting also applies to the part made by the process.
• The process can be applied on metals and plastics.
• The term casting is commonly used for metals and the term molding is
used for plastics.

Prepare mold pour liquid metal solidify, cut out extra part finish
 Applications
• Machine tool bed, frames, door handles, locks
• Water supply & sewage pipes
• Piston, piston rings, cylinder blocks, automobile parts.
• Roller, flywheels, pulley, handle wheel, wheels of many cars.
• Brackets, housing for motors, pumps, etc.
• Small parts, i.e., dental crowns, jewelry, small statues
• Wood burning stoves, railway wheels, big bells, big statues

Railway wheels Wood burning stoves Piston Sewage pipes

 Applications

23 feet, C-clamps
6 tonnes ,
99.72% iron,
Flywheel No rust since
5th century AD

Cylinder Block Iron pillar

Hooks and clamps
 Advantages
• Any shape & any size can be made by casting.
• Any type of material, ferrous or non-ferrous, can be used.
• Some casting processes can produce parts to net shape (no further manufacturing operations are
required)
• Final shape can be obtained, minimizing further operation of machining or forging.
• High cost or complex machines are not required
 Limitations
• Limitations on mechanical properties.
• Poor dimensional accuracy and surface finish for some processes; e.g., sand casting, but it can be
better for investment casting.
• Safety hazards to workers due to hot molten metals & Polluted environment.
• Requires relatively thick walls (>3mm)
• Labor intensive & slow
• Automation is difficult
• Tolerances: 0.125 mm to 2.5 mm
• Surface finish:
die casting 8-16 micro-inches (1-3 mm)
sand casting - 500 micro-inches (10-25 mm)
 Metal Forming
• Metal forming includes a large group of manufacturing processes in
which plastic deformation is used to change the shape of metal work
pieces
• Plastic deformation: a permanent change of shape, i.e., the stress in
materials is larger than its yield strength but less than fracture
strength.
• Metal remains in solid state in the whole process. Twork<Tm
• Metal with low yield strength and high ductility is in favor of metal
forming.
• Usually a die/punch set-up is needed to force deformed metal into the
shape.
 Forging
• It can be defined as the controlled plastic deformation of metals or alloys to a
desired size or shape using compressive force exerted through some type of
die by hammer, a press or upsetting machine.
• Principle of working: A bar or billet or blank is compressed by the application of
impact force or squeezing pressure to flow plastically in between two flat dies or
inside the impression of the desired shapes.
– The oldest metal forming operation (called blacksmithing).
– Forging is generally a hot working operation though cold forging is used
sometimes.
– In forging, the shape of the raw material is changed by repositioning material
rather than removing it.
 Applications

Examples – high-strength parts for automotive and aircrafts like engine crank shafts and connecting
rods, gears, aircraft structural components & jet engine turbine, etc.
 Advantages
• Better mechanical properties , when the grain flow direction are properly directed for the
specific application .
• Forgings can be held to within fairly close dimensional tolerance.
• Forgings products offer great resistance to impact & fatigue loads due to extra working
during the process.
• It allows material to be displaced / moved where it needed thus reduction in weight,
wastages & cost.
• Coarse or columnar grain are refined (as most forging are hot worked).
• Impunities in the metal in the form of inclusion are broken up & distributed throughout
the metal.
• Internal porosity and cracks welded up giving high reliability to parts.
• High production rate and Relatively smooth surface.
 Limitations
• Tooling & handling cost is high.
• In hot forging , due to high temperature of metal , there is rapid oxidation
or scaling of the surface resulting in poor surface finish .
• Forging operation is limited to simple shapes & has limitation for parts
having under cuts , re-entrant surface etc.
• Some materials are not readily worked by forging.
• Usually forgings cost more than castings.
 Rolling
• Rolling is a bulk deformation process in which the metal is plastically deformed by
compressive forces exerted by two opposing rolls. The rolls rotate to pull and
simultaneously squeeze the work between them.
• Is widely used to convert steel ingots into blooms, billets, and slabs, and
subsequently into plates, sheets and strips
Advantages:
• Provides high production rate
• Provides good control over the dimensions of the finished product
Type of Rolling:
• Hot rolling: Metal is rolled at a temperature above its recrystallization temperature.
Higher reduction in the cross-section is achieved
• Cold rolling: Metal is rolled at a temperature below its recrystallization temperature.
Better strength and control of dimensions are achieved.
• Based on work piece geometry :
Flat rolling - used to reduce thickness of a rectangular cross section
Shape rolling - square cross section is formed into a shape such as an
I‑beam
 Applications

Slab Production

Rolling of sheet metal Rolled Sheets

Screw manufacturing
 Extrusion
• Extrusion is defined as the process of shaping
material, such as aluminum, by forcing it to flow
through a shaped die orifice under high pressure.
Extruded material emerges as an elongated piece
with the same profile as the die opening.

