Presentation On:

Production Processes

Submitted By: Abdul Samir Rahimi

Abdul Matin Noori
Ahmad Khalid Ahmadi
Antonio Gomez Franque
Anubhav Jha
Basharmal Ahmadzai
Esha Bagla Submitted To: Mr. Anil Verma
 Content Layout
1. Fabrication Processes

2. Metal Working Processes

 Forming processes

 Heat Treatment Processes

 Welding Processes

 Surface Treatment Processes

3. Machining Processes
 Production Process
The production process is concerned with
transforming a range of inputs into those outputs that
are required by the market.
In the course of production of metal several activities
are involved, e.g. cleaning, washing, altering,
repairing, melting, forging etc… Such activities
performed in materials and parts are known as
production processes.
This involves two main sets of resources:
a) Transforming resources
b) Transformed resources

The Transforming resources include the buildings,

machinery, computers, and people that carry out the
transforming processes.

The Transformed resources are the raw materials and

components that are transformed into end products.

• It is very important for businesses to identify the

processes that add value, so that they can enhance these
processes to the ongoing benefit of the business.
Fabrication Process
 1. Fabrication
A fabrication or Process
conditioning process modifies the
physical characteristics of materials with the help of
certain labor and machine operations.

Types Of Fabrication Process:

 Iron Smelting
 Steel Making
 Steel Rolling
 Iron Smelting
Smelting involves heating up ore until the metal
becomes spongy and the chemical compounds in the
ore begin to break down. Most important, it releases
oxygen from the iron ore, which makes up a high
percentage of common iron ores. The most primitive
facility used to smelt iron is a bloomery.
 Steel Making
Steel making involves re-melting the pig iron and
processing the molten iron to reduce the carbon
content. Several other metals are then added to give
physical characteristics to the iron.
Different process like simplex, Duplex and
Triplex processes are used in steel making process.
 Steel Rolling
In this process, liquid steel is cast to ingots. These
rectangular pyramids are then rolled into blooms
which are square section lengths of steel. Blooms are
further heated and rolled into billets.
Metal Working Process
 2. Metal Working Processes
a) Metal Forming processes involve rough shaping of
materials and metal objects.
These processes are in following types:
 Casting
 Forging
 Hot Rolling
 Extrusion
 Mettallurgy
 Sizing
b) Heat Treatment Processes: Heat treatment process is
the process of heating and cooling metals in order to
obtain certain desired properties, heat treatment of
steel alloys is needed to modify physical and electrical
properties of steel, to improve the resistance to heat, to
obtain maximum hardness and strength.

All heat treatment processes include the following steps:

 Heating the metal to a predetermined temperature
depending on the size shape and composition of charge.
 Holding the object at a predetermined temperature for
uniformity of the temperature within the object to
effect heat saturation.
 Cooling the object at a certain rate.
 The major heat treatment process include steel
hardening, surface hardening, normalizing etc….

c) Welding Process
Mechanically the parts maybe joined together by nuts,
bolts etc…, Non mechanically joining is done with the
help of welding and soldering processes.

Welding refers to joining or fusing the materials when

they are in plastic or molten state. Melting process
involves the use of heat which is obtained from gas
flames, electrical arc or electrical resistance.
Some of the welding processes are as
follow:
1) Forge Welding
2) Gas Welding
3) Flow Welding
4) Thermit Welding
5) Arc Welding
6) Induction Welding
7) Resistance Welding
8) Soldering
d) Surface Treatment Process
Surface treatment refers to those chemical and mechanical
processes which are used to alter the surface
characteristics of a metal.
The generally used surface treatment processes are as
follow:
• Tumbling: It is the process of cleaning the casted objects
by inducing frictions. In tumbling, the castings are
tumbled in a tumbling barrel containing an abrasive
substance.
• Short Penning: This process involves air blasting small
shots against a metal surface to increase the hardness of
the surface.
Painting: Painting refers to protective coating on metal
or plastic objects. It is very familiar process, several types
of paint or colors are used in paintings.

Plastic Coating: This is similar to surface painting but

the difference is that plastic coating is more durable than
painting.

Enameling: In this process a white brittle protective

finish is used.

Golva-noising: This is basically a hot-dip process used to

yield an anti-rust zinc coating.
Machining Process
 3. Machining Process
Machining processes are concerned with the shaping of
metal objects to precise contours.

The common used machining processes are as follow:

i. Flame cutting: Flame cutting is a relatively
economical process of cutting a metal object into thick
pieces. Cuts up to 40 inches thick can be obtained.
ii. Sawing: Sawing is another cutting operation used in
shaping metal objects. The commonly used saw is
Hacksaw.
iii. Die-Cutting: In this process a press consisting die of
punching or blanking type is used for cutting metal
objects. The punching die makes a hole in the work-
piece and the metal removed by the die is the scrap.

iv. Turning: Turning is the operation of cutting and

removing the material form the work piece.

v. Grinding: Grinding operation is used gradually to

remove metal from the work-piece and for finishing
the surface of a metal object.
vi. Planning: In this operation a single point cutter is
used for generating a plane or flat surface. In this
process the work-piece reciprocates while the cutting
tool is moved for each new stroke at right angle to the
job. The cutter remains stationary while the work-
piece is moved back and forth beneath its surface.

vii. Shaping: This is similar to planning but in this

process the work-piece is kept stationary and the
cutter reciprocates. The shaper takes smaller work
compared to planner.