1. Forming is a metalworking process that shapes metal by deforming it without removing material. Common forming processes include rolling, extrusion, forging, and die forming. 2. Joining processes like welding, brazing, and adhesive bonding are used to connect metal components together. Welding involves melting materials to join them, while brazing uses a filler metal below the melting point of the base materials. 3. Machining removes material using tools like lathes, mills, drills and grinders to shape a workpiece. It allows for tight tolerances but incurs significant material removal and waste.

1. PRESENTED BY:
KUNAL BHASIN

2. Manufacturing processes are the steps through which raw materials
are transformed into a final product. The manufacturing process
begins with the creation of the materials from which the design is
made. These materials are then modified through manufacturing
processes to become the required part.

4. Forming, or metal forming, is the metalworking process of
fashioning metal parts and objects through mechanical
deformation; the work piece is reshaped without adding or
removing material, and its mass remains unchanged.
CHARACTERISTICS:
 Large, heavy and expensive machinery is required.
 Production runs with many parts and steps.

5. FORMING
COMPRESSIVE TENSILE BENDING SHEARING

6. It involves those processes where the primary means of metal
deformation is done. It includes the following processes:
ROLLING
EXTRUSION
The material is passed through a pair of rollers.
The material is forced through an orifice.

7. DIE FORMING
FORGING
Where the material is stamped by a press around or
onto a die.
Where the material is shaped by localized compressive
forces

8. Tensile forming involves those processes where raw material is
extended to a point till it fractures.
EXPANDING
STRETCHING
Where the tensile load is applied along the longitudinal
axis of the work piece.
Where the circumference of a hollow body is
increased.

9. This category of forming processes involves those operations where it
involves both tensile stresses and compressive loads.
DEEP DRAWING
A flat sheet metal blank is formed into a
hollow body open on one side or a hollow
body is formed into a hollow body with a
smaller cross-section.

10. METAL SPINNING
FLANGE
Basically a metal disk or cylinder is rotated at
high speed by using specially designed tool
through which symmetric product are formed.
It is a process of producing protruding rim,
edge, rib, or collar, as on a wheel or a pipe
shaft, used to strengthen an object, hold it in
place, or attach it to another object.

11. Bending is a manufacturing
process that produces a V-
shape, U-shape, or channel
shape. Similar to other
forming processes it does not
cause any change in the
volume of the material.
Usually this sheet metal bending process can be carried out
cold but may require to heat the metal sometimes.

12. When a great enough shearing
force is applied, the tensile stress in
the material will exceed the ultimate
strength and the material will fail and
separate at the cut location.
Shearing is also known as die cutting and cuts the stock without
the formation of chips or the use of burning or melting. The
process can be performed manually or through electric power.

13. Gravity die casting Process
In this reusable metallic molds are used for creating the
mold cavity where molten metal are poured without
applying any force or pressure other than gravity.

14. Ideal applications- Suitable for producing aluminum alloy
and other similar light metal components.
Advantages:
 Low cost set up
 Quick cycle time
 Waste can be recycled
 Good surface finish compare
Disadvantages:
 Chances of defects are high
 Suitable for simple components

15. Squeeze casting Process
It requires pressure or force to be applied on the molten metal to
push the molten metal to be fill the heated metallic mold cavity.

16. Ideal applications- Small complex mass produced by
aluminum alloy or other similar metals.
Advantages:
 Less porosity
 Very less wastage
 Good surface finish
 Less post casting operation required
 Good strength due to finer micro structure
Disadvantages:
 High tooling and equipment cost

17. Centrifugal casting Process
In this, the tabular and axisymmetric components are
produced by revolving the mold at high speed(300-3000 rpm)
about its own axis while pouring the molten metal into the
mold cavity.

18. Ideal application- Suitable for making cylinders, flywheels
made of iron, steel etc.
Advantages:
 Low tooling costs
 Very less wastage
Disadvantages:
 Lower mechanical strength

19. Sheet metal punching process
It is the process of removing part of the sheet metal by using
punching press and punching tool.

20. Ideal application- Suitable for making mass production of the
sheet metal components.
Advantages:
 Same machine can be used for manufacturing different
components by changing the dies.
Disadvantages:
 High equipment and tooling costs

21. What is MACHINING?
1. MACHINING IS ANY OF VARIOUS PROCESSES IN WHICH A PIECE OF RAW MATERIAL IS
CUT INTO A DESIRED FINAL SHAPE AND SIZE BY A CONTROLLED MATERIAL-REMOVAL
PROCESS.
2. MACHINING IS A PART OF THE MANUFACTURE OF MANY METAL PRODUCTS, BUT IT CAN
ALSO BE USED ON MATERIALS SUCH AS WOOD, PLASTIC, CERAMIC, AND COMPOSITES.

