CONVENTIONAL

MANUFACTURING PROCESSES

Dr. K. Vivekananda
Assistant Professor
Department of Mechatronics Engineering,
IFHE University, Hyderabad, Telangana, India.
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 What is Fabrication ?
 Fabrication is the processes to create component parts that can be
used to make a product or structure, as well as the process of
constructing an item from standardized parts.

 Fabrication synonyms are manufacturing, production, forming,

framing, making etc..

 Manufacturing is the processing of converting raw materials into a

finished product that can be sold to a consumer.

 The material as found in nature is called raw material.

 The process of making a product is called manufacturing and the

process is called manufacturing process.

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 What do we mean by digital?
Digital describes electronic technology that generates, stores, and
processes data in terms of two states: positive and non-positive.

Positive is expressed or represented by the number 1 and non-positive

by the number 0.

Thus, data transmitted or stored with digital technology is expressed as

a string of 0's and 1's.

Digital data can be used to store very complex information

Examples of digital data are digital images, digital video, video games,
web pages and websites, social media, databases, digital audio such as
MP3, electronic documents and electronic books.
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Introduction of Digital Fabrication
Fabrication can be done manually, but the processes are often
automated these days with the use of computer aided designs
(CAD) that can be programmed into computer numerical
control (CNC) and 3D-Printing technologies that can
communicate directly with machines on the shop floor.

It can reducing lead times, costs and material usage while

improving accuracy and quality.

The most common forms of digital fabrication technologies are:

 CNC Machining: where desired shapes can be made with
using computer programs
 3D Printing: where objects are built up out of layers of metal
or plastic

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 Digital Fabrication
Digital fabrication is a design and manufacturing workflow where
digital data directly drives manufacturing equipment to form
various part geometries.

This data most often comes from CAD (computer-aided design),

which is then transferred to CAM (computer-aided manufacturing).

Digital Fabrication makes it possible to manufacture and fabricate

as a functional tool instead of conventional machines.

It is expected that this will become the backbone of all future

design and fabrication initiatives.

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Manufacturing Process and its
interaction with the 5 M’s
Men

Methods

Manufacturing
Machinery Process Product

Material

Money
Classifications of Manufacturing Processes

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 Manufacturing Processes
Manufacturing Processes are broadly classified in to five
groups:

Casting

Machining

Forming

Powder metallurgy

Joining
 Casting Process
• Casting is a manufacturing process the molten material is poured into a cavity
of the desired shape and size of the product to be produced, allowing it to
solidify.

Cavity Desired shape/ End product

• The cavity is made in a suitable material held in a box called mould.
• After solidification, the end product is extended from the mould
 Casting process
Below figure shows a metal casting process in which the cavity in sand is
filled with the molten metal.

Examples of the products that are manufactured by the casting process are
frying pans, machine bases, automobile engines, carburetors and gun
barrels.
• The range of products that
can be manufactured by the
casting process vary from a
small nail to very big
components and simple
shapes to very intricate
shapes, which cannot be
manufactured by any other
processes. For example, the
largest cannon in the world,
situated at Jaigarh fort,
Jaipur, weighing 50 tons,
was manufactured by the
process of casting in the
seventeenth century
According to the tourism department,
the Jaivana cannon is a world famous cannon,
and: It was cast in 1720 during the reign of
Maharaja Sawai Jai Singh II (1699-1743) at the
foundry at Jaigarh. Its 20 foot long barrel
weighs 50 tons, with a diameter of 11 inches.
 Machining
The processes of removing the unwanted material from a given
workpiece to give it required shape is known as machining.

The removal of unwanted material may be done by a manual

process or by using a machine called machining tool, and using
tools called cutting tools. 13
 Machining
 Using the machining process, it is possible to manufacture
components with very close dimensional tolerances, which cannot
be obtained by the other methods of manufacturing.
 Examples: Gears, automobile parts, and nuts and bolts.

