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MANUFACTURING PROCESSES
WHAT IS MANUFACTURING?
It is the process of converting raw material into finished
product by using machine.
Classification of Manufacturing process:
1. Casting
2. Metal forming/Deformation
3. Machining/Metal Cutting Process.
4. Surface finishing
5. Powder metallurgy
6. Sheet metal working
7. Metal Joining process
8. Process effecting change in properties.
CASTING PROCESS
In casting, Molten metal like cast iron, copper, aluminum is
poured into mould of desired shape.
After that allowing the molten metal to cool and solidify in
the mould.
Applications of casting:
Cylinder blocks, piston, clutch housing, gear blank
Jet engine blades, gear box housing
Machine tool beds, frames, gears
Water supply pipes, sanitary fittings
TYPES OF CASTING PROCESSES
Sand casting – In this process castings are made
using sand mould.
SPECIAL TYPE OF CASTING PROCESS
Permanent Mould Casting Process – there is metallic mould,
so we can use no. of times (25000 times)
This is also known as gravity die casting
DIE CASTING PROCESS
Making of casting by injecting the molten metal under high
pressure into mould.
This is also known as pressure die casting
METAL FORMING PROCESS
Component of desired shape and size obtained through the
plastic deformation of metal under action of externally
applied force.
Forging Process:
First metal is heated and then plastically deformed to
desired size under compressive force.
CLASSIFICATION OF FORGING BASED ON
TYPES OF DIES
Open die forging process: Closed Dies Forging
CLASSIFICATION BASED ON MODE OF
APPLICATION OF COMPRESSIVE FORCE
Hand forging:
DROP FORGING
It is the process of deforming the hot material into desired
shape by raising the die with the help of pneumatic cylinder
and allowing it to fall so as to impart blow on material
PRESS FORGING
It is the process of deforming the hot material into desired
shape by raising the die with the help of pneumatic cylinder
and allowing it to fall so as to impart blow on material
UPSET FORGING
Upset forging is operated in horizontal direction
SHEET METAL WORKING (PRESS WORKING)
Process of manufacturing the components from the sheet
metal.
Thickness of the sheet metal ranging from 0.1 mm to about
6-8 mm.
Types of sheet metal working:
Sheet metal cutting process
Sheet metal forming process
SHEET METAL CUTTING PROCESS
Piercing : Producing a hole of any desired shape in a sheet
metal by using punch and die.