INTRODUCTION TO

MANUFACTURING
PROCESS
Dr. N. YUVARAJ
Department of Mechanical Engineering

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Car Assembly Line Engine

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Engine Block Piston 9
 Manufacturing Process
• Primary Manufacturing Processes
• Secondary Manufacturing Processes or Machining Processes
• Joining Processes
• Surface finishing Processes
• Processes effecting change in properties

PRIMARY MANUFACTURING PROCESSES:

• The Products obtained through primary manufacturing processes may or

may not undergo further operations, depending upon the functions they
have to perform. The processes from which we get directly usable articles
and do not require further processing before use, are called primary
manufacturing processes.
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Car working principle
• https://www.youtube.com/watch?v=dmnu7HL3bQo

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Die casting principle
• https://www.youtube.com/watch?v=iSyBsdJkQu8

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Car Welding (Manual)
Automatic Car welding

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Hot Rolling, Forging 16
Sheet Metal Forming Process

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 Manufacturing Processes are divided into two types:
(i) Some of these processes finish the product to its usable form
(ii) Other require further working to finish the component to the desired shape and size.

• For example: Casting need re - melting of INGOT in Cupola furnace and then pouring of
this molten metal into sand mould to obtain the CASTINGS.
• These casting may or may not require further operations depending upon their use.

• Better dimensional accuracy is obtained in Forging, Cold Rolling, Die Casting, Metal
Spinning and Wire drawing, than Casting.

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COMMON PRIMARY MANUFACTURING PROCESSES:
 Casting
 Forging
 Power Metal Forming
 Gas Cutting
 Extruding
 Rolling
 Bending
 Drawing
 Piercing
 Shearing
 Squeezing
 Spinning
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 Forming
 SECONDARY MANUFACTURING PROCESSES:

• Many parts or articles need further processing after the primary processes.
• These articles are subjected to one or more of the machining operations, called secondary manufacturing
processes, to obtain the desired shape and dimensional accuracy.
• Basically we get roughly finished products through primary operations. In all these cases, the primary
operations precedes the secondary operations.
• The secondary operations are mainly necessary when a very close dimensional accuracy and a very high
degree of surface finish are required or some such shape is to be produced which is not possible through
primary operations.

• These operations require the use of one or more machine tools, various types of cutting tools and cutters,
job holding devices, marking and measuring instruments, testing devices and gauges. Use of these tools
leads to the desired dimensional control and degree of surface finish.

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COMMON SECONDARY MANUFACTURING PROCESSES
• Turning
• Knurling
• Threading
• Drilling
• Boring
• Shaping,
• Milling,
• Hobbing
• Broaching
• Grinding
• Honing
• Unconventional Machining 21
Turning (Lathe) Milling Gear Cutting

Laser Drilling
Grinding Drilling

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 JOINING PROCESSES
• Joining processes are used for joining metal parts and in fabrication work.
• These processes are required when large lengths of standard sections are required or many pieces are to be joined
together to fabricate a desired structure.
• Smaller lengths or pieces are joined together to give the desired length of structure. Also when in pipes steam or water
tight joints are needed, we apply joining processes. Joining processes may be Temporary (Nut and Bolts), Semi Permanent
(Riveted Joints) and Permanent (Welded Joints).
• Sintering is anther process, which enables bonding of metal particles (powder metal) by heat and pressure. By this
process we get metal filter element (Porous Metals), called Micronics Filters used in hydraulic systems of aircraft,
Hydraulic Systems of Heavy Cranes and also used in Power Packs.

• Common Joining Processes

Welding, Soldering, Brazing
Riveting, Screwing,
Sintering & Adhesive Bonding

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 SURFACE FINISHING PROCESSES
• These processes are not metal removing processes, they only provide a good surface
finish or a decorative or protective coating on to the metal surface, a very negligible
amount of metal removal or addition may take place. Thus, any appreciable variation
in dimensions will not be effected by these processes.
• Common Surface Finishing Processes:
• Buffing, Polishing, Honing, Lapping,
• Grinding, Super finishing,
• Electroplating, Metal Spraying, Deburring,
• Inorganic Coating
• Painting & Galvanizing

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 PROCESSES AFFECTING CHANGE IN PROPERTIES
• These Processes imparts certain specific properties to the metal parts to make them suitable for specific use or
application.

• Most physical properties, like hardening, softening and grain refinement etc., call for particular heat treatment.

• Heat treatments not only affect the physical properties, but in most cases also make a marked change in the internal
structure of the most metal. So is the case with Cold and Hot working of metals.

• They, apart from shaping the metal, have an appreciable effect on the physical properties and internal structure of the
metal.

• All such processes which affect the physical properties and in most cases the internal structure of the metal, fall in this
category processes affecting change in properties.

Common processes affecting change in properties:

• Heat Treatment
• Cold Working
• Hot Working 25
 References
• From various websites taken for study purpose only
• A Course In Workshop Technology Vol-I
By RAGHUWANSHI
Publisher: DHANPAT RAI & Co. (P) LTD

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