Introduction To Manufacturing Process

Manufacturing Process:

          Manufacturing is the production of work pieces having defined geometric shapes. It is one of the most important production technologies. other technologies are process technology and energy technology.

Classification of Manufacturing Process:

          Manufacturing Process can be classified in six groups. They are:

 Primary Shaping or Forming Processes:

          Primary shaping or Forming is manufacturing of a solid body from a molter or gaseous state or form an amorphous material. Amorphous materials are gases, liquids, powders, fibres, chips, melts and like. A primary shaping or forming tool contains a hollow space, which, with the allowance for contraction usually corresponds to the form of the product. Here, cohesion is normally created among particles. Some of the important primary shaping processes are;

                   1. Casting

                   2. Powder Metallurgy

                   3. Plastic Technology

Deforming Processes:

          Deforming processes make use of suitable stresses like compression, tension, shear or combined stresses to cause plastic deformation of the materials to produce required shapes without changing its mass or material composition. In forming, no material is removed: they are deformed and displaced. Some of the forming process are;

                   1. Forging

                   2. Extrusion

                   3. Rolling

                   4. Sheet metal working

                   5. Rotary swaging

                   6. Thread forming

                   7. Explosive forming

                   8. Electromagnetic forming

Machining / Removing Processes:

          The principle used in all machining processes is to generate the surface required by providing suitable relative motions between the work piece and the tool. In these processes material is removed from the unwanted regions of the input material. In this, the work material is subjected to a lower stress as compared to forming processes. Some of the machining processes are,

                   1. Turning

                   2. Drilling

                   3. Milling

                   4. Grinding

                   5. EDM

                   6. ECM

                   7. Shaping and planning

                   8. Ultrasonic machining

 Joining Processes:

          In this process two or more pieces of metal parts are united together to make sub-assembly or final product. The joining process can be carried out by fusing, pressing, rubbing, riveting or any other means of assembling. Some of the important joining processes are;

                   1. Pressure welding

                   2. Diffusion Welding

                   3. Brazing

                   4. Resistance welding

                   5. Explosive welding

                   6. Soldering

Surface Finishing Processes:

          These processes are utilized to provide intended surface finish on the metal surface of a job. By imparting a surface finishing process, dimension of the part is not changed functionally; either a very negligible amount of metal is removed from or certain material is added to the surface of the job. Surface cleaning process is also accepted as a surface finishing process. Some of the surface finishing processes are;

                   1. Plastic coating

                   2. Metallic coating

                   3. Organic finishes

                   4. Inorganic finishes

                   5. Anodizing        

                   6. Buffing  

                   7. Honing

                   8. Tumbling

                   9. Electro-plating

                   10. Lapping

                   11. Sanding

Material Properties Modification Process:

          In this type of process, material properties of a work piece is changed in order to achieve desirable characteristics without changing the shape. Some of the processes are;

                   1. Heat and surface treatment

                   2. Annealing

                   3. Stress relieving