Module No.

1: INTRODUCTION
Lecture No-4

Description and Taxonomy of the Manufacturing Processes

Metal Casting (Net Shape Processes) Metal Casting is one of the oldest known method for shaping the materials. It involves pouring molten metal into a mold having the required shaped cavity and then allowing it to solidify. When solidified, the desired metal object is taken out from the mold either by breaking it or taking the mold apart. The solidified object is called the casting. In this process, intricate parts can be given strength and rigidity which is frequently not obtainable by any other manufacturing process. The major metal casting processes are: Sand casting Permanent mold casting Continuous casting Die casting Slush casting Centrifugal casting Evaporative-pattern casting Lost wax casting Shell molding Vacuum sealed molding

Molding (Net Shape Processes) Molding is generally used in plastics. A hollowed-out block in which liquid, plastic, molten glass or some ceramic material is filled is called a mold. The filled in material

hardens and gets set inside the mold, replicating its shape. Inorder to remove the hardened substance, a release agent is used. There are about eight major molding. processes in

Hot compression molding Transfer molding Injection molding Extrusion molding Laminating Vacuum forming Expandable bead molding

Metal Forming (Net Shape Processes) Metal forming is a process which involves the shaping of materials in a solid form. It can be defined as a bulk deformation process that induces change in shape under the applied force. Metal forming is of two basic types; namely hot forming and cold forming. Hot forming is performed by heating the metal above the re-crystalline temperature. Hot forming reduces its yield stress, so that its shape can be easily changed / formed by applying the force. Cold forming is performed by heating the metal below its recrystalline temperature. The major metal forming processes are as given below: Smith Forging Drop Forge Press, Extrusion Cold and Hot Rolling Sheet Metal Embossing Blanking, Shearing Notching Perforating, Nibbling Electroforming Explosive Forming

Material Removal Processes / Machining (Subtractive Processes)

Metal removal processes in which we remove the excess material to give the final shape to the product, are often termed as secondary or machining processes. They are also termed as finishing processes; which are done to give the required finish or tolerance to the end product. This means that in both the cases i.e. either removal of material or finishing of part, the product to be cut or finished is made by one of the other processes described above. At instances, the product geometry is very complex, to be produced by other processes. In such cases the basic shape of the product is produced using other processes and the final shape is created by using some machining process. The major metal removal / machining processes are as given below: Milling, Turning, Drilling Broaching, Shaping, Planning Honing, Etching, Grinding Finishing Processes Abrasive Flow Machining Abrasive Jet Machining Water Jet Machining Electro Discharge Machining (EDM) Wire Cut EDM Electro Chemical Machining (ECM) Ultrasonic Machining/Drilling (USM / USD) Electron Beam Machining (EBM) Laser Beam Machining (LBM) Electro Chemical Grinding (ECG) Hybrid Processes

Joining (Additive Processes) There are three basic methods of joining material together: 1. 2. Joining using fasteners (rivets, screws, bolts and nuts etc.) Joining by adding gluing material in-between the two components (brazing, soldering) 3. Joining by fusing the material together with an aim to have the joint which have same metallic properties of the parts to be joined (welding) Out of the above three, the most popular method (though applications may bind us to use other methods too) is welding. Welding is defined as the process of joining two similar or dissimilar metallic/ material components through the application of heat. Filler metal can be used and pressure may also be applied as per the necessity. ARC welding, GAS welding Thermit welding Soldering, Brazing Submerged ARC welding Plasma ARC welding Plasma-MIG welding Projection welding Seam welding Solid State; Ultrasonic, Explosive welding: Friction welding Electron beam welding Laser welding

Rapid Manufacturing (Additive Processes)

Rapid manufacturing is an emerging additive fabrication technique. It is made use in manufacturing mainly the solid objects. Using an additive approach by sequential delivery of energy and/or materials, layer by layer the RM machines fabricate plastic, wood, ceramic and metal powders to form physical objects. In-order to control the process, computerized programs through mathematical modeling are made used in manufacturing.

The major rapid manufacturing processes are as given below: Stereo-lithography Selective laser sintering Fused deposition modeling Three dimensional printing Laminated object manufacturing Laser engineered net shaping

Taxonomy of the Manufacturing Processes The classification of the manufacturing processes descried above is summarized in Fig. 1.4.1. The processes which are relatively new and advanced have been shown below in a different color/ shade. These processes and their details will be discussed in the following lectures.

Manufacturing Processes

CASTING
Sand Casting

FORMING
Smith Forging

MACHINING
Milling, Turning Drilling Broaching, Shaping Planning Honning, Etching Grinding Finishing Abrasive flow machining Abrasive Jet Water Jet Electro-discharge machining Wire-cut EDM Electro-Chemical

JOINING
Arc welding Gas welding Thermit welding Soldering, Brazing Submerged arc welding Plasma ARC Plasma MIG Projection welding Seam welding Solid state Ultrasonic Explosive friction Electron Beam Laser welding Adhesive Bonding

RAPID MANUFACTURING
Stereolithography Selective Laser sintering Fused deposition modelling Laminated object manufacturing Laser engineered net shaping

Permanent mold Drop Forging casting Press, Extrusion Continuous Cold and Hot casting Rolling Die Casting Centrifugal casting Evaporative pattern casting Hybrid EPC Ceramic Shell casting Shell Molding Vacuum sealed molding Sheet metal working Embossing Blanking, Shearing Notching Nibbling Electroforming Explosive Forming

Lost wax casting Perforatting

Fig. 1.4.1 Taxonomy of the Manufacturing Processes