1. Manufacturing Process

2. Introduction
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.

3. CASTING

4. 1. Casting Process
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.

5. There are six basic steps in making sand castings:
Patternmaking
Core making
Molding
Melting and pouring
Cleaning and Inspection

7. Casting processes Advantages:
Intricate shapes can be cast
Products of very large size can be made
Economical if large number of similar products are required to be made
As compared to forging the products made are lighter as exact radii, contours, bosses, collars, ribs, etc. can be made

8. Casting Processes Disadvantages:
A great deal of material wastage in the form of runners and risers.
Strength of the material is less as compared to forging particularly if direction of loading is to be considered
Many defects caused even with a small mistake
Not economical for small volumes of products in general
Some materials are not very conducive to casting

9. FORMING

10. 2. Forming Process
Forming process make use of suitable stresses like compression, tension, shear or combined stresses to cause plastic deformation of the materials to produce required shapes.
In forming, no material is removed i.e. they are deformed and displaced.

11. Basic Types of Metal Forming Processes
Bulk deformation
Rolling processes
Forging processes
Extrusion processes
Wire and bar drawing
Sheet metalworking
Bending operations
Deep or cup drawing
Shearing processes

12. Rolling
Rolling: Rolling is a fabricating process in which the metal, plastic, paper, glass, etc. is passed through a pair (or pairs) of rolls.
There are two types of rolling process, flat and profile rolling.
In flat rolling the final shape of the product is either classed as sheet (typically thickness less than 3 mm, also called “strip”) or plate (typically thickness more than 3 mm).

13. Profile rolling
In profile rolling, the final product may be a round rod or other shaped bar such as a structural section (beam, channel).
Rolling is also classified according to the temperature of the metal rolled.
If the temperature of the metal is above its recrystallization temperature then the process is termed as hot rolling,
If the temperature of metal is below its recrystallization temperature the process is termed as cold rolling.

14. Steps in Rolling Process
The staring raw material in rolling is the ingot which is obtained by using a metal die.
Ingot may have any geometrical cross section.
Prepare molten metal in a furnace.
Pour clean well prepared molten metal with correct temperature into a metal die cavity and allow it to cool.
Take out the solid metal.* This solid metal is referred to as Ingot or Ingot casting.
The Ingot is then passed through the rolls to get the next set of products blooms, billets, bars, slabs, plates, sheets or Structural components.

16. 3. Forging:
Forging is a metal working process in which useful shape is obtained in solid state by hammering or pressing metal.
It is one of the oldest metalworking arts with its origin about some thousands of years back.
Some examples of shapes obtained by forging process: Crane hook, connecting rod of IC engine, spanner, gear blanks .etc.

17. Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained.
Forging offers uniformity of composition and structure.
Forging results in metallurgical recrystallization and grain refinement as a result of the thermal cycle and deformation process.

18. This strengthens the resulting steel product particularly in terms of impact and shear strength.
Forged steel is generally stronger and more reliable than castings and plate steel due to the fact that the grain flows of the steel are altered, conforming to the shape of the part.

20. 4. Extrusion process:
Extrusion- It is the process by which a block/billet of metal is reduced in cross section by forcing it to flow through a die orifice under high pressure.
Extrusion is a metal working process in which cross section of metal is reduced by forcing the metal through a die orifice under high pressure.

21. 4. Extrusion process:
It is used to produce cylindrical bars, tubes and sections of any regular or irregular types.
Forces required to extrude a metal are quite high and hence hot extrusion is most widely done as deformation resistance of metal is low at high temperature.
However, cold extrusion is also performed for soft metals like Aluminum, lead etc.