MANUFACTURING

PROCESSES
Presented By:
Muhammad Idrees
04-ME-33

INTRODUCTION

Basically manufacturing is value adding activity

where the conversion of materials into products adds
value to original material.
Thus the objective of a company engaged in
manufacturing is to add value and do so in most
efficient manner, using the least amount of time,
material, money, space and manpower.
To minimize waste and maximize efficiency we need a
well designed and efficient manufacturing system.

MANUFACTURING PROCESS

A manufacturing process converts unfinished

materials into finished products often using a
machine tool e.g. injection molding,
progressive stamping, welding.

Manufacturing process is all that by which we

convert Stuff into Things

CLASSIFICATION

M a n u f a c t u r in g P r o c e s s e s
C a s t in g P r o c e s s e s
F o r n in g P r o c e s s e s
M a c h in in g P r o c e s s e s
J o in in g P r o c e s s e s
S u rfa c e P ro c e s s e s

CASTING

IT IS SUITED WHEN:

The part is very large and of complex

shape.
The component has internal cavity.
The material of component is difficult to
machine.
The metal used is expensive and so there is
to be little waste.
The component has irregular curved
surfaces.

IMPORTANT FACTORS IN
CASTING OPERATION

The flow of the molten metal into the mold cavity

Heat transfer during solidification and cooling of
the metal in the mold (The metal grain sizes are
smaller near the mold than in the center)
Influence of the type of mold material
Solidification of the metal from its molten state

Casting
Processes
Expendable Mould
Casting

Sand Casting
Shell Casting
Plaster Casting
Ceramic Casting
Investment Casting

Permanent Mould
Casting

Low Pressure
Casting
Vacuum Casting
Squeeze Casting
Centrifugal Casting
Injection Molding
Compression Molding
Continuous Casting

STEPS IN SAND CASTING

Figure Outline of production steps in a typical sand-casting operation.

11

SAND CASTING

SCHEMATIC ILLUSTRATION OF INVESMENT CASTING

1. WAX INJECTION : Wax replicas of the

desired castings are produced by injection

molding. These replicas are called
patterns.

2. ASSEMBLY : The patterns are attached to

a central wax stick, called a sprue, to
form a casting cluster or assembly.

3. SHELL BUILDING : The shell is built by

immersing the assembly in a liquid ceramic
slurry and then into a bed of extremely fine
sand. Up to eight layers may be applied in this
manner.
4. DEWAX : Once the ceramic is dry, the wax is
melted out, creating a negative impression of
the assembly within the shell.

5. CONVENTIONAL CASTING
In the conventional process, the shell is filled with
molten metal by gravity pouring. As the metal cools,
the parts and gates, sprue and pouring cup become
one solid casting.

6. KNOCKOUT
When the metal has cooled and solidified, the ceramic
shell is broken off by vibration or water blasting.

7. CUT OFF
The parts are cut away from the central sprue
using a high speed friction saw.

8. FINISHED CASTINGS
After minor finishing operations, the metal
castings--identical to the original wax
patterns--are ready for shipment to the
customer.

DIE CASTING

Example of permanent-mold casting

Molten metal is forced into the die cavity at pressures ranging
from .7MPa 700MPa
Parts made from here range from:
Hand tools
Toys
Appliance components
There are two basic types of die casting machines
Hot-chamber - involves the use of a piston to push molten
metal in to the die cavity
Cold-chamber molten metal is poured in to the injection
chamber & the shot chamber is not heated

HOT CHAMBER DIE CASTING

1. The die is closed and the

piston rises, opening the
port and allowing molten
metal to fill the cylinder.

2. The plunger moves down

and seals the port pushing
the molten metal through
the gooseneck and nozzle
into the die cavity, where it
is held under pressure until
it solidifies.

3. The die opens and the

cores, if any, retract. The
casting remains in only
one die, the ejector side.
The plunger returns,
allowing residual molten
metal to flow back through
the nozzle and gooseneck.

4. Ejector pins push the

casting out of the ejector
die. As the plunger
uncovers the filling hole,
molten metal flows
through the inlet to refill
the gooseneck, as in step
(1).

COLD DIE CASTING PROCESS

2. The plunger pushes the molten

metal into the die cavity where it is
held under pressure until
solidification.

1. The die is closed and the

molten metal is ladled into the
cold-chamber shot sleeve.

4. Ejector pins push the

casting out of the ejector die
and the plunger returns to its
original position.

3. The die opens and the

plunger advances, to ensure
that the casting remains in the
ejector die. Cores, if any,
retract.

