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Manufacturing Process
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Manufacturing Process and Its Classification – A Complete Guide

by norwegianprototypes
written by norwegianprototypes

Manufacturing Process is one of the main parts of the production process. It is that process which involves the changes of sizes/dimensions or shape of the part. Transportation or material storage is not a part of the manufacturing process. This article is dedicated to explaining different types of manufacturing processes.

Manufacturing Process Classification

Different materials are needed for manufacturing. So before starting the manufacturing process the properties of the engineering materials should be known. Available engineering raw materials needed for manufacturing, equipment, tools, and machines all are of great significance.

These materials, equipment, tools, machines are mainly made of metals which are collected from ores. The metals are extracted from the ores and then molten metal goes through some foundry processes. Pre-foundry processes involve the purification of the metal. These pure molten metals are poured into the moulds and thus we got ingots. These ingots are processed in some other mills to get the desired shape. Thus we get billets, blooms, slabs, sheets and rods or tubes. These shapes further go through some other processes and usable shapes are obtained. Usable shapes are done in different machining and manufacturing shops. We will discuss the six major groups used to convert ingots into usable metals. So let’s start-

complete manufacturing techniques

First One – Primary Shaping Process

Primary shaping process is used to give the amorphous material a well-defined shape. Some of the primary shaping processes produce final products and other needs additional machining works. Primary shaping process involves casting process, plastic forming technology, powder metallurgy, bending of the metals, forging and gas cutting and many more. For example, in casting technology, the molten metal is needed to be poured on the moulds and it needs to cool down. Afterwards, the cooled metal object may need some extra machining through grinding or lathe machine or some milling operation.  Please Read: Different Casting Process Explained. 

 Second- Machining process

As mentioned earlier primary process may not give the complete finished goods. Machining is one of the processes of making the primary shapes into finished goods. The components or parts are subjected to machine shops for finishing. It is used to give desired shape and size to the cylindrical and flat objects. The process to remove unwanted materials from the jobs using cutting tools is known as machining. The purpose is to give perfect dimension and desired shape. Machines used for these operations include lathe, milling, drilling, shaper, planner etc. The materials subjected to machining operations include the shapes of a bar, rod, tubes and flat surfaces. For greater dimensional accuracy and surface finish the machining processes are important. They also provide the good surface finish. At the time of machining different multi-point cutting tools, jigs and fixtures and measuring devices are used. Machining produces a lot of waste metals in the form of chips. These days CNC machining is used for better accuracy and quick machining. Turning, knurling, parting, facing, boring, reaming, slotting, punching, threading, milling, gear cutting are some of the metal removing processes. For a better idea about machining tools follow The classification of machining tools. 

Third – Metal Forming process

Metal forming is another manufacturing technique used to give the metal desired shape through the application of pressure/stress, forces like compression or tension or shear or the combination of both. By applying these forces permanent deformation of the metal is achieved. These processes are also known as mechanical working processes. These mechanical working processes are classified into two categories, one – hot working processes and two-cold working processes. Metal forming process does not incorporate metal removing. The metal is deformed and sometimes displaced by the application of forces. Metal forming always include plastic deformation. In this technique, directly usable articles can be made. Wires, rods, cold drinks bottles, tubes are made by the metal forming process.  The hot working process includes forging, hot spinning, rolling, extrusion, hot drawing etc. Cold Working Process include cold forging, cold rolling, sheet metal working, punching, piercing, squeezing, notching etc.

Fourth –Joining Processes

Joining is a process we are using in our everyday life frequently. Different sub-assemblies are joined together to get a completely assembled product. In fabrication process joining is used frequently. In manufacturing or fabrication, two or more metal parts are put together and joined by means of fusion, riveting, screwing, applying pressure and rubbing. These joining processes are needed to make air-tight joints and semi-permanent and permanent fasteners. These joining techniques are very important in making bigger assemblies. For example, an aeroplane is assembled by putting together more than a thousand subassemblies. The joining process includes different types of welding, soldering and brazing, riveting and screwing, pressing, nut and bolt joints etc. Please Read:

Fifth- Surface Finishing

Surface finishing is a process which is applied to get the desired levelling of the surface and also to obtain the desired smoothness. Very negligible amount of the materials is removed from the surface by this process and does not involve any effective change in the dimensions. It is not an effective metal removing process and should not be confused with the machining process. Putting some kind of coating over the metal is also a surface finishing process. Various surface finishing processes include honing, lapping, super finishing, sanding, deburring, electroplating, buffing, painting, anodizing, galvanizing etc. Sherardizing, Parkerizing, plastic coating or metal spraying is also known as one kind of surface-finishing process. Surface finishing provides excellent finishing of the metal surface and at the same time gives good protection from the environmental contaminants.

Sixth- Processes that involve the changes in the material properties

Different properties of the same metal are desired for different applications. So metal property is needed to be changed in those cases. Material property change may include improved hardness, greater ductility, durability etc. For some particular uses or operations, suitable properties are needed to be incorporated. Some operations need softer material, some need harder. The properties of the materials change when the total grain size of the materials are regrouped or reorganized. Different grain conditions provide different properties. The grain sizes are changed by the application of different heat treatments. By heat treatments, the internal structure of the material is changed. And they achieve different improved properties. Common heat treatment methods include –annealing, hardening, case hardening, normalizing, grain refining, tempering and age hardening etc.

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prototype model
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The Complete Methodology for Prototypes

by norwegianprototypes
written by norwegianprototypes

If you are going for a product manufacturing in a large scale it is always necessary to build a prototype. The prototype is a functional product which is similar to the final or finished product but it may not be fault proof. So making a prototype and modifying it till it is flawless will help the final product to become completely defect free. From a prototype we can learn and also tests can be performed. For incremental development the prototype making is significant. The quality of the product and the business expectation have to be kept in mind while designing the proto.

