Fundamentals of Manufacturing Processes

Manufacturing Process Specific Advantages and Limitations

DHEERENDRA KUMAR DWIVEDI

MECHANICAL & INDUSTRIAL ENGINEERING DEPARTMENT

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 Main manufacturing processes
• Casting
• Forming
• Machining
• Joining
• Regenerative processes

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 Sibelco India

• Shortest route to get complex Casting

shapes even with internal • Moderate surface finishing and
features like through and blind tolerance
holes • Possibility of external and internal
• Mechanical properties don’t defects
limit the capability of process • Tendency of interaction with ambient
• Compatible for custom, batch air
and mass production • Often Needs machining processing and
• Compatible for very few heat treatment
mm/gm size to m/ton size • Difficult for high melting temperature
casting metals
• Common method for composite • Chemical and metallurgical
materials heterogeneity
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 Forming
• High production rate
• Improved mechanical
properties
• Reduced internal defects
• Compressive residual stress
• Easy automation
• Close control over the
properties
• High strength to weight ratio
• Anisotropic structure and
properties
• Limited to simple shapes
• Needs machining to achieve
required finish and tolerance
• Difficult control of process
parameters
• Mechanical properties namely
yield strength and ductility affects
success of process
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 Machining
• Very good surface finish
• Close control over
dimensions
• Complex shapes
• Capability to produce high
aspect ration features
• Variety of surfaces flat,
curved, mix of various
profiles
• Loss metal worth in form
of chips
• Low production rate
• Skilled worker
• High initial investment on
machine tool
• Hard metals difficult to
cut
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 Welding and allied processes
• Helps to develop large structure
using simple shapes
• To develop components which
otherwise can not be made using
other manufacturing processes
• Joining of similar and dissimilar
metals
• Joint can be stronger than base
metal
• Joining in liquid, solid and liquid-
solid variants as per need
• Heat affected zone
• Heterogeneity in terms of
mechanical and metallurgical
properties
• Residual stress
• Increased corrosion tendency
• Colour mismatch possibility
• Thin/thick sections need extra care
• Needs secondary processing
• Low reliability
• Notch sensitive
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 Regenerative process
• Complex shape • Limited to
plastic/polymers
• Ease manufacturing
• Ribbed surface
• Wide variety • High initial investment
• Quick response time • Low volume production
• Ability to deal with • High cost
dynamic demand for
variety of products