Shaping the Future: The Art of Machining
and Forming
(By Siddharth Nair, CE22B106)
Contents:
• Introduction to Forming
• Types of Forming Processes
• Introduction to Machining
• Types of Machining Processes
• Applications of Forming and Machining
• Future of Forming and Machining
Introduction to Forming
• Forming is the fashioning of metal parts and objects through
mechanical deformation.
Introduction to Forming
• Forming is the fashioning of metal parts and objects through
mechanical deformation.
• That is, the workpiece is reshaped without adding or removing
material. Hence, the mass remains constant.
Types of Forming Processes
• Rolling, where the material is passed through a pair of rollers.
• Extrusion, where the material is pushed through an orifice.
• Die forming, where the material is stamped by a press around or onto a die.
• Forging, where the material is shaped by localized compressive forces.
• Indenting, where a tool is pressed into the workpiece.
• Bending, involves operations where a bending load is the primary cause of
plastic deformation.
• Shearing, involves operations where a shearing load is the primary cause of
plastic deformation.
Introduction to Machining
• Machining is a process in which a material (often metal) is cut to a
desired final shape and size by a controlled material-removal process.
Introduction to Machining
• Machining is a process in which a material (often metal) is cut to a
desired final shape and size by a controlled material-removal process.
• Machining is a type of subtractive manufacturing, in contrast to 3D
Printing (additive manufacturing), utilizing controlled addition of
material
Types of Machining Processes
The three principal machining processes are classified as turning, drilling and milling. Other
operations falling into miscellaneous categories include shaping, planing,
boring, broaching and sawing.
• Turning operations are those that rotate the workpiece as the primary method of moving
metal against the cutting tool. Lathes are the principal machine tool used in turning.
• Milling operations are operations in which the cutting tool rotates to bring cutting edges to
bear against the workpiece. Milling machines are the principal machine tool used in milling.
• Drilling operations are those in which holes are produced or refined by bringing a rotating
cutter with cutting edges at the lower extremity into contact with the workpiece. Drilling
operations are done primarily in drill presses but sometimes on lathes or mills.
• Miscellaneous operations may not be strictly machining, in that they may not
produce swarf/debris, but are still performed at a typical machine tool. Burnishing is an
example; it produces no swarf but can be performed at a lathe, mill, or drill press
Applications of Forming and Machining
• Aerospace industry - Forming and machining processes are used to manufacture components for airplanes, helicopters,
and spacecraft, such as engine parts, landing gear, and structural components.
• Automotive industry - Forming and machining processes are used to manufacture various automotive parts, such as
engine blocks, transmission gears, and chassis components.
• Medical industry - Forming and machining processes are used to manufacture medical devices, such as implants,
surgical instruments, and orthopedic equipment.
• Consumer goods - Forming and machining processes are used to manufacture a variety of consumer goods, such as
kitchen appliances, electronics, and household tools.
• Construction industry - Forming and machining processes are used to manufacture building materials such as steel
beams, concrete forms, and roofing materials.
• Energy industry - Forming and machining processes are used to manufacture components for power generation and
distribution, such as wind turbine blades, nuclear reactor components, and gas turbine parts.
• Defense industry - Forming and machining processes are used to manufacture various defense components such as
tanks, submarines, and missiles.
• Tooling industry - Forming and machining processes are used to manufacture tools, dies, and molds for various
manufacturing applications
Future of Forming and Machining
• Smart Manufacturing: Integration of AI, ML, IoT for more efficient
and flexible manufacturing processes
• Additive Manufacturing: 3D Printing has the potential to disrupt
traditional forming and machining methods due to higher precision
and accuracy with design complexity
• Sustainable Manufacturing: The forming and machining industry is
likely to adopt sustainable practices like waster reduction, recycling
and green energy sources
