Types of Manufacturing Process

OVERVIEW OF MANUFACTURING PROCESS
TYPES OF MANUFACTURING PROCESS

1. Classification based on Process
a. Shaping
b. Joining
c. Finishing
2. Classification based on quantity of production
d. Unit wise
e. Batch production
f. Mass Production
CLASSIFICATION BASED ON PROCESS
SHAPING
• Manufacturing a solid product of define size and shape
from a given material is called shaping.
• Shaping is used to change the size and shape of a
workpiece.
• It will remove material from the workpiece.
• It is taken in three possible states:
→ In solid State:- eg. Forging, Rolling, Extrusion,
Drawing etc.
→In Liquid or semi liquid state:- eg. Casting, Injection
moulding etc.
→In powder from:- eg. Powder Metallurgy.
JOINING
• It means connecting two or more pieces or
components together in a permanent or
temporary joined with or without application of
heat or pressure.
• Types of Joining
A. Welding, Riveting, Brazing, Soldering:
Permanent Joining
B. Bolting: Temporary Joining
FINISHING
• Finishing involves altering the surface of a manufactured
part to achieve the desired appearance and provide
protection from outside elements, corrosion, wear and
rust.
• Types of finishing
a. Inherent finish: It provides natural finish because
further work not needed.
Example materials such as timber, stone, brick and glass.
b. Applied finishes: It provide with colouring as further
finish is needed.
Example materials such as types of paint or plaster to
timber or walls.
BASIC MANUFACTURING PROCESS
 CASTING
 MACHINING
 WELDING
 SHEARING EXTRUSION
 HEAT TREATMENT
 UNCONVENTIONAL MACHINING
CASTING
• Casting is a manufacturing process in which a
liquid material is usually poured into a mold,
which contains a hollow cavity of the desired
shape, and then allowed to solidify. The solidified
part is also known as a casting, which is ejected or
broken out of the mold to complete the process.
• Examples are epoxy, concrete, plaster and clay,
Metal.
• Examples of cast parts: frames, machine
components, valves, pipes
STEPS IN CASTING
1. Patternmaking: It involves making a replica of the product

to be cast, which can then be used to shape the mold cavity
and provide accurate dimensions and characteristics.
2. Molding: The mold is prepared to receive the molten metal.
3. Melting and pouring: Metals need to be melted in a
furnace. The molten metal is then poured into the cavity of
the mold and left to harden.
4. Shakeout and cleaning: Once the molten metal solidifies it
is removed from the mold and cleaned.
5. Heat treatment and inspection: Depending on its final
usage, the product may then undergo various finishing
treatments and inspections.
https://youtu.be/h2RiLz1-v4Q
ADVANTAGES OF CASTING
1. Cost : Castings provide a more cost-effective option when it comes to
low- volume manufacturing because of speed, low tooling costs and
also provides a simple process to produce parts that can be done
without machining.
2. Time- Rapid Manufacturing because it require minimal tooling. Parts
can be produced quickly and in minimal or mass quantities, making
them a perfect option for low-volume manufacturing.
3. Complex Structures: It is a great choice for complex parts as they offer
design flexibility as castings can be offered in a variety of sizes and
shapes.
4. Product Quality: It offer high compressive strength and can produce
thin walls without losing structural integrity as metal castings are
poured in a mold which can quickly get consecutive quality cast parts.
5. The Surface Finish Of The Part: Although metal castings don’t
automatically have finished surfaces but it can quickly be ground,
smoothed, or painted to finish your part.
MACHINING
• Machining involves shaping a piece of material
to a final desired shape by removing material in
a controlled manner.
• Since machining processes utilize machine tools
like machining centers and work by removing
material, they are often termed as subtractive
manufacturing processes.
Stages of the Machining Process
1. Creating Blueprints: To create a conceptual idea of the part that is

required is done through engineering drawings and blueprints of the
part, with the intended dimensions mentioned on the blueprints.
2. Creating CAD Models: Blueprints of the part are converted into a
digital 3D model. This is done by using Computer Aided Design
(CAD) software. This is the job of a programmer.
3. The CAD models are converted to Computer Aided Manufacturing
(CAM) programs. The CAM program is the language that the CNC
machine understands. CAD programs can also tell if there are any
issues with the design that will give errors in the machining process.
4. Machine Setup: The machine setup is carried out by the operator
and involves adjusting the tooling and mounting the workpiece
materials on the CNC machine.
5. Program Execution: Once the machine is ready, the operator
executes the program and shape the final part.
APPLICATION OF MACHINING PROCESS
• Engine components
• Machine components
• Automotive parts
• Agricultural equipments
• Gears
• Aerospace components
• Screw holes
• Cranes
• Engine cylinders
• Furniture making
Types of Machining process
• Turning
• Milling
• Drilling
https://www.youtube.com/watch?v=3rB5KfSyR4g
WELDING
• Welding is a fabrication process that joins two or
more metals using heat, pressure, or both to form
a strong, permanent bond.
• Weldable materials generally include metals and
thermoplastics, but welding other materials like
wood are also possible.
• Two factors affect welding process
1. Heat (Fusion welding)
2. Pressure (Pressure welding)
https://www.youtube.com/watch?v=CCzhT81GrBo
WELDING
SHEARING EXTRUSION

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OVERVIEW OF MANUFACTURING PROCESS

TYPES OF MANUFACTURING PROCESS

1. Patternmaking: It involves making a replica of the product

1. Creating Blueprints: To create a conceptual idea of the part that is

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