PRESSURE CASTING

Figure (a) The bottom-pressure casting process utilizes graphite molds for the production of
steel railroad wheels. Source: The Griffin Wheel Division of Amsted Industries Incorporated.
(b) Gravity-pouring method of casting a railroad wheel. Note that the pouring basin also
serves as a riser. Railroad wheels can also be manufactured by forging.

CENTRIFUGAL CASTING

FORMING
PROCESSES

GENERAL FEATURES

Materials are processed in solid state.

No need to handle molten material.

No deal with complexities of solidification.

Material is not wasted as there is no cutting

process.

Plasticity, the ability to flow as solid without

deterioration of properties, is the property that
supports these processes.

Only Ductile materials are processed.

FORMING PROCESS
It is suited when:
The part is to be formed from sheet metal
The part has no internal cavities.
Long lengths of constant cross section are required.
Seamless cup-shaped objects or cans are required.
The component is to be made from material in wire
or bar form.

FORMING PROCESSES ACCORDING TO

MATERIAL TEMPERATURE

F o r m in g P r o c e s s e s
H o t W o r k in g

C o ld W o r k in g

W a r m W o r k in g

HOT WORKING PROCESS

Deformation made in this process involves materials

of Low surface area to thickness ratio.

When metals are plastically deformed at temperature

sufficiently above their re-crystallization temperature,
the process is called hot working.

Deformation and Re-crystallization occur

simultaneously.
Material is worked above its both Recrystallization temperature and 0.6 times of its
melting temperature.

COLD WORKING PROCESS

When metals are plastically deformed at

temperature below their re-crystallization
temperature, the process is called

cold working.

Deformation processes under conditions where

Recovery processes are not active.

Working temperature is usually less than 0.3 times
the work piece melting temperature.

WORM WORKING PROCESS

Deformation processes under conditions of

Transition i.e working temperature is
between 0.3 and 0.6 times the work piece
melting temperature.

F o r m in g
P ro c e s s e s
B u lk F o r m in g
R o llin g
D r a w in g
E x t r u s io n
F o r g in g

S h e e t F o r m in g
W ir e D r a w in g
S w a g in g
R o ll F o r m in g
D e e p D r a w in g
V a c c u m F o r m in g
S u p e r p la s t ic
F o r m in g
S h e e tm e ta l
F o r m in g

P o w d e r P r o c e s s in g

ROLL FORGING OPERATION

FIGURE Schematic illustration of a roll forging (cross-rolling) operation. Tapered leaf

springs and knives can be made by this process with specially designed rolls. Source: After J.
Holub.

FLAT AND SHAPE

ROLLING OPERATION

STAGES IN SHAPE ROLLING

RING ROLLING

FIGURE (a) Schematic illustration of a ring-rolling operation. Reducing the thickness results
in an increase in the parts diameter. (b) Examples of cross-sections that can be formed by ring
rolling.

THREAD ROLLING PROCESS

FIGURE Thread-rolling processes: (a) flat dies and (b) two-roller dies. These
processes are used extensively in making threaded fasteners at high rates of production.

EXTRUSION

FIGURE Extrusion and

examples of products made by
sectioning off extrusions.
Source: Kaiser Aluminum.

FIGURE Schematic illustration of three

different types of metal flow in direct
extrusion.

TYPES OF EXTRUSION

FIGURE Types of extrusion. (a) direct; (b) indirect; (c)

hydrostatic; (d) impact.

EXTRUSION OF COMPLICATED
SHAPES

FIGURE (a) An extruded 6063-T6 aluminum ladder lock for aluminum extension ladders.
This part is 8 mm (5/16in.) thick and is sawed from the extrusion. (See Fig. (b) Components
of various dies for extruding intricate hollow shapes. Source for (b)

DRAWING

FIGURE Variables in drawing

round rod or wire.

TUBE DRAWING

FIGURE Various methods of tube drawing.

SWAGING
FIGURE Schematic illustration of the swaging process: (a) side view and (b)
front view. (c) Schematic illustration of roller arrangement, curvature on the
four radial hammers (that give motion to the dies), and the radial movement of a
hammer as it rotates over the rolls.

FIGURE Reduction of outer and inner diameters of

tubes by swaging. (a) Free sinking without a mandrel.
The ends of solid bars and wire are tapered (pointing)
by this process in order to feed the material into the
conical die. (b) Sinking on a mandrel. Coaxial tubes of
different materials can also be swaged in one operation.

