Chapter -1

MANUFACTURING PROCESSES
1.

Introduction:
ORES metals are extracted by SIUTABLE REFINING PROCESSES from the Ores. These
extracted metals are in the form molten metals. Then molten metals are poured into moulds to
give commercial casting, called INGOTS. Most of you might have studied extraction of metals
from ores, in your previous classes in the school.
These INGOTS are further subjected to one or more processes to obtain usable metal products
of different shapes and sizes. All these further processes used for changing the ingots into
usable products can be classified as:
a.
b.
c.
d.
e.

1.1

Primary Manufacturing Processes

Secondary Manufacturing Processes or Machining Processes
Joining Processes
Surface finishing Processes
Processes effecting change in properties

PRIMARY MANUFACTURING PROCESSES:

The Products obtained through primary manufacturing processes may or may not undergo
further operations, depending upon the functions they have to perform. The processes from
which we get directly usable articles and do not require further processing before use, are called
PRIMARY MANUFACTURING PROCESSES. Manufacturing Processes are divided into two types:
(i)
Some of these processes finish the product to its usable form
(ii)
Other require further working to finish the component to the desired shape and size.
For example: Casting need re - melting of INGOT in Cupola furnace and then pouring of
this molten metal into sand mould to obtain the CASTINGS. These casting may or may
not require further operations depending upon their use. But Better dimensional
accuracy is obtained in Forging, Cold Rolling, Die Casting, Metal Spinning and Wire
drawing, than Casting.

1.1.1

COMMON PRIMARY MANUFACTURING PROCESSES:

1. Casting
2
3. Power Metal Forming
4.
5. Extruding
6.
7. Bending
8.
9. Piercing
10.
11. Sqeezing
12.
13. Forming`
14

Forging
Gas Cutting
Rolling
Drawing
Shearing
Spinning
Crushing

1.2

SECONDARY MANUFACTURING PROCESSES:

Many parts or articles need further processing after the primary processes. These articles are
subjected to one or more of the machining operations, called secondary manufacturing
processes, to obtain the desired shape and dimensional accuracy. Basically we get roughly
finished products through primary operations. In all these cases, the primary operations
precedes the secondary operations.
The secondary operations are mainly necessary when a very close dimensional accuracy and a
very high degree of surface finish are required or some such shape is to be produced which is
not possible through primary operations. These operations require the use of one or more
machine tools, various types of cutting tools and cutters, job holding devices, marking and
measuring instruments, testing devices and gauges. Use of these tools leads to the desired
dimensional control and degree of surface finish.

1.2.1

COMMON SECONDARY MANUFACTURING PROCESSES:

Turning
Knurling
Drilling
Boring
Slotting
Shaping
Milling
Hobbing
Grinding
Honing

Threading
Planning
Sawing
Broaching
Unconventional Machining

1.3

JOINING PROCESSES:
Joining processes are used for joining metal parts and in fabrication work. These processes are
required when large lengths of standard sections are required or many pieces are to be joined
together to fabricate a desired structure. In These cases, smaller lengths or pieces are joined
together to give the desired length of structure. Also when in pipes steam or water tight joints
are needed, we apply joining processes. Joining processes may be Temporary (Nut and Bolts),
Semi Permanent (Riveted Joints) and Permanent (Welded Joints). Sintering is anther process,
which enables bonding of metal particles (powder metal) by heat and pressure. By this process
we get metal filter element (Porous Metals), called Micronics Filters used in hydraulic systems of
aircraft, Hydraulic Systems of Heavy Cranes and also used in Power Packs.

1.3.1

Common Joining Processes:

Welding
Riveting
Sintering

1.4

1.4.1

Soldering
Screwing
Shrink Fitting

Brazing
Press Fitting
Adhesive Bonding

SURFACE FINISHING PROCESSES

These processes are not metal removing processes, they only provide a good surface finish or a
decorative or protective coating on to the metal surface, a very negligible amount of metal
removal or addition may take place. Thus, any appreciable variation in dimensions will not be
effected by these processes.
Common Surface Finishing Processes:
Buffing
Polishing
Honing
Lapping
Tumbling
Belt grinding
Supper finishing
Sanding
Electroplating
Metal Spraying
De-burring
Inorganic Coating
Anodizing
Sheradising
Painting
Galvanizing

1.5

PROCESSES AFFECTING CHANGE IN PROPERTIES:

These Processes imparts certain specific properties to the metal parts to make them suitable for
specific use or application. Most physical properties, like hardening, softening and grain
refinement etc., call for particular heat treatment. Heat treatments not only affect the physical
properties, but in most cases also make a marked change in the internal structure of the most
metal. So is the case with Cold and Hot working of metals. They, apart from shaping the metal,
have an appreciable effect on the physical properties and internal structure of the metal.
Similarly, an operation, called shot peening, imparts resistance to fatigue. All such processes
which affect the physical properties and in most cases the internal structure of the metal, fall in
this category processes affecting change in properties.

1.5.1

Common processes affecting change in properties:

Heat Treatment
Cold Working
Hot Working
Shot Peening