Debre Berhan University

College of Engineering
Department of Mechanical Engineering

Course Title

Manufacturing – 1
MEng3181
Chapter One
Systematic survey on the most important
production processes in the metal-working industry

Prepared by: Gebremichael Tasew

02/21/2021 Manufacturing - I 1
Content

I. Introduction to manufacturing

II. Materials in manufacturing (Recall)

III. Manufacturing processes

IV. Classification of manufacturing processes

2
 Learning outcomes

After completion of this chapter students should have the following attributes,

₪ Should be able to define manufacturing from different point of views.

₪ Should have a good understanding about the varieties of engineering martials

with their unique properties.

₪ Should have a deep understanding about different types of manufacturing

processes especially particulate and metal forming processes. 3

 1.1. Introduction to manufacturing

The word manufacture is derived from two Latin words, manus (hand) and
factus (make); the combination means made by hand.
Definition
 Technologically, manufacturing is the application of physical and chemical
processes to alter the geometry, properties, and/or appearance of a given
starting material to end products.

4
 Cont’d

 Manufacturing is concerned with making products. A manufactured product may

itself be used to make other products, such as;
• A large press, to shape flat Sheetmetal into automobile bodies,

• A drill, for producing holes,

• Industrial sawing machines, for making clothing at high rates,
 Manufacturing is the making of goods by hand or by machine that upon completion
the business sells to a customer.

5
 Cont’d

 Economically, manufacturing is the transformation of materials into items of

greater value by means of one or more processing and/or assembly
operations,

6
 A. What is Manufacturing Engineering?

 Manufacturing Engineering is the branch of engineering that is concerned with

understanding, analyzing and improving complex industrial, manufacturing and
infrastructure systems.
 Manufacturing Engineers:
• design a product,
• select the best technologies and processes for manufacturing it,

• plan and design the factory that will produce the product, and
• oversee the running, management, maintenance and improvement of the factory. 
7
 B. Manufacturing industries

 Industry consists of enterprises and organizations that produce or supply goods and services.
Industries can be classified as;
• Primary industries (raw material extraction) cultivate and exploit natural resources,
such as agriculture and mining. E.g. Agriculture, Mining, Petroleum mining…
• Secondary industries (manufacturing) take the out puts of the primary industries and
convert them into consumer and capital goods. E.g. automotive, computer, tire and
rubber…
• Tertiary industries (service) constitute the service sector of the economy. E.g. Banking,
education, governmet, hotel, insurance...
8
1.2. materials in manufacturing (recall)

 Engineering materials chemistries, mechanical and physical properties are different,

 these differences affect the manufacturing processes that can be used to produce
products from them.
 A manufacturing engineer should first know the varieties of martials with their unique
properties in order to manufacture quality products in every aspect.
 Most engineering materials can be classified into one of three basic categories: (1)
metals, (2) ceramics, and (3) polymers.
 In addition to the three basic categories, there are composites nonhomogeneous
9
mixtures of the other three basic types rather than a unique category.
 cont’d

metal  Metals used in manufacturing are usually alloys,

Engineering Materials

which are composed of two or more elements, with

at least one being a metallic element.
Ceramics
 Metals are further classified as ferrous and non
ferrous metals,
Polymers  Ferrous metals are based on iron; the group
includes steel ( 0.02% to 2.11 % carbon) and cast
composites iron (2% to 4%).

10
 cont’d

metal  Ferrous Metals are magnetic and give little resistance

Engineering Materials

to corrosion.
 A non-ferrous metal is a metal, including alloys, that
Ceramics does not contain iron (ferrite) in appreciable amounts.
 Non-ferrous metals are used because of desirable
Polymers properties such as low weight (e.g. aluminium), higher
conductivity (e.g. copper), non-magnetic property or
resistance to corrosion (e.g. zinc).
composites

11
 cont’d

metal  Generally more costly than ferrous metals,

Engineering Materials

 Metallic properties;
• shiny
Ceramics
• Malleable
• Ductile
Polymers • Excellent conductors of heat and electricity
• Have high melting and boiling point
composites

12
 cont’d

metal  A ceramic is an inorganic, non-

Engineering Materials

metallic, solid material comprising metal
and non-metal atoms primarily held
Ceramics
in ionic and covalent bonds.
 typical nonmetallic elements are oxygen,
Polymers nitrogen, and carbon.
Cations Anions
composites

13
 cont’d

metal  Ceramic have the following properties,

Engineering Materials

• Strong and hard

• Brittle
Ceramics
• Semi or Non conductors of heat and electricity
• Good Corrosion and wear resistance
Polymers  Ceramic e.gs glasses, clay, cutting tools,

composites

14
 cont’d

metal  A polymer (synonym; plastics) is a compound formed of

Engineering Materials

repeating molecule units called monomers.