CROSS-SECTIONS PRODUCED
BY SWAGING

FIGURE (a) Typical cross-sections produced by swaging tube blanks with a constant wall thickness on shaped
mandrels. Rifling of small gun barrels can also be made by swaging, using a specially shaped mandrel. The
formed tube is then removed by slipping it out of the mandrel. (b) These parts can also be made by swaging.

FORMING PROCESSES FOR

ROCKET CASING

FIGURE The forming processes involves in the manufacture of solid

rocket casings for the U.S. Space Shuttle.

SPACE SHUTTLE LAUNCH

FIGURE The Space Shuttle Atlantis is launched by two strap-on solid

rocket boosters. Source:NASA

MACHINING
PROCESSES

WHAT IS MACHINING

Removing material from a workpiece

In the form of chips.

As in case of MECHANICAL machining
processes.

Without formation of chips.

As in case of NON-TRADITIONAL machining
processes.

M a c h in in g
Processes
M e c h a n ic a l
M a c h in in g
P ro c e s s e s
C u t t in g
P ro c e s s e s

N o n - T r a d it io n a l
M a c h in in g
P ro c e s s e s

A b r a s iv e
P ro c e s s e s

C u t t in g
Processes
T o o l T ra n s l a te s
B ro a c h in g
S h a p in g

T o o l R o ta te s
V e rti c a l M /C ' i n g
D ril l P re s s
M illin g

W /P T ra n s l a te s

H o ri z o n ta l M /C ' i n g
M il l i n g
B o ri n g

P la n in g

W /P R o ta te s

V e rti c a l M /C ' i n g
B o ri n g
T u rre t L a th e

H o ri z o n ta l M /C ' i n g
L a th e

A b r a s iv e
Processes
L a p p in g
P ro c e s s

H o n n in g
P ro c e s s

P o lis h in g
P ro c e s s

G r in d in g
P ro c e s s e s

B u ffin g
P ro c e s s

N o n - T r a d it io n a l
M a c h in in g

C h e m ic a l
C h e m ic a l
M i llin g
P h o to - C h e m ic a l
m / c 'in g

E le c t r o c h e m ic a l
E .C .M
E le c t r o s t r e a m
D r illin g
S h a p e d tu b e
E le c t r o ly t ic m / c in g
STEM

M e c h a n ic a l
A b r a s iv e
J e t m / c 'in g
A b r a s iv e
W a te rJ e t
m / c 'in g
U lt r a s o n ic m / c 'in g
( I m p a c t G r in d in g )
W a te rJ e t
m / c 'in g

T h e rm a l
EDM
EBM
LBM
P la s m a A r c
C u t t in g ( P A C )
P r e c is io n
PAC
W ir e E D M

TYPES OF NTM PROCESSES

MECHANICAL

CHEMICAL

Chemical reaction b/w a

liquid reagent and the
w/p results in etching.

THERMAL
High temperatures in
very localized regions
evaporate material.

High velocity abrasive or

liquid or their mixture
removes material.

ELECTOCHEMICAL
Material removal is resulted by
an electrolytic reaction at w/p
surface.

WATER JET CUTTING

JOINING
PROCESSES

TYPES OF JOINING
PROCESSES
J o in in g
Processes
W e ld in g
P ro c e s s e s

A d h e s iv e
B o n d in g

M e c h a n ic a l
F a s te n e rs

B r a z in g &
S o ld e r in g

W e ld in g
P ro c e s s e s
F u s io n
W e ld in g
C h e m ic a l
O x if u e l
T h e r m it

S o lid S t a t e
W e ld in g
E le c t r ic a l
A r c W e ld in g
R e s is t a n c e
E le c t r o n B e a m
Laser B eam

E le c t r ic a l
R e s is t a n c e

C h e m ic a l
D if fu s io n
E x p lu s io n

M e c h a n ic a l
C o ld
F r ic t io n
U lt r a s o n ic

OXY FUEL WELDING

Uses heat from

combustion (fire)
between oxygen and a
fuel

Filler metal may or may

not be used

What type of weld is

made without filler
metal?
Autogenous weld

OXYACETYLENE WELDING

Most common fuel used

is acetylene

Oxyacetylene welding is
flexible

ARC WELDING

Uses an electric arc to

coalesce metals

Arc welding is the most

common method of welding
metals

Electricity travels from

electrode to base metal to
ground

SHEILDED METAL ARC

WELDING

Arc is protected by the

electrode coating

Also called Stick

Welding

GAS METAL ARC WELDING

Shielding gas protects

arc between wire
electrode and weld
Uses argon gas
Also called MIG
welding

GAS TUNGSTUN ARC WELDING

Arc is protected by gas

surrounding the
electrode
Uses tungsten gas
Also called TIG Welding

FLUX CORED ARC WELDING

Electrode contains a
flux center

Flux prevents harmful

substances from forming
on the weld

SUBMERGED ARC WELDING

Arc travels between

bare electrode and weld.