 When machining is used for cutting metals, it is commonly referred

to as metal cutting process.
 Some examples of metal cutting process are drilling, turning,
milling and grinding.
 Lot of material is wasted as scrap in the machining process. 14
Machining

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Machining - Lathe
Lathe equipped with a variety of attachments and accessories
to facilitate the machining and to perform the specialized
tasks.
 Machining
Turning
Turning is the most basic lathe operation in which excess material
from the given work piece is removed to reduce its diameter.
FACING
 Facing is the operation of machining the end or face of the job held
in a chuck or face plate.
 Facing is used for reducing the length of the workpiece
 Facing operation is carried out using turning tool
 The operation involves feeding the tool perpendicular to the axis of
rotation of the work piece from outer surface to centre.
 Length of tool travel is half the diameter of the job.
KNURLING
 A knurling operation, carried out on a lathe, is used to produce
regular patterned rough surface
 Knurling is the process of embossing a diamond shaped regular
pattern on the surface of work piece using a tool called Knurling
tool.
 Knurling is not a metal cutting process. It is a method of squeezing
the metal hard enough to cause plastic movements of metal in to
peaks and troughs.
Grooving
 Groove or grooving is the process of producing a narrow groove on
the surface of a cylindrical job.
 The diameter is workpiece is reduced slightly from the surface over
a narrow width.
 The job is revolved at a slow speed and the grooving tool is fed
straight into the work by rotating the cross-slide screw.
 There is no feed in groove operation
Parting
 Parting is the operation of cutting a work piece into two parts.

 If slow feed is used, the tool will not cut continuously but will
ride on the surface for a revolution or two, and then bite in
suddenly. This phenomenon is known as hogging.
Chamfering
 Chamfering is the operation of beveling the sharp ends of the
work piece to avoid any injuries to the person using the
finished product.
 It is provided better look, to enable nut to start freely on
treaded workpiece.
 Chamfering angle usually 450
Taper Turning
A tapered job is one whose diameter decreases or increases gradually so that it
assumes conical shape.

Tan α = D1-D2/2L

α = angle of taper,
D1 = larger diameter in mm,
D2 = smaller diameter in mm,
L = Length of taper in mm.
The conicity K of the taper is defined as
K = D1-D2/L
The amount of taper in a workpiece is usually specified by the ratio of the
difference in diameters of the taper to its length. This is termed as the "conicity"
and it is designated by the letter K.
Taper turning by Swiveling the compound rest

The compound rest has a circular base graduated in

degrees, which can be swiveled at any angle.
Thread cutting
 It is the operation of producing a helical groove of specific
shape, say ‘V’ or square on a cylindrical surface.
 Thread cutting operation is done on lathe using a single
point tool called thread cutting tool.
 Forming
• Forming process encompasses a wide variety of techniques,
which make use of suitable force, pressure or stresses like
compression, tension, shear or their combinations to cause a
permanent deformation of the material to give it the
required shape.

• In forming process, no material is removed and wasted, but

is only displaced and deformed.

• Examples of metal forming process included, rolling,

forgoing, drawing, extrusion etc.

• Examples kitchen utensils, wires, cold drink bottle caps,

collapsible tubes, rails, etc.
Forming

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 Forming
Rolling Process
• Theprocess of shaping metals and alloys into semi finished or finished
condition by passing between the rolls is known as rolling.

• Thisprocess involves the plastic deformation of the metal in which the

thickness of the metal reduced, while the length and width are increased
 Forming
Extrusion Process
 It a block of metal is reduced in cross section by forcing it to flow
through a die orifice under high pressure.
 The extrusion process may be done either in cold or in hot condition.
 If extrusion process is done at room temperature or slightly elevated
temp. , it is called cold extrusion process.
Metal forming process

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 Powder Metallurgy
o In powder metallurgy, fine powdered materials are blended, pressed into a
desired shape in a die and then heated in a controlled atmosphere to bond
the contacting surfaces of the particles and get the desired properties.
o Examples: gears, tungsten wires for electric bulbs, cutting tools, etc.

o The size of the product that can be made by this process ranges from tiny
balls for ballpoint pen tips to parts weight up to 50kg.
o The products manufactured by this process have good dimensional
accuracy and finish.
o The products usually do not require any further processing.
Powder Metallurgy

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 Joining
 In this process, two or more pieces are joined together to produce the
required shape and/or size of the product.