 Monomer atoms share electrons to form very large
Ceramics molecules.
 Polymers usually consist of carbon plus one or more other
Polymers elements, such as hydrogen, nitrogen, oxygen, and
chlorine.
 Plastics can be formed, machined, cast, and joined into
composites various shapes With relative ease.

15
 cont’d

metal  Polymers properties:

Engineering Materials

• Light (low density)

• Easy to shape
Ceramics
• Cheap and non toxic
• Have high strength to weight ratio
Polymers • Resistance to chemicals and corrosion

composites

16
 cont’d

 Composites do not really constitute a separate category

metal
Engineering Materials

of materials; they are mixtures of the other three types.

 A composite material is a material made from two or
Ceramics more constituent materials with significantly different
physical and chemical properties that, when combined
produces a material with superior properties than its
Polymers constituents.
 New composite materials are preferred because most
composites of the time they are light and strong.

17
 cont’d

metal  Typical engineered composite materials include:

Engineering Materials

• Carbon fibre
• concrete
Ceramics
• Reinforced plastics, such as fibre-reinforced polymer
• Metal composites
Polymers
• Ceramic composites (composite of ceramic and metal
matrices)
composites

18
 1.3. manufacturing processes

 A manufacturing process is a designed procedure that results in physical and/or

chemical changes to a starting work material with the intention of increasing the value
of that material.
 Manufacturing operations can be divided into two basic types: (1) processing
operations and (2) assembly operations.
 A processing operation transforms a work material closer to the final desired product.
 An assembly operation joins two or more components to create a new entity called
subassembly, assembly or product.
19
1.4. Classification of manufacturing processes

Permanent
joining process
Assembly
operations
Mechanical
fasteners

Manufacturing
processes
Shaping process

Property
Processing
enhancing
operations
process

Surface
processing
operations 20
 cont’d

Shaping processes

C, Deformation process D, Material removal or

A, Solidification processes B, Particulate processing
(forging, rolling extrusion and machining
(casting, and molding) (powder metallurgy)
drawing) (turning, drilling, milling)

 In this chapter we mostly will concentrate on shaping processes since they are most
important production processes in metal working industry especially in growing countries.
21
 A. Solidification process (casting)

 Casting is a process in which molten metal flows by gravity or other force into a mold where it
solidifies in the shape of the mold cavity.
 It is one of the oldest shaping processes, dating back about 6000 years.
 Casting is most often used for making complex shapes that would be otherwise difficult or
uneconomical to make by other methods.
 The principle of casting seems simple;
• Melt the metal,
• Pour it into a mold, and let it cool and solidify; yet there are many factors that affect the
quality of casting product. 22
 B. Particulate process (powder metallurgy)

 Powder metallurgy (PM) is a metal processing technology in which parts are produced
from metallic powders.
 In the usual PM production sequence, the powders are compressed (pressed) into the
desired shape and then heated to cause bonding of the particles into a hard, rigid
mass.
 A powder can be defined as a finely divided particulate of solid engineering materials.
 Engineering powders could be metals and/or ceramics.

23
I. Basic steps in powder metallurgy

Finishing
Sintering operations

compacting

Blending
and Mixing

Powder
production

24
 (step 1) Production of Metallic Powders

 In general, producers of metallic powders are not the same companies as those that
make PM parts
 Any metal can be made into powder form.

 Three principal methods by which metallic powders are commercially produced

• Gas Atomization
• Chemical reduction
• Electrolytic deposition
 In addition, mechanical methods are occasionally used to reduce powder sizes
25
Cont’d

 Air atomization process

 Chemical reduction and Electrolytic deposition (reading assignment)

26
 (Step 2) blending and mixing

 To achieve successful results in compaction and sintering, the metallic powders must
be thoroughly homogenized.
 Blending refers to when powders of the same chemical composition but possibly
different particle sizes are intermingled. Different particle sizes are often blended to
reduce porosity.
 Mixing refers to powders of different chemistries being combined.