SAW (Submerged Arc

Welding)
The electric current arcs
beneath the flux powder.
When the flux melts, the
weld bead appears

PLASMA ARC WELDING

Arc travels between the

tungsten electrode and
weld.

RESISTANCE WELDING

Uses heat and pressure

to bond metals

MECHANICAL FASTENERS
M e c h a n ic a l
F a s te n e rs
In te g e ra l
F a s te n e rs

D is c r e t e
F a s te n e rs
T h re a d e d

N o n -T h re a d e d

S c re w s
N u ts
B o lt s

R iv e t s
P in s
S t a p le s

In t e g e r a l
F a s te n e rs
S e a m in g
C r im p in g
S t it c h in g

MAJOR CLASSES OF
MECHANICA ASSEMBLY
1.

2.

Methods that allow for disassembly

Example: threaded fasteners
Methods that create a permanent joint
Example: rivets

THREADED FASTENERS
Discrete hardware components that have external or
internal threads for assembly of parts
Most important category of mechanical assembly
In nearly all cases, threaded fasteners permit disassembly
Common threaded fastener types are screws, bolts, and
nuts

SELF TAPPNING SCREWS

Designed to form or cut threads in a preexisting

hole into which it is being turned
Also called a tapping screw
Figure:
Selftapping screws:
(a) threadforming,
and
(b) threadcutting

RIVETS
Unthreaded, headed pin used to join two or more parts by passing
pin through holes in parts and forming a second head in the
pin on the opposite side
Widely used fasteners for achieving a permanent mechanically
fastened joint
Clearance hole into which rivet is inserted must be close to the
diameter of the rivet
Figure Five basic rivet
types, also shown in
assembled configuration:
(a) solid, (b) tubular, (c)
semitubular, (d)
bifurcated, and (e)
compression

INTERFACE FITS
Assembly methods based on mechanical interference between the
two mating parts being joined
The interference, either during assembly or after joining, holds
the parts together
Interference fit methods include:
Press fitting
Shrink and expansion fits
Snap fits
Retaining rings

SNAP FITS
Joining of two parts in which mating elements possess a temporary
interference during assembly, but once assembled they interlock
During assembly, one or both parts elastically deform to
accommodate temporary interference
Usually designed for slight interference after assembly
Originally conceived as a method ideally suited for industrial robots

ADHESIVE BONDING
A d h e s iv e B o n d in g
E p o x ie s

C y a n o a c r y la t e s

A n a e r o b ic s

A c r y lic s

U re th a n e s

S ilic o n s

H ig h T e m p .
A d h e s iv e s

H o t M e lt s

BRAZING
It is the permanent joining of metals(similar or
dissimilar), ceramics and composites thru the
use of heat and filler metal.
Melting temperature of filler metal necessarily
is above 4500C but lower than those of base
metals.

SOLDERING

It is brazing type of operation where filler

metal has a melting temperature below 4500C.

SURFACE
PROCESSES

SURFACE PROCESS

From the definition of manufacturing

processes, surface processes are not among
the basic manufacturing processes. But they
are integral to them.
Surface processes are carried out once all
manufacturing processing is completed,
with the exception of heat treatments.
They are also called as finishing processes

S urface Processes
B u lk T r e a t m e n t s
S o lu t io n
T re a tm e n ts
P r e c ip it a t io n
H a r d e n in g
I n d u c t io n
H a r d e n in g
A n n e a lin g

S u r fa c e T r e a t m e n t s
A n o d iz in g
C a r b u r iz in g
C a r b o n it r id in g
N it r id in g
S h o t P e e n in g
F la m e
H a r d e n in g

S u r fa c e C o a t in g s
T h e rm a l
s p r a y in g
C e r a m ic
c o a t in g
E le c t r o p la t in g
E le c t r o le s s
p la t in g
C h e m /P h y s
v a p o u r d e p o s it io n

C le a n in g P r o c e s s e s
M e c h a n ic a l
C le a n in g
W ir e
B r u s h in g
B e lt S a n d in g
B u ffin g
T u m b lin g

C h e m ic a l
C le a n in g
A lk a lin e
c le a n in g
P ic k lin g
S o lv e n t
c le a n in g
V apour
d e g r e a s in g