22. Machining tools
1. Boring tools: These are typically used as finishing equipment to enlarge holes previously cut
into the material.
2. Cutting tools: Devices such as saws and shears are typical examples of cutting implements.
They are often used to cut material with predetermined dimensions, such as sheet metal, into a
desired shape.
3. Drilling tools: This category consists of two-edged rotating devices that create round holes
parallel to the axis of rotation.
4. Grinding tools: These instruments apply a rotating wheel to achieve a fine finish or to make
light cuts on a work piece.
5. Milling tools: A milling tool employs a rotating cutting surface with several blades to create
non-circular holes or cut unique designs out of the material.
6. Turning tools: These tools rotate a work piece on its axis while a cutting tool shapes it
to form. Lathes are the most common type of turning equipment

23. 1. Boring 2. Drilling
3. Thread Cutting
4. Grooving

24. What is CNC
Machining ?
Computer numerical control
Machining it is a automated
process.
It requires software and
programming, usually in the G-
code language, to guide a
machining tool in shaping the
workpiece according to preset
parameters.

25. Advantages
1. High production cycles: Once the CNC machine has been properly coded, it
usually needs minimal maintenance or downtime, allowing for a faster production rate.
2. Low manufacturing costs: Due to its turnover speed and low manual labor
requirements, CNC machining can be a cost-efficient process, particularly for high-volume
production runs.
3. Uniform production: CNC machining is typically precise and yields a high level of
design consistency among its products.

26. CASTING

27. What is Casting?
Casting is a manufacturing process by 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. Casting materials are usually metals or
various cold setting materials that cure after mixing two or more
components together; examples
are epoxy, concrete, plaster and clay. Casting is most often used for
making complex shapes that would be otherwise difficult or
uneconomical to make by other methods.

28. Types of Casting

29. Casting Process
It is the oldest
manufacturing process in
which liquid molten metal is
poured into a perforated
casting cavity of refractory
material. Allow liquid metal
to solidify, after solidification
the casting metal can be
taken out by breaking the
mould. Casting process is
used to produce
components such as
pistons, mill rolls, wheels,
cylinder blocks, liners,
machine tool beds.

31. Advantages
Advantages of casting process:
• Molten metal flows into ant small section in molten cavity, hence any complex
shape can be easily produced.
• Practically any type of material can be casted.
• Ideal method is by producing small quantities
• Due to small cooling rate from all directions, the properties of casting are same in
all directions.
• Any size of casting can be produced like up to 200 tonnes.
• Casting is the often cheapest and most direct way of producing a shape with
certain desired mechanical properties.
• Certain metals and alloys such as highly creep resistant metal-based alloys for gas
turbines cannot be worked mechanically and can be cast only.
• Heavy equipment like machine leads, ship’s propeller etc. can be cast easily in the
required size rather than fabricating them by joining several small pieces.
• Casting is best suited for composite components requiring different properties in
different direction. These are made by incorporating preferable inserts in a casting.
For example, aluminium conductors into slots in iron armature for electric motors,
wear resistant skins onto shock resistant components.

32. Limitations
• With normal casting process
the dimensional accuracies
and surface finish is less.
• Defects are unavoidable.
• It is labor intensive.

33. Joining:-

34. Why do we need joining?
To restrict some degrees of freedom of motion for components (i.e. to make
mechanisms).
(a) A complex shaped component may be impossible/expensive to
manufacture, but it may be possible/cheaper to make it in several parts and
then join them.
(b) Some products are better made as assemblies, since they can be
disassembled for maintenance.
(c) Transporting a disassembled product is sometimes easier/feasible
compared to transporting the entire product. A good example of this is the
beautiful TsingMa bridge of Hong Kong; individual sections were fabricated,
raised to the correct position, and then welded/riveted together to construct
the structure.

35. Joining
Process
Welding Brazing and
Soldering
Adhesive
bonding

36. Welding:-
In the welding process, two or more parts are heated and
melted or forced together causing the joined parts to
function as one.

37. Brazing:-
During the brazing process a filler metal is melted and distributed in
between multiple solid metal components after they have been
heated to the proper temperature. The filler metal must have a
melting point that is above 840 degrees Fahrenheit but below the
melting point of the base metals and the metal must also have high
fluidity and wettability. No melting of the base metals occurs during
brazing.

38. Brazing:-
During the brazing process a filler metal is melted and distributed in
between multiple solid metal components after they have been
heated to the proper temperature. The filler metal must have a
melting point that is above 840 degrees Fahrenheit but below the
melting point of the base metals and the metal must also have high
fluidity and wettability. No melting of the base metals occurs during
brazing.

39. Adhesive bonding:-
Adhesive bonding is a low cost process that normally has
100% material utilization. In adhesive bonding a filler
material called an adhesive is used to hold multiple
closely spaced parts together through surface
attachment. The adhesive is a nonmetallic substance
often it is a polymer.