27
 (Step 3) compaction

 Compaction is the step in which the blended powders are pressed into various shapes
in dies,
 The purpose being;

• Obtain required shape, density, and particle-to-particle contact, and

• To make the part sufficiently strong for further processing.
 The pressed powder is known as green compact, meaning; it has low strength and can
be damaged easily.

28
Alternative pressing techniques(isostatic pressing)

 In conventional pressing pressure is applied uniaxially causing uneven density and

porosity. This is caused b/c metallic powders do not readily flow in directions
perpendicular to the applied pressure.
 isostatic pressing, pressure is applied from all directions against the powders that
are contained in a flexible mold; hydraulic pressure is used to achieve even
compaction.
 Cold isostatic pressing (CIP) (at room temperature) The mold, made of elastomer
material like rubber, is oversized to compensate for shrinkage.
29
 Cont’d

 Water or oil is used to provide the hydrostatic pressure against the mold inside the
chamber.

30
31
 Cont’d

 Hot isostatic pressing (HIP) is carried out at high temperatures and pressures, using a
gas such as argon or helium as the compression medium.
 The container generally is made of a high-melting-point sheet metal to withstand the
high temperatures.

32
 What is porosity?

 Porosity is Ratio of volume of the pores (empty spaces) in the powder to the bulk
volume.

33
 (Step 4) sintering

 Sintering is a heat treatment operation performed on the green compact to bond its
metallic particles, thereby increasing strength and hardness.

34
(step 5) Finishing operations

 Finishing operations like electroplating, painting and machining can be

applied to PM products to enhance different properties.
 Finishing operations are mainly useful for appearance and corrosion
resistance purposes.

35
 II. Advantage of PM

 The PM process itself involves very little waste of material; about 97% of the starting
powders are converted to product.
 PM parts can be made with a specified level of porosity, to produce porous metal parts
like Filters, oil‑impregnated bearings and gears.
 PM parts can be mass produced to near net shape.
 Near net shape implies that the initial production of the item is very close to the final
(net) shape, reducing the need for surface finishing. Reducing traditional finishing such
as machining or grinding eliminates more than two-thirds of the production costs in
some industries.
 the opportunity to mix various metals into alloys that would be difficult or impossible
to produce by other means.

36
III. Limitations of PM

 The process is capital intensive (cost of dies is very high)

 Metallic powders are expensive.

 Problems in storing and handling metal powders: certain metals could be fire
hazards, toxic etc.
 Limitations on part geometry because metal powders do not readily flow
laterally in the die during pressing.
 Variations in density throughout part may be a problem, especially for complex
geometries.
37
 C. metal forming processes

 Metal forming processes dominates the class of shaping operations identified as the
deformation processes.
 Metal forming includes a large group of manufacturing processes in which plastic
deformation is used to change the shape of metal to work pieces.
 Deformation results from the use of a tool, usually called a die in metal forming,
which applies stresses that exceed the yield strength of the metal.
 The metal therefore deforms to take a shape determined by the geometry of the die.

38
Cont’d

 To be successfully formed, a metal must possess certain properties. Desirable

properties include;
• Low yield strength, and
• High ductility and malleability.
 These properties are affected by temperature.
 Ductility and malleability are increased and yield strength is reduced when work
temperature is raised.
 Metal forming processes can be classified into two basic categories: bulk deformation
39
processes and sheet metalworking processes.
 Cont’d

 Bulk deformation processes are generally characterized by significant deformations

and massive shape changes, and the surface area-to-volume of the work is relatively
small.
 Sheet metal working (press working) is the term often applied to sheet metal
operations because of the press machines used to perform these operations
 A part produced in a sheet metal operation is often called a stamping.
 Sheet metal operations are always performed as cold working processes and are
usually accomplished using a set of tools called a punch and die.
40
 Cont’d

 The punch is the positive portion and the die is the negative portion of the tool set.

bending drawing

shearing

Fig. basic sheet metal working processes 41

basic sheet metal processes

 Bending involves straining of a metal sheet or plate to take an angle along a

straight axis.
 Drawing refers to the forming of a flat metal sheet into a hollow or concave shape,
such as a cup, by stretching the metal.
 A shearing operation cuts the work using a punch and die.
 The miscellaneous processes are shaping processes that do not use punch and die
tooling. Examples of these processes are stretch forming, roll bending, etc.

42
 Temperatures in metal forming

 There are three temperature ranges that are used in metal forming: cold, warm and hot working.

