FABRICATION PROCESSES 1. FORGING- It is a manufacturing process involving the shape of metal using localized compressive forces .

forging is often classified according to the temperature at which it is performed: cold, hot or warm forging . forged parts usually require further processing to achieve a finished part. Forging can produce a piece that is stronger than an equivalent cast or machined part. As the metal is shaped during the forging process ,its internal grains deforms to follow the general shape of the part. As a result ,the grain is continuous through the part, giving rise to a piece with improved strength characteristics . Some metal may be forged cold, but iron and steel are always hot forged. Hot forging prevents the work hardening that would result from cold forging, which would increase the difficulty of performing secondary machining operations on the piece.

2. Welding Operations : There are two types of welding being done: METAL INERT GAS WELDING ( MIG ):
It is a welding process in which an electric arc is formed between a consumable electrode wire electrode and a work piece metal, which heat the work piece metal, causing them to melt,and join. Along with a wire electrode a shielding gas is fed through the welding gun,which shields the process from contaminants in the air. The process can be semi automatic or automatic. A constant voltage, direct current power source is most commonly used with mig ,but constant current systems ,as well as alternating current ,can be used. Mig is applied to steels because it allowed for lower welding time compared to the other welding processes. It is most commonly industrial welding process, preferred for its versatility ,speed and the relative ease of adapting the process to robotic automation. The basic necessary equipment is a welding gun, a wire feed unit, a welding power supply, an electrode wire, and a shielding gas supply . the control switch or trigger when

pressed by the operator ,initiates the wire feed,electric power and shielding gas flow, causing an electric arc to be struck. Shielding gas is necessary to protect the welding area from the atmospheric gases such as nitrogen and oxygen .which can cause fusion, porosity , Oxy acetylene welding they are the processes that use fuel gases and oxygen to cut and weld metals. Pure oxygen is used instead of air ,is used to increase the flame temperature to allow the localized melting of the work piece metal eg steel in a room environment . a welding torch is used to weld metal. Welding metal results when two pieces are heated to a temperature that produces a shared pool of molten metal. The molten pool is generally supplied with additional metal called filler. Filler materials depends upon the material to be welded. A cutting torch is used to heat the metal to the kindling temperature. A stream of oxygen is then trained on the metal , and metal burns in that oxygen and then flow out of the cut as an oxide slag.

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DRILLING : It is a cutting process that uses a drill bit to cut or enlarge a hole in solid materials. The drill bit is a multipoint ,end cutting tool . it cuts by applying pressure and rotation to the work piece ,which forms chips at the cutting edge. When possible drilled holes should be located to the work piece .this minimizes the drill bit tendency to deflected, which causes the hole to be misplaced. Cutting fluid is commonly used to cool the drill bit,increases the tool life, increases speeds and feeds, and also increases the surface finishes. 4. ROLLING : IT is a metal forming process in which a metal is paired through a rolls it is classified according to the temperature of the metal rolled.if the temperature is above recrystallization temperature then it is called hot rolling. If the temperature is below recrystallization temperature then it is called cold rolling. The starting metal is usually large pieces of metal such as billets which is passed directly through rolling mills at appropriate temperature. Hot rolling is used to produce sheet metal.