Manufacturing Processes

By Premchand Kumar
Deoghar ( Jharkhand)
What is Manufacturing?
Conversion of Raw materials into required
products.
Manufacturing can be done by using hand, tools,
machinery, chemical processes etc.
Manufacturing can be on small scale basis or on
large scale basis.
Different Processes
Forming
Casting
Machining
Welding
Forming
Forming is a shaping process in which a metal
subjected to mechanical forces.
Metal or Metal alloy when subjected to
mechanical force undergoes change in required
shape.
Metal undergoes plastic deformation.
Cold Working Process
Plastic deformation of metals at a temperature
below the recrystallisation temperature.
The metal undergoes strain hardening thus
requiring more and more force for plastic
deformation.
The maximum amount of deformation that can be
given is limited.
Hot Working Process
Plastic deformation of metals at a temperature
above the recrystallisation temperature.
Large deformation can be successively done as the
metal remain soft and ductile.
Hot working does not produce strain hardening,
but improves ductility.
Types of Forming Process
Forging
Rolling
Extrusion
Drawing
Forging
In forging the metal are deformed into the
required shapes by application of repeated blows
from a hammer.
The metal (raw material) which is usually used is a
piece of circular bar or square cross-section block.
Slightly larger volume of raw material is taken and
excess material is machined off.
Types of Die Forging
Open die Forging
 Closed Die Forging

Upper Die

Workpiece Final Product

Lower Die (Stationary)

Flash
Rolling
Metals and alloys are plastically deformed into
semifinished or finished products by being pressed
between two rolls which are rotating.
The metal gets subjected to high compressive force
as it gets squeezed by the rolls.
The cross-section of metal gets reduced and the
length will get increased
Types of Rolling
Two high mills
Three high mills
Four high mills
Defects in Rolling

Center Split

Alligatoring Defect

Edge Cracks
Wavy Edges
Extrusion
Extrusion is the process of confining the metal in a
closed cavity and allowing it to flow from one
opening.
The metal comes out as a long strip having same
cross-section as the die opening.
Extrusion is commonly used for manufacture of
solid and hollow sections.
Types of Extrusion
Hot Extrusion
1) Forward or Direct Extrusion
2) Backward or Indirect Extrusion
Cold Extrusion
1) Hooker Extrusion
2) Hydrostatic Extrusion
3) Impact Extrusion
4) Cold Extrusion Forging
Forward or Direct Extrusion

The material to
be extruded is
in the form of a
block.

The block is pressed from behind by means of a

ram and a follower pad.
The material is forced to squeeze through the die
opening
Backward or Indirect Extrusion

The block is inserted

into the container.
The ram is made hollow
and is pressed against
the block.
The block is extruded out of the ram as the
ram is pressed against.
Hooker Extrusion

Used to produce small thin walled tube.

Process is done in two stages.
1) The blank is converted into cup shaped piece
2)The walls of the
cup are thinned
and is elongated.
Hydrostatic Extrusion

The pressure is applied to the metal blank on all

side through a fluid medium.
The commonly used fluid mediums are glycerine,
ethyl glycol, castor oil.
Very high pressures are
used i.e. 1000-3000 MPa
Impact Extrusion

The punch is allowed to impact on the blank with

high velocity.
Wire Drawing
Rods of metal are pulled through the die.
Dies are conical in shape having a hole in the
center.
Included angle of cone is usually 8° to 24°.
Rods of metal undergoes plastic deformation thus
reducing its diameter and increase in length.
Wire Drawing
Casting
Manufacturing a part by heating a metal above its
melting point and pouring the liquid metal in a
cavity of required shape and size.
After the liquid cools and solidifies, it acquires the
shape and size of finished product.
The casting process includes the following process:

1) Preparation of pattern.
2) Preparation of a mould.
3) Melting of metal in furnace.
4) Pouring of molten metal into mould cavity.
5) Breaking the mould to retrieve the casting.
6) Cleaning the casting and cutting off risers,
runners.
Patterns

Patterns are replicas of the casting.

Similar in shape and size of final product, but not
exactly the same.
Patterns are provided with some allowances to
obtain the exact dimensions of final product.
Common allowances given are: Shrinkage
allowance, Machining allowance, Draft allowance.
Moulding sand properties
High Refractoriness
High Permeability
Green sand Strength
Good Flowability
Good Collapsibility
High Cohesiveness
High Adhesiveness
Defects in Casting
Defects in Casting
Machining
1) Lathe
2) Shaper
3) Milling
Lathe
Lathe is one of the most commonly used machining
process.
Cutting tool is used which is much harder than the
work piece to be machined.
Machining is done by the relative motion between
the cutting tool and the part.
The cutting tool is given a sharp cutting edge and it
is forced to penetrate inside the work piece upto a
small depth.
The various operations possible in Lathe are:

1) Turning
2) Facing
3) Taper turning
4) Parting
5) Boring
6) Threading
Shaper
Shaper is used to produce a flat surface.
Capable of machining a horizontal, vertical or
inclined flat surface.
The tool cuts in forward direction and is idle in
return direction.
The Shaper works on slotted lever quick return
mechanism.
Shaper
Mechanism of Shaper
Milling
Machining process performed with a rotary cutter
with several cutting edges arranged on the
periphery of the cutter.
Used to generate flat or curved profile.
Produces great surface finish.
There are two types of Plain milling process
1) Up Milling
2) Down Milling
Up Milling Down Milling
Face milling

Face Milling is the

milling of surfaces
that are perpendicular
to the cutter axis.
Welding
Welding means process of joining of two metal
parts together.
Welding is a strong and permanent joint.
Fusion Welding: Heating the ends of metals to be
joined above the melting point and fuse them.
Pressure Welding: Heating the ends of metals to
be joined just below the melting point and fusing
them by applying a pressure.
Gas Welding
Types of Flames
The chemical reaction between acetylene gas
and oxygen is given as:
Types of Joint
Welding Defects