 Cold working (also known as cold forming) is metal forming performed at room temperature or
slightly above.
• Advantages;
 Greater accuracy
 Better surface finish
 Higher strength and hardness
 No heating of the work, so no fuel cost.
• Disadvantage;
 higher forces and power are required to perform the operation. 43
 Cont’d

 Warm Working is when forming operations are performed at temperatures somewhat above
room temperature but below the recrystallization temperature.
• Advantages over cold working;
 Lower forces and power,
 More intricate work geometries possible
 Need for annealing may be reduced or eliminated.

 Recrystallization is the process in which deformed grains of the crystal structure are replaced
by a new set of stress-free grains that nucleate and grow until all the original grains have been
consumed. 44
 Cont’d

 Hot working (also called hot forming) involves deformation at temperatures above the
recrystallization temperature.
 Hot working is usually carried out at temperatures somewhat above half of melting
temperature.
• Advantages;
 The shape of the workpart can be significantly altered,
 Lower forces and power are required to deform the metal,
 Metals that usually fracture in cold working can be hot formed,
45
Cont’d

• Disadvantages
 Lower dimensional accuracy,
 Higher total energy required (due to the thermal energy to heat the workpiece),
 Work surface oxidation,
 Poorer surface finish, and
 Shorter tool life.

46
I. Rolling

 Rolling is a deformation process in which the thickness of the work is reduced by

compressive forces exerted by two opposing rolls.
 The rolls rotate to pull and simultaneously squeeze the work between them.

47
 Cont’d

 Most rolling processes are very capital intensive, requiring massive pieces of equipment,
called rolling mills, to perform them.
 Rolling first is carried out at elevated temperatures (hot rolling).
 During this phase, the coarse-grained, brittle, and porous structure of the ingot (or the
continuously cast metal) is broken down into a wrought structure having a finer grain
size and enhanced properties.
 Subsequently, rolling typically is carried out at room temperature (cold rolling),
whereby the rolled product has higher strength and hardness and a better surface
finish. 48
 1. Basic sequence of steps in a steel rolling

 The work starts out as a cast steel ingot that has just solidified.
 Then, the ingot is placed in a furnace for many hours until it has reached a uniform
temperature throughout the ingot, so that the metal will flow consistently during
rolling.
 The heating operation is called soaking, and the furnaces in which it is carried out are
called soaking pits.
 From soaking pits, the ingot is moved to the rolling mill, where it is rolled into one of
three intermediate shapes called blooms, billets, or slabs.
49
 Cont’d

 Bloom is the product of first breakdown of ingot. It has a square cross section 150 mm x 150
mm (6 in x 6 in) or larger.
 Billet is the product obtained from a further reduction by hot rolling (cross sectional area >
40x40 mm2).
 Slab is rolled from an ingot or a bloom and has a rectangular cross section of width 250 mm
(10 in) or more and thickness 40 mm (1.5 in) or more.
 Plate is the product with a thickness > 6 mm.
 Sheet is the product with a thickness < 6 mm and width > 600 mm.
 Strip is the product with a thickness < 6 mm and width < 600 mm. 50
51
Production chain

52
 2. Flat and shape rolling

 Flat rolling involves the rolling of workparts of rectangular cross section in which the
width is greater than the thickness like slabs, strips, sheets, and plates.
 In flat rolling, the work is squeezed between two rolls so that its thickness is reduced by
an amount called the draft.
 In shape rolling, the work is deformed into a contoured cross section.
 Products made by shape rolling include construction shapes such as I-beams, L-beams,
and U-channels
 The process is accomplished by passing the work through rolls that have the reverse of
the desired shape. 53
 Cont’d

 Shaping rolls are more complicated and expensive; and the work, usually starting as a
square shape, requires a gradual transformation through several rolls in order to
achieve the final cross section.

Flat rolling shape rolling 54

3. Arrangements of rollers used in rolling mills

 Rolling mill is a machine or a factory for shaping metal by passing it through rollers
 A rolling mill basically consists of;

• Rolls
• Bearings
• A housing for containing these parts
• A drive (motor) for applying power to the rolls and controlling the speed

55
Cont’d

TWO HIGH MILL

 Consist of Two opposing rolls squeezing
the workpart.

THREE HIGH MILL

 Consist of upper and lower driven rolls and
a middle roll, which rotates by friction.

56
Cont’d

FOUR HIGH MILL

 Small-diameter rolls (less
strength & rigidity) are supported
by larger-diameter backing rolls.