Please Read more manufacturing articles here:

Manufacturing product through the prototyping

Some basic things should be kept in mind while designing the product prototype.

  • The idea should be simple.
  • The perfection cannot be achieved by one trial.
  • You have to have a clear idea about the options and limitations you have in your manufacturing plant.

Achieving the product from your innovative idea

For achieving your targeted product you have to maintain these five steps

  • Documentation – It will help you keep the records and you can derive something from the previous working experiences. It will be also good for ISO certification if you are looking for one.
  • Continuous Research- These days research is very easy. Thousands of models are there for almost every product on the internet. Also, journals and publications are there. So take ideas and research it for making the product unique.
  • Manufacturing- After those two steps start building your prototype. Then test it. Look for errors. After doing trials make it perfect.
  • Patenting- Patent the product. It is your innovation so patenting is necessary.
  • Marketing- After the patent start for the marketing. Without marketing, you will not be in a position to sell it.

Steps involved in making the prototype realistic and obvious for manufacturing

Complete Prototype Methodology

Defining your main goal:

A good team is needed to define the goals with whom you can discuss. The brainstorming is also needed. So asked your team to work on the prototype and figure out the problems that can occur and find the ways to resolve it.

A limited amount of options:

Don’t think too further for developing the proto. If you have defined the goal then collect the best ideas and methods. Stick to the limited features. It will help to refine it further along the way.

Designing from scratch

Start designing your prototype on the paper. It is an old method but it always provides a better understanding of the concept. A preliminary design is needed to be done in the paper. This design should have as many details as possible.

Sharing and collecting feedback

Discuss with the people involved in the design work about the concept you developed on the paper. It can be shared with the stakeholders for making it more realistic. The creative team, clients, managers of the productions should be included in providing the feedback. A thorough evaluation of the prototype will give a clear idea of the feasibility, strength, and weakness of the prototype.

Editing

Edit and modify your design after collecting the feedback from the people. The design can be scaled down for the necessity of the testing.

Perform the CAD

After the finalization of the design put it in the CAD and engage your draftsmen to give it the professional look.

Ask for approval

You are creating the prototype for manufacturing. So your complete design is needed to be approved by the client. Get the approval of the client. If the prototype gives an actual feel to the customer it will be approved easily.

Continuous Documentation

Documentation should be going on continuously for the future reference.

Advantages of the prototype Model

  • Prototype verification actively involves the clients or the customer in the process. It improves the product quality.
  • The working model of the actual product is visible in this methodology. So the clients are getting a better idea of the product.
  • Almost error free designing can be ensured as the errors are identified and rectified at an early
  • Before entering the final manufacturing process client feedback is available. It helps to understand the client demands and leads to a better
  • Problems in the functionality are identified at an early stage.
  • Confusing features and difficult functions are understood by the client as well as the designer while following the methodology of the prototype.
  • With the help of the prototype users with a lesser idea of the product can get a decent idea.
  • Prototype building is advantageous for both users and manufacturer. Sometimes the client is not confident about the capability of the manufacturer. After building a model prototype the customer gets an idea and the manufacturer gets a chance to prove himself.
  • Prototyping removes the risk of failure. Potential risks are identified and removed earlier.

Disadvantages of the Prototyping

  • In this method, the processes or techniques are applied and then repaired and finally, you need to build another prototype as the final one.
  • The methodology can be very complex. The continuous modification and concept developing can lead to a more complex system which may expand beyond the original idea.
  • The incomplete idea or the insufficient problems analysis can lead to an incomplete Which may not be used in the final manufacturing.

 

The perfect places to use prototype models

  • The prototype should be used in the places where the end users are directly involved and have a lot of interaction with the system.
  • These days the online works and web developing needs the direct involvement of the customers. In these cases, the prototyping is very good. It takes time but prototyping is best suited for the online works or UI development etc.
  • Any kind of new vehicle design always needs a final prototype design. It will be tested with the prototype and finally, the product will be manufactured.
  • Most of the cases all the mechanical products or parts are needed to be built as a prototype
  • The prototype is needed at those places where refining and testing the functionality of the design is a must.
  • To reach the desired performance level prototyping is essential.

To get a complete concept of the prototypes, follow this link:

 

 

 

 

 

 

 

 

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TIG welding basics
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TIG welding Working Principles and Applications

by norwegianprototypes
written by norwegianprototypes

TIG welding stands for Tungsten Inert Gas Welding. It is one the metal inert gas welding used frequently in the manufacturing industry. It is also known as Gas Tungsten Arc welding(GTAW). It is used in those cases where high purity is needed to be maintained in the welded joints. For example, you cannot imagine nuclear power-plants, aviation companies, food and beverage companies and pharmaceuticals without the application of TIG welding. Most of the times it is used for welding non-ferrous metals. Like any other inert gas welding, it uses an inert gas for shielding. Most of the times, Argon or Helium is used for the inert gas shielding.

Please Read Different Types of Casting Process and their advantages. 

For more info about TIG, you can go through TIG advantages and Disadvantages 

TIG welding Working Principles

There are some basic differences between Metal Inert Gas (MIG) welding and the TIG. In the MIG the metal is continuously fed as a filler metal while doing the welding. But in TIG the base metal is melted and the filler metal is hand fed at the same time. The Tungsten stick is not consumed and works as an electrode.  So the basic difference between TIG and MIG is the non-consumable electrode used in TIG. While the welding process is going on the total welding area is shielded by the inert gas helium or argon. The inert gas is used to avoid the contamination of the welds from the environment.

TIG is not an easy task. It is the most complex form of welding. Let’s discuss the techniques-

Techniques for Performing TIG welding

  