Manufacturing Processes

Solidification Processes: placing melted

material in a mold and allowing it
to solidify.
Bulk Deformation Processes: inducing
the desired shape by gross
deformation of a workpiece.
Sheet-Metal Forming Processes:
forming parts from thin (< ¼”)
sheets.
Material Removal Processes: removing
material (machining) to form the
desired shape.
Surface Finishing Processes: slight
material removal to refine the
texture of a surface.
Joining Processes: attaching two parts
to created the desired shape.
 Solidification
Casting: molten metal is poured into
a mold
Sprue
Drag

Parting Line

Cope Cavity

Injection Molding: molten plastic is

forced (under pressure) into
a mold
Mold Hopper

Heater

Moveable Platen Stationary Platen

 Extruding: molten plastic or metal is
forced through a die.
Die

Mandrel
Heating zone

Powder Metals: fine particles of

metal is pressed into dies
and then heated (sintered).
Upper Punch

Powder Feed
Shoe
Die
Lower Punch

Core Rod
 Bulk Deformation
Forging: Heated metal is repeatedly
struck (hammered) into a
die.
Upper Die

Material Stock Lower Die

Rolling: stock is rolled between two

rollers to shape it.
Extruding: a round billet is placed in a
chamber and forced through a
die opening by a ram.
Billet
Ram Die

Extruded Product

Drawing: reducing the diameter of a

bar or tube by pulling it
through a die.

Wire or Rod
 Sheet Metal Forming
Shearing: process of cutting sheet
metal parts with a single
stroke. Punch
Sheet

Die

Bending: creates folds, flanges, curls,

seams or corrugations in a
sheet metal part. Performed
on a press brake.

Hold-down Ram with

Punch

Sheet
Die
 Material Removal
Milling : A cutter is rotated over, and
feed into, a stationary part.
Speed
Feed

Turning: A part is rotated on a lathe,

while a tool is run into and
along the part

Speed

Feed
Sawing: Part is cut by several small
cutting edges arrainged in a
narrow line on a blade.

Drilling : A fluted tool is rotated and

plunged into a part, creating
a rough hole.
Reaming: Similar to drilling,
however, only a small
amount of material is
removed, producing very
accurate diamters.

Boring: Enlarging of a hole by means

of a single-point cutting
tool. Boring provides an
accurate diameter, or a
stepped, tapered, contoured
or recessed diameter
 Broaching: A cutting process which
converts cylindrical holes
into square, rectangular,
hexagonal, etc., holes.

Pull Direction
Before After
 Surface Finishing
Grinding: A flat surface is held
against an abrasive wheel.

Lapping: A flat surface is held

against a rotating wheel
coated with abrasive
powder called lapping
compound.

lapping workpiece
compound
Deburring: Removing the ridges that
develop along the edges of a
parts by tumbling the part
with abrasive pellets.
 Joining
Weld: permantently joining metal by
heating a joint to a suitable
temperature to create atomic
bonds between two parts.
Electrode
(filler material)
Arc Gap

-
Generator

+
Cable

Adhesive: Glue parts together.

Because of their strength,
synthetic organic adhesives
are most common. They are
classified as:
§ chemically reactive § hot melt
§ pressure sensitive § evaporative
Brazing/Soldering: A filler material
is placed between the two
parts to be joined. The
temperature is raised to melt
the filler material, but not
the parts.

ü Mechanical Joining