CLUSTER OR SENDZIMIR
 Each of the work rolls is
supported by two backing
rolls.
57
II. Forging

 Forging is a deformation process in which the work is compressed between two

dies, using either impact force or gradual pressure to form the part.
 It is the oldest of the metal forming operations.

 forging is an important industrial process used to make a variety of high-strength

component
 These components include engine crankshafts and connecting rods, gears,
aircraft structural components, and jet engine turbine parts.

58
1. Classification of forging

 By working temperature forging can be classified as cold, warm and hot forging.

 By type of equipment used; A forging machine that applies an impact load is called a
forging hammer, while one that applies gradual pressure is called a forging press.
 By the degree to which the flow of the work metal is constrained by the dies; it is
classified as
a) Open-die forging
b) Impression-die forging
c) Flashless forging
59
 a. open die forging (upset forging)

 In open-die forging, the work is compressed between two flat (or almost flat) dies, thus
allowing the metal to flow without constraint in a lateral direction relative to the die surfaces.
 The process is used for mostly large objects or when the number of parts produced is small.
 Open-die forging is often used to perform the work-piece for Impression-die forging

 Shapes generated by open-die operations are simple; examples include shafts, disks, and
rings.
 An important contribution of open-die hot-forging is that it creates a favorable grain flow and
metallurgical structure in the metal.

60
Cont’d

61
 b. Impression-die forging (closed-die forging)

 The work-piece is deformed between two die halves which carry the impressions of
the desired final shape.
 The work-piece is deformed under high pressure in a closed cavity.

 This processes is normally used for smaller components.

 The process provide precision with close dimensional tolerance than open die forging.
 In this type of operation a portion of the work metal flows beyond the die impression
to form flash.

62
63
64
 Cont’d

 Impression-die forging is not capable of close tolerance work, and machining is often
required to achieve the accuracies needed.
 Machining is performed on those portions of the part that require precision finishing (e.g.,
holes, threads, etc. Generally, surfaces that mate with other components).
 The advantages of forging, compared to machining are:
• Higher production rates,
• Conservation of metal,
• Greater strength, and
• Favorable grain orientation of the metal that results from forging. 65
 Cont’d
Forged product
In forging process grains are directional
aligned and has been deliberately oriented
in a direction requiring maximum strength.
This also yields ductility and resistance to
impact and fatigue.
Machined product
Machining generally has Unidirectional
grain flow. Grains has been cut when
changing contour, exposing grain ends. This
renders the material more liable to fatigue
and more sensitive to stress, corrosion and
cracking.
66
 I. functions of flash

 Flash is excess metal, Which squirts out of the cavity as a thick ribbon of metal, that
must be trimmed off later.
 The flash serves two purposes:
• Acts as a ‘safety value’ for excess metal.
• Builds up high pressure to ensure that the metal fills all recesses of the die cavity.
 As the flash begins to form in the die gap, friction between the flash and dies resists
flow of bulk metal into the gap, thus constraining the bulk of the work material to
remain in the die cavity.
67
Cont’d

 Metal flow is further restricted because the thin flash cools quickly against the
die plates, thereby increasing its resistance to deformation.
 Restricting metal flow in the gap causes the compression pressures on the
part to increase significantly, thus forcing the material to fill the details of
cavities and ensures a high-quality product.

68
ii. Impression die terminology

69
Cont’d

 Parting line (flash line): The parting line is the plane that divides the upper die
from the lower die.
• Its selection by the designer affects grain flow, required load, and flash
formation.
 Draft: Draft is the amount of taper on the sides of the part required to remove it
from the die.
 Webs and ribs: A web is a thin portion of the forging that is parallel to the parting
line, while a rib is a thin portion that is perpendicular to the parting line.
70
 Cont’d

 Fillet and corner radii: Fillets and corners are curved surface connecting ribs and webs and
are defined as.
• A corner is a convex arc, which joins two intersecting sides at an external angle of more
than 180°
• fillet is a concave arc, which joins two intersecting sides at an external angle of less than
180°
 Flash formation plays a critical role in impression-die forging by causing pressure buildup
inside the die to promote filling of the cavity.
• This pressure buildup is controlled by designing a flash land and gutter into the die.
71
 c. Flash less forging

 In flash less forging, the work is completely constrained within the die and no excess flash is
produced.
 Most importantly, the work volume must equal the space in the die cavity within a very close
tolerance.
• If the starting blank is too large, excessive pressures may cause damage to the die or
press.
• If the blank is too small, the cavity will not be filled.
 Flashless forging is often classified as a precision forging process.
 Coining is a special application of flashless forging.
72
73
 2. Forging operations

FULLURING
 Is used to reduce the cross- sectional area of
the of a portion of the stock.
 It is accomplished by dies with convex surfaces.

