classification of manufacturing processes 1

8/4/2019 Classification of Manufacturing Processes 1

1/19

CLASSIFICATION

OF

MANUFACTURING PROCESS


2/19

Classification of Manufacturing Processes

A) Primary Shaping

Processes

B) Secondary

C) Surface Finish Process

D) Assembly / Joining Process

E) Processes Effecting

Change in surface Properties

F) Unconventional

Manufacturing process

Forming

Sheet Metal work

Machining / chip

removal


3/19

A) Primary Shaping Processes

CastingManufacturing process by which a liquid material is poured into a mould which contains a

hollow cavity of the desired shape and allowed to solidify. The solid casting is then ejected orbroken out to complete the process.

ForgingShaping the metal, after heating to a desired temperature (up to the plastic / red hot stage) byusing localized compressive force. Forging is done by a smith using hammer, press, furnaceand anvil.

ExtrudingExtrusion is a process used to create objects of a fixed cross-sectional profile. A material ispushed through a die of the desired cross-section. The two main advantages of this processover other manufacturing processes are its ability to create very complex cross-sections andwork materials that are brittle, because the material only encounters compressive and shearstresses. It also forms finished parts with an excellent surface finish

RollingThe process of shaping metal by passing them through "rollers" or "rolls" held at a controlleddistance or separation.

Sheet DrawingIn drawing, a blank of sheet metal is restrained at the edges, and the middle section is forcedby a punch into a die to stretch the metal into a cup shaped drawn part. This drawn part canbe circular, rectangular or just about any cross-section.


4/19

Wire DrawingWire drawing is a metalworking process used to reduce thediameter of a wire by pulling the wire through a single, or seriesof drawing dies.

Powder Metal FormingThe metal powder is compacted by placing in a closed metalcavity (the die) under pressure. This compacted material is placedin an oven and sintered in a controlled atmosphere at hightemperatures and the metal powders coalesce and form a solid.

Plastic Technology

1. Injection molding - Material is fed into a heated barrel, mixed, andforced into a mold cavity where it cools and hardens to theconfiguration of the mold cavity.

1. Thermoforming is a manufacturing process where a plastic sheet isheated to a pliable forming temperature, formed to a specific shape ina mold, and trimmed to create a usable product.

1. The blow molding process begins with melting down the plastic andforming it into a parison or preform. The parison is a tube-like piece ofplastic with a hole in one end in which compressed air can passthrough.The basic process has two fundamental phases. First, a pre-form of hot plastic resin in a somewhat tubular/bowl shape is created.Then, a pressurized gas, usually air, is used to expand the hot pre-formand press/suck it against a mold cavity.


5/19


6/19


7/19


8/19


9/19


10/19
http://www.aluminum-profiles.com/products/Aluminum_Screen_Profile.jpg


11/19


12/19


13/19

Chip Removing Process/ Machining

B) Secondary Shaping Process

Turning Facing Knurling Threading

Drilling

Grooving

Drilling is a cutting process that uses a

drill bit to cut or enlarge a hole in solid

materials. The drill bit is a multipoint,

end cutting tool. It cuts by applying

pressure and rotation to the work piece,

which forms chips at the cutting edge

Boring is a cutting operation that

uses a single-point cutting tool or

a boring head to produce conical

or cylindrical surfaces by

enlarging an existing opening in a

work piece

Boring

Planing is a cutting process that uses

a cutting tool in stationary positionwith rotation and job in motion. It is

best suited for large work pieces to

get the geometrical accuracy.

Planing

Shaping is used to machine flat or

plane surfaces in horizontal and

angular planes.

Shaping

Slotting is used to machine flat or

plane surface in vertical planes. It is

mainly used for internal machining of

blind holes of vertical machining of

complicated shapes wich are difficult

to produce on shaping machine

Slotting


14/19

Broaching is a machining process that uses a

toothed tool, called a broach, to remove

material. There are two main types of

broaching: linear and rotary. In linearbroaching, which is the more common

process, the broach is run linearly against a

surface of the work piece to affect the cut

Broaching

Grinding is an abrasive

machining process that

uses a grinding wheel as

the cutting tool.

Grinding

Milling is the process of removing

metal by feeding the work past a

rotating multipoint cutter. In

milling operation the rate of metalremoval is rapid as the cutter

rotates at a high speed and has

many cutting edges. Thus the job

are machines at a faster rate than

with single point tool and the

surface is also better dur to

multicutting edges.

Milling

Chamfering is an operation of beveling

the extreme end of the work piece.Chamfer is provided for better look, to

remove burrs and protect the end of the

work piece from being damaged.

Chamfering


15/19

Forming Process (hot & cold)

Coining

Bending

RollingDrawing

Spinning


16/19

Sheet metal operations

Shearing:

Piercing. Producing noncircular holes Punching. Producing circular holes (punched out is

waste)

Perforating. Number of small holes near to each other

Blanking. Blank sheet to desired shape. (blanked out isrequired part)

Cutting off. Removing a piece from sheet along a line(a,b,c)

Parting. Removal of scrap between two work pieces/parting line.

Notching. Removal of small material from side or edge(d)

Slitting. Cutting in a line along the length (e)

Lancing. Bending one side after cutting other sides (f)

Trimming. Removing excess material around theparting line


17/19

2.Bending:

Angle bending. Curling.

Forming.

Plunging.


18/19

C) Surface Finish Process: Grinding:

Polishing: Precision metalremaking, to remove scratches &

minor surface imperfections,abrasive particles are used.

Buffing: To bring maximum luster,before plating & after polishing.

Honning: Circular holes.

Lapping: Geometrically truesurface, very close fit between twocontact surfaces.

Electro Plating

Metal Spraying

D) Joining Process: Welding > 450C (840F)

Soldering < 450C

Brazing 450C

Riveting

Screw Fastening

Pressing

Adhesive Joining

Interlocking

Stretching

Knotting (appliqu)

E) Processes EffectingChange in Properties:

Heat Treatment: annealing,

hardening, tempering.

Shotpeaning,

Shot Penning


19/19

Surface Finish Notations

8.25

Turning

Milling

Planning

& Shaping

Drilling

1.68

Planning &Shaping

Drilling

Boring

Milling

Forging

0.0251.6

Grinding Boring

Milling

Turning

Reaming

< 0.025

Lapping

Honing

classification of manufacturing processes 1

Documents