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Overview of Manufacturing Processes

The document discusses several main manufacturing processes including casting, forming, machining, joining, and regenerative processes. It outlines some specific advantages and limitations of each process such as casting allowing for complex internal shapes but often requiring further machining. Forming allows for high production rates and improved properties but is limited to simple shapes. Machining provides very good surface finish and control over dimensions but has high tooling costs and low production rates.

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alagar krishna kumar
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120 views7 pages

Overview of Manufacturing Processes

The document discusses several main manufacturing processes including casting, forming, machining, joining, and regenerative processes. It outlines some specific advantages and limitations of each process such as casting allowing for complex internal shapes but often requiring further machining. Forming allows for high production rates and improved properties but is limited to simple shapes. Machining provides very good surface finish and control over dimensions but has high tooling costs and low production rates.

Uploaded by

alagar krishna kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Fundamentals of Manufacturing Processes

Manufacturing Process Specific Advantages and Limitations

DHEERENDRA KUMAR DWIVEDI


MECHANICAL & INDUSTRIAL ENGINEERING DEPARTMENT

1
Main manufacturing processes
• Casting
• Forming
• Machining
• Joining
• Regenerative processes

2
Sibelco India

• Shortest route to get complex Casting


shapes even with internal • Moderate surface finishing and
features like through and blind tolerance
holes • Possibility of external and internal
• Mechanical properties don’t defects
limit the capability of process • Tendency of interaction with ambient
• Compatible for custom, batch air
and mass production • Often Needs machining processing and
• Compatible for very few heat treatment
mm/gm size to m/ton size • Difficult for high melting temperature
casting metals
• Common method for composite • Chemical and metallurgical
materials heterogeneity
3
Forming
• High production rate • Anisotropic structure and
properties
• Improved mechanical
properties • Limited to simple shapes
• Reduced internal defects • Needs machining to achieve
required finish and tolerance
• Compressive residual stress
• Difficult control of process
• Easy automation
parameters
• Close control over the
• Mechanical properties namely
properties
yield strength and ductility affects
• High strength to weight ratio success of process
4
Machining
• Very good surface finish • Loss metal worth in form
• Close control over of chips
dimensions • Low production rate
• Complex shapes • Skilled worker
• Capability to produce high • High initial investment on
aspect ration features
machine tool
• Variety of surfaces flat,
curved, mix of various • Hard metals difficult to
profiles cut

5
Welding and allied processes
• Helps to develop large structure • Heat affected zone
using simple shapes • Heterogeneity in terms of
• To develop components which mechanical and metallurgical
otherwise can not be made using properties
other manufacturing processes • Residual stress
• Joining of similar and dissimilar • Increased corrosion tendency
metals • Colour mismatch possibility
• Joint can be stronger than base • Thin/thick sections need extra care
metal • Needs secondary processing
• Joining in liquid, solid and liquid- • Low reliability
solid variants as per need
• Notch sensitive

6
Regenerative process
• Complex shape • Limited to
plastic/polymers
• Ease manufacturing
• Ribbed surface
• Wide variety • High initial investment
• Quick response time • Low volume production
• Ability to deal with • High cost
dynamic demand for
variety of products

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