• Toothpaste tube is a very good example of the

process.

• A ram /Punch advances from one end of the die

and causes the metal to flow plastically through
the die
 Extrusion Cont..
• Extrusion is a continuous pressure forming process much like squeezing
toothpaste out of a tube.
• Almost always performed hot
• Flow is complex, with a lot of redundant work (bending and unbending)
• Friction plays an important part
– Surface of billet tends to stick to container, extrusion surface is new
• Metals such as aluminum, copper, magnesium, and stainless steel are
easily extruded.
• Can be complex sections, which cannot be rolled.
 Applications
• Railings for sliding doors
• Window frames
• Tubing having various cross-sections
• Aluminum ladders
• Numerous structural and architectural
shapes
 Advantages
• Many shapes can be produced that are not possible with rolling
• Amount of reduction in a single step is only limited by the equipment, not the
material or the design
• Dies are relatively inexpensive
• Small quantities of a desired shape can be produced economically
• It can be applied to difficult to form, like stainless steel, nickel based alloys and
other high-temperature materials.
• Automation of extrusion process is simpler as items are produced in a single
passing.
• No time is lost when changing shapes since the dies may be readily removed and
replaced.
• Dimensional accuracy of extruded parts is generally superior to that of rolled
ones.
 Welding
Welding is a joining process which produces coalescence of materials by:
heating them to suitable temperatures (with or without melting)
with or without the application of pressure or
by the application of pressure alone, and
with or without the use of a third material called filler material.
Groups of welding processes:
• Autogeneous welding: Joining of similar metals by melting edges together and without addition of filler metal
• Homogeneous Welding: joining similar metals with filler metal of same metal composition
• Heterogeneous Welding: Joining dissimilar metals with or without filler metal

Major Classification of welding processes

▪ Liquid state or Fusion Welding: Work pieces are heated above melting pointed at the joint location. Heat is
generated by electric arc, electric resistance, blacksmith’s fire, chemical reaction, friction or atomic adhesion
▪ Solid state welding: Workpieces are heated to plastic state (above recrystalization temperature but below
melting point). Joint is prepared by applying pressure on joint location.
 Types of Welding Techniques
There are many different methods of welding. The difference between them is
outlined by two important features
• The way the metal is heated
• The way additional filler metal if any is fed into the weld
Welding Processes

Fusion Welding Solid state Welding

Heat generated by
Heat generated by

Thermo-chemical energy Electrical Energy Mechanical Energy Electrical Energy

Gas Thermit Arc Electron Laser Electro-slag Friction Resistance

Welding Welding welding Beam Beam Welding Welding Welding

Forge
TIG MIG SMAW Submerged Plasma arc Welding
arc welding Welding
Ultrasonic
Welding
 Numerical Control (NC) Machine
• It is defined as a machine that is controlled by a set of instructions in the form of numbers,
letters, and symbols. The group of instructions is called a program.

NC Machine Parts Produced by NC Machine

Computer Numerical Control (NC) Machine
• It is defined as the machine that is used to control the speed of the workpiece and tool with
the help of programs prepared in the computer. The program is written in alphanumeric data.

CNC Machine Parts Produced by CNC Machine

Difference between NC & CNC Machines
Difference between NC & CNC Machines
 3-D Printing
Additive Manufacturing – Layer Manufacturing
Additive manufacturing, also known as 3D printing, rapid prototyping or freeform
fabrication, is ‘the process of joining materials to make objects from 3D model data,
usually layer upon layer, as opposed to subtractive manufacturing methodologies’
such as machining.

CAD image of a teacup with further images showing the effects of building using different layer
thicknesses
3-D Printing Process

Generic process of CAD to part, showing all 8 stages

 Advantages
• Elimination of design constraints
• Allow parts to be produced with complex geometry with no additional costs

related to complexity

• Build speed; reduction of lead time

• Flexibility in design
• No expensive tooling requirements
• Dimensional accuracy
• Wide range of materials (polymers, metals, ceramics)
• Well suited to the manufacture of high value replacement and repair parts
• Green manufacturing, clean, minimal waste
 Limitations

Material choice: Non weldable metals cannot be processed by additive manufacturing

and difficult-to-weld alloys require specific approaches.

Material properties: Parts made by additive manufacturing tend to show anisotropy in

the Z axis (construction direction).

• The densities of 99.9% can be reached, there can be some residual

internal porosities.

• Mechanical propertiesareusually superior to cast parts but in general

inferior to
wrought parts.
Thank you