 Before joining, the components may be manufactured by any of the

process disused earlier.

 The joint can be permanent, semi permanent or temporary.

 The permanent joining can be done by fusing the metals together.

 For this kind of joining, metal is locally heated or melted and filler
material may be used.

 Examples of permeant joining process include welding, brazing and

soldering
 Joining
 The temporary joining of the components can be done using nuts, bolts,
screws, etc.
 Adhesive are also used to make temporary joints.

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 Joining
Brazing is a joining process that uses a filler metal to join two base metals together at
temperatures above 840 degrees Fahrenheit (450 º C). Soldering is a joining process that
uses a filler metal to join two base metals together at temperatures below 840 (450 º C).

Riveting
Metal Joining Process

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Welding Joining
 Welding process can be defined as the process of metallurgically joining
two pieces of metals by fusing to produce essentially a single piece of the
metal.
 The welding process joins two pieces of metal by applying intense heat or
pressure or both to melt the edges of the metal so that they fuse
permanently.
 In welding filler material may also be used.
 The heat required for the process of welding can be obtained by using an
electric arc, electric current, gas flame or chemical reaction.
Non-conventional
Machining

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 Allied Activities
The manufacturing activity, in addition, requires some allied
activates to produce the finished product.

The three important activities are:

 Measurement

 Assembly

 Property changing Measure app in iPhone

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 Measurement
 Each product must have a defined size, shape and other characteristics
as per the design specifications.
 To manufacture the product to the specified size, the size must be
measured and checked during and after the manufacturing process.
 This involves measuring size, smoothness and other features, in addition
to their checking.
 These are called measurement and inspection.

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 Assembly
More than 20,000 parts are put together to make a car, below figure shows
a car with its major parts.

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 Assembly
The process of putting the parts
together to form the product, which
performs the desired function, is
called assembly.

An assemblage of parts may

require some parts to be joined
together but assembly should not
be confused with the joining
process.

Most of the products cannot be

manufactured a single unit, they
are manufactured as different
components using one or more of
the manufacturing processes, and
these components are assembled to
get the desire product. 43
 Property changing
 In many situations during manufacturing, we required to
change the properties of the material being used.

 A hard material is difficult to shape by cutting , forming, etc.

 If we can soften it before shaping and re-harden after the

desired shape and size is obtained, the manufacturing become
easy.

 It is possible to alter the properties of some material such as

hardness by subjecting material to a specific process.

 Steel and other ferrous materials are the best examples of such
materials.
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Selection of manufacturing process
 A component or product can be manufactured by more than one process.

 We have alternatives of several processes for the manufacture of a given

component.

 The selection of a suitable process is based on the following

considerations:

 Volume of production

 Expected quality and properties of the components

 Technical viability of the process

 Economy

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 Types of production
Based on the quality of product, manufacturing activity
can be classified under the following three categories:

1. Job shop production

2. Batch production

3. Mass production

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 Job shop production
 Low volume of production and variety of work characterize job shop
production.
 Job shop production is commonly used to meet specific customer orders
requiring one or very few numbers of the product having a very specific
design and specifications.
 Examples of the products made from job shop production include a
space vehicle, a special tool, an easy chairs of ones comfort, etc.

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 Batch production
 Batch production involves the manufacture of medium quantity of an item
or product.

 The orders for the product may be repetitive or non-repetitive.

 Typical examples of the products made in batch production include

textbooks, furniture, and so on.

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 Mass production
 Mass production is characterized by manufacture of identical products in
bulk quantities.
 In mass production environment, the entire organization is dedicated for
the manufacture of a particular type of production.
 Examples of mass production are pens, refills, screws, cars and scooters.
 Since the machines and equipment are involved in the manufacture of
single type of production
 It must be for special purpose rather than for general purpose and hence
the investment required for machine tools and equipment is high.

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Thank you
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