Introduction to

Manufacturing
Process

Casting Processes

These are the only processes

where liquid metal in used.
Casting is the oldest known
manufacturing process.
It requires preparation of a cavity
usually in a refractory material to
resemble closely to the object to
be realized.
Molten metal is poured into this
refractory mould cavity and is
allowed to solidify.
The object after solidification is
removed from the mould.

Forming Processes

These are solid state manufacturing processes involving minimum

amount of material wastage and faster production.
Metal is heated to a temperature which is slightly below the
solidus temperature and then a large force is applied such that the
material flows and take the desired shape.
The desired shape is controlled by means of certain tools called
dies which may be completely or partially closed during
manufacture.
These processes are normally used for large scale production
rates.

Extrusion
Drop forging

Rolling Process
Wire Drawing

Fabrication processes
These are secondary manufacturing processes where the starting raw
materials are processed by any of the previous methods.
It essentially involves joining pieces either temporarily or permanently so that
they would perform the necessary function.
The joining can be achieved by both heat and pressure and / or a joining
material.
Gas Welding
Resistance Welding

Arc Welding

Material Removal Processes

These are also secondary manufacturing processes where the

additional unwanted material is removed in the form of chips from
the blank material by a harder tool so that a final desired shape
can be obtained.
Material removal is the most expensive manufacturing process
because more energy is consumed, and also a lot of waste
material is generated in the process.

Turning

Milling

Shaping

Grinding

Drilling
Sawing

Abrasive Machining
Categories
The Metal abrasion action is adopted during
grinding, honing and super finishing processes
that employ either a solid grinding wheel or
sticks in the form of bonded abrasive.

Furthermore in lapping, polishing, and buffing,

loose abrasives are used as tools in a liquid
medium.

The requirements that lead to the

development of nontraditional
machining

Very high hardness and strength of the material.

The work piece is too flexible or slender to support the cutting or

grinding forces.

The shape of the part is complex, such as internal and external

profiles, or small diameter holes.

Surface finish or tolerance better than those obtainable conventional

process.

Temperature rise or residual stress in the work piece are undesirable.

Conventional Machining VS
NonConventional Machining

The cutting tool and workpiece are always in physical contact, with a
relative motion against each other, which results in friction and a
significant tool wear.

In non-traditional processes, there is no physical contact between the

tool and workpiece. Although in some non-traditional processes tool
wear exists, it rarely is a significant problem.

Material removal rate of the traditional processes is limited by the

mechanical properties of the work material. Non-traditional processes
easily deal with such difficult-to-cut materials like ceramics and
ceramic based tool materials, fiber reinforced materials, carbides,
titanium-based alloys.

Continue

In traditional processes, the relative motion between the tool and work
piece is typically rotary or reciprocating. Thus, the shape of the work
surfaces is limited to circular or flat shapes. In spite of widely used CNC
systems, machining of three-dimensional surfaces is still a difficult task.
Most non-traditional processes were develop just to solve this problem.

Machining of small cavities, slits, blind or through holes is difficult with

traditional processes, whereas it is a simple work for some nontraditional processes.

Traditional processes are well established, use relatively simple and

inexpensive machinery and readily available cutting tools. Nontraditional processes require expensive equipment and tooling as well
as skilled labor, which increases significantly the production cost.

Advanced cutting tool materials

(a) Coated carbides - TiC, TiCN, TiN, Al2O3
(b) Cermets -These sintered hard inserts
are made by combining cer from ceramics
like TiC, TiN ( or )TiCN and met from metal
(binder) like Ni, Ni-Co, Fe etc.
(c) Coronite -Coronite is made basically by
combining HSS for strength and
toughness and tungsten carbides for
heat and wear resistance. Microfine
TiCN particles are uniformly dispersed into
the matrix

(d) High Performance Ceramics

(HPC) Sinterability, microstructure, strength
and toughness of Al2O3 ceramics were
improved to some extent by adding
TiO2 and MgO
(e) Cubic Boron Nitride (cBN)
(f) Diamond