Manufacturing Processes

Introduction
Dr. Harlal Singh Mali
Manufacturing process deals with the conventional methods of forming,
machining, welding etc. of materials.
Some conventional manufacturing process are:
 Rolling
 Forging
 Bending
 Drawing
 Casting
 Deep Drawing etc.
These conventional operations are manual and limited to certain materials and
accuracy.
The Advanced Manufacturing process deals with use of different types of energy
(mechanical, chemical etc.) to get better output.
Types
 Mechanical-
o Abrasive Jet Machining
o Water Jet Machining
o Ultra Sonic Machining
o Abrasive Flow Machining
o Abrasive Water Jet Machining
 Thermoelectric
o Plasma Arc Machining
o Laser Beam Machining
o Electron Beam Machining
o Electric Discharge Machining
 Chemical & Electrochemical
o Chemical Machining
o Electrochemical Machining
 Hybrid
o Electro Chemical Grinding
Dr. Harlal S. Mali, MNIT Jaipur Page 1
 o Electric Discharge Abrasive Grinding
o Electro Chemical Abrasive Manufacturing

Energy Used In AMPs

Type Of Energy Process

Energy in direct Laser, Electric-Discharge, Electro-Chemical

form

Mechanical type AJM, USM, WJM, AWJM

Abrasive Based AFM, CMP, MAF, MRF, MRAFF, MFP

Nano –Finishing

Thermo-Electric EDM, WEDM, EDDG (diamond), EDG, ELID (dressing), LBM,

type EBM, PAC (cutting)

Chemical and ECM, ECD (deburring), STEM (shape tube electrode), ESD (Electro
Electro-Chemical Stream Drilling), CM (Chemical), PCM (Photo chemical), FIB

Classification of Manufacturing Processes

1. By Cutting
Material Removal by visible chips removed by penetration of cutting tool.
 Need :- (a) Cutting Tool
(b) Work-Piece
(c) Machine Tool
 Major Material Removal Processes, could be categorised based on
symmetric or prismatic surfaces.
 Types of Cutting Tools: - Generation, Form, Form & Generation.

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2. By Abrasion
Material Removal by multiple of hard, small angular abrasive grains of
indefinite numbers and shape.
 Need :- (a) Abrasive (Bonded/Loose) Cutter
(b) Work Piece
(c) Machine Tool
 Enable close material removal and good surface finish.
 Can take material harder than 400HV.
 10 times more energy required.
 Minute chips invisible in most cases.
 Small machining allowance.

3. By Erosion
 No chips or lay pattern formed.
 Low volumetric removal rate.
 Removal of successive surface layer as a result of dissolution, melting and
vaporisation.
 Can be further classified in two types
o Electro chemical erosion :- CHM, ECM
o Thermal erosion :- EDM, EBM, LBM, PBM.

Disadvantages of Cutting and Abrasion

Both cutting and abrasion adhere compression/ shear chip formation causes
inherent disadvantages such as

• Residual stress

• Work-piece distortion

• Size and complexity limited.

• High cost (Specific Cases)

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 Hybrid Machining

HYBRID MACHINING

ECM
ECM + EDM +
+EDM+
Abrasion Abrasion
Abrasion

• ECG • ECDG • EDG

• ECS (ELECTRO • AEDG
• ECH CHEMICAL (Abrasive
• ECB DISCHARGE Electro
GRIDING) Discharge
Grinding)

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 Machining By Cutting

Machining by Cutting

1.Form 2.Generatio 3.Form and

n Generation
• Shaping • Turning
• Thread
• Planning • Shaping
cutting
• Drilling • Planning
• Slot
• Form • Pocket
cutting
turning milling
• Gear
Form Counter
Single point
Form tool Fed hobbing
Form tool
tool fed
Fed

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 Machining by Abrasion

Machining by Abrasion

1.Grinding 2.Surface 3.Advance

Finishing Abrasion

• Surface • Honing • USM

• Creep Fed • Lapping • AJM
• Centerless • Super • AWJM
• Cylindrical finishing • AFM
• Polishing • MAF
• Buffing

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