EDGING
 Is used to shape the ends of the bars and to gather
metal.
 The metal flow is confined in the horizontal direction
but it is free to flow laterally to fill the die. 74
 Cont’d
COGGING
 consists of a sequence of forging
compressions along the length of a
workpiece to reduce cross section
and increase length.

PIERCING AND PUNCHING

 Are used to produce holes in metals

75
3. Forging machines

Drop hammer Screw press Crank press Hydraulic press

76
 Cont’d

 Forging hammers(Drop hammers) operate by applying an impact loading against the

work.
 Drop hammers can be classified as gravity drop hammers and power drop hammers.

• Gravity drop hammers achieve their energy by the falling weight of a heavy ram.
• Power drop hammers accelerate the ram by pressurized air or steam.

 One of the disadvantages of drop hammers is that a large amount of the impact

energy is transmitted through the anvil and into the floor of the building.

77
 Cont’d

 Presses apply gradual pressure, rather than sudden impact, to accomplish the
forging operation.
 Forging presses include mechanical presses, hydraulic presses, and screw presses.

• Mechanical presses operate by cranks or knuckle joints, which convert the

rotating motion of a drive motor into the translation motion of the ram.
• Hydraulic presses use a hydraulically driven piston to actuate the ram.
• Screw presses apply force by a screw mechanism that drives the vertical ram.

78
 III. Extrusion

 Extrusion is a compression process in which the work metal is forced to flow through a
die opening to produce a desired cross-sectional shape.

79
 1. Classification of extrusion

 One important distinction is between

(a) direct extrusion and

(b) Indirect extrusion.
 By working temperature: cold, warm, or hot extrusion.
 Finally, extrusion is performed as either a continuous process or a discrete process.

80
 a. Direct extrusion

 A metal billet is loaded into a container, and a ram compresses the material, forcing it to
flow through one or more openings in a die at the opposite end of the container.
 One of the problems in direct extrusion is the significant friction that exists between the
work surface and the walls of the container which increases the ram force required.
 In hot extrusion, the friction problem is aggravated by the presence of an oxide layer on
the surface of the billet.
 To address these problems, a dummy block is often used between the ram and the billet.

81
Cont’d

 The diameter of the dummy block is slightly smaller than the billet diameter, so
that a narrow ring of work metal (mostly the oxide layer) is left in the container,
leaving the final product free of oxides.
 In order to produce hallow products, the starting billet is prepared with a hole
parallel to its axis.
 This allows passage of a mandrel that is attached to the dummy block.

82
83
 b, Indirect extrusion

 In indirect extrusion, also called backward extrusion and reverse extrusion, the die is
mounted to the ram rather than at the opposite end of the container.

84
Cont’d

 As the ram penetrates into the work, the metal is forced to flow through the clearance in a
direction opposite to the motion of the ram.
 Limitations of indirect extrusion are imposed by the:

• lower rigidity of the hollow ram and

• difficulty in supporting the extruded product as it exits the die.
 Indirect extrusion can produce hollow (tubular) cross sections,
 There are practical limitations on the length of the extruded part that can be made by this
method.
• Support of the ram becomes a problem as work length increases. 85
 IV. Wire and bar drawing

 In the context of bulk deformation, drawing is an operation in which the

cross section of a bar, rod, or wire is reduced by pulling it through a die
opening.

86
 Cont’d

 The general features of the process are similar to those of extrusion.

 The difference is that the work is pulled through the die in drawing, whereas it is
pushed through the die in extrusion.
 The basic difference between bar drawing and wire drawing is the stock size that is
processed.
• Bar drawing is the term used for large diameter bar and rod stock,
• While, wire drawing applies to small diameter stock.

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Cont’d

 Bar drawing is generally accomplished as a single-draft operation. Meaning, the

stock is pulled through one die opening.
 Because the beginning stock has a large diameter, it is in the form of a straight
cylindrical piece rather than coiled.
 By contrast, wire is drawn from coils consisting of several hundred (or even several
thousand) feet of wire and is passed through a series of draw dies.
 The number of dies varies typically between 4 and 12.

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D. Material removal or machining processes

 The material removal processes are a family of shaping operations in

which excess material is removed from a starting work-part so that

what remains is the desired final geometry.

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