40. PROCESS OF GIVING SHAPE TO THE SOFT RAW MATERIALS BY
PASSING IT THROUGH A SET OF ROLLERS WITHOUT APPLYING HEAT.
ADVANTAGES:
GOOD SURFACE FINISH
GOOD DIMENSIONAL
COST EFFECTIVE PROCESS
DISADVANTAGES:
CANNOT CHANGE THE SHAPE DRASTICALLY
REQUIRE ANNEALING BEFORE ROLLING
COLD ROLLING PROCESS

41. If the temperature of the metal is above its recrystallization
temperature then the process is known as Hot rolling .
Advantages:
Drastic shape change is possible
Good microstructure & good strength
Disadvantages:
Less dimensional tolerance compared to cold rolling
Poor surface finish
HOT ROLLING PROCESS

42. Given shape by applying high force(hammer) with the presence of
heat.
Advantages:
Good strength
Versatility in design
Disadvantages:
Equipment & tooling cost is high
Forging is skillful job
FORGING PROCESS

43. Process of making components by pumping the liquid materials into
the mold.
Advantages:
Good surface finish
High production rate
Fully automated(less manpower)
Disadvantage:
High tooling and equipment cost
INJECTION MODELLING
PROCESS

44. Air is pumped after pumping the molten materials into the two piece
mold cavity, the combine effect produce walled components.
Advantages:
Lower manufacturing cost per item
Variety of designs
Disadvantages:
Only hollow parts can be produced
BLOW MOLDING
PROCESS

45. Single point cutting tool used for removing materials from a fast
rotating work piece by using a machine called lathe.
Advantages:
Lead time is shorter
Tight tolerance cannot be achieved
Disadvantages:
Large scrap wastage
Equipment cost is quite high
TURNING PROCESS

46. Making hole in a work piece by removing materials from it by means of
a rotating cutting tool called drill bit.
Advantages:
Variety of materials can be chosen
Lead time is shorter
Disadvantages:
Large scrap wastage
DRILLING PROCESS

47. Layer by layer materials removing process from the work piece.
Advantages:
Lead time is shorter
Variety of materials can be chosen
Disadvantages:
Large scrap wastage
Equipment cost is high
MILLING PROCESS

48. Use grinding wheel as cutting tool to make surface smoother.
Advantages:
Good surface finish
Lead time is shorter
Disadvantages:
Large scrap wastage
GRINDING PROCESS

49. Moving the work piece slowly against some sort of abrasives. Can be
performed manually or by machine.
Advantages:
Great surface finish
Variety of materials can be chosen
Disadvantages:
Slow process
LAPPING PROCESS

50. Mechanically rubbing the honing stone against the work piece
surface along the controlled path.
Advantages:
Good surface finish
Variety of materials can be chosen
Disadvantages:
Equipment cost is high
HONING PROCESS

51. Abrasive jet machining
Abrasive jet machining (AJM), also known
as abrasive micro-blasting, pencil
blasting and micro-abrasive blasting, is
anabrasive blasting machining process that
uses abrasives propelled by a high velocity gas to
erode material from the work piece. Common uses
include cutting heat-sensitive, brittle, thin, or hard
materials. Specifically it is used to cut intricate
shapes or form specific edge shapes.
Advantage:
1. Hard Materials can be Machined.
2. Complex Profile can be Created.
3. Very Good Surface can be Achieved.

52. Fusion Welding
Fusion welding is a generic term for welding
processes that rely upon melting to join materials of
similar compositions and melting points. Due to the
high-temperature phase transitions inherent to these
processes, a heat-affected zone is created in the
material (although some techniques, like beam
welding, often minimize this effect by introducing
comparatively little heat into the workpiece.
Advantage:
Variety of materials can be chosen
Variety of welding design can be Chosen

53. Oxy-fuel welding (commonly
called oxyacetylene welding, oxy welding,
or gas welding in the U.S.) and oxy-fuel
cutting are processes that use fuel gases and
oxygen to weld and cut metals, respectively.
French engineers Edmond Fouché and
Charles Picard became the first to develop
oxygen-acetylene welding in 1903. Pure
oxygen, instead of air, is used to increase
the flame temperature to allow localized
melting of the work piece material (e.g. steel)
in a room environment. A common
propane/air flame burns at about 2,000 °C
(3,630 °F), a propane/oxygen flame burns at
about 2,500 °C (4,530 °F), and an
acetylene/oxygen flame burns at about
3,500 °C (6,330 °F).
Oxy-fuel welding
Advantages:
1.Less equipment Cost.
2.Portable equipment.
3.Easy to Operate.

54. Powder metallurgy is the process of blending fine powdered materials, pressing them
into a desired shape or form (compacting), and then heating the compressed material
in a controlled atmosphere to bond the material sintering. The powder metallurgy
process generally consists of four basic steps: powder manufacture, powder
blending, compacting, and sintering. Compacting is generally performed at room
temperature, and the elevated-temperature process of sintering is usually conducted at
atmospheric pressure. Optional secondary processing often follows to obtain special
properties or enhanced precision. The use of powder metal technology bypasses the
need to manufacture the resulting products by metal removal processes, thereby
reducing costs.
Powder metallurgy is also used in "3D printing" of metals.
Powder Metallurgy

55. Advantage:
 Very less Machining operation required after the Components are
Produced
 Rate of Production is very high.
 Scrap wastage is very less.
 Complex 3D objects can be Created

56. Rapid prototyping is a group of techniques used to quickly fabricate a scale
model of a physical part or assembly using three-dimensional computer aided
design (CAD) data. Construction of the part or assembly is usually done using 3D
printing or "additive layer manufacturing" technology.
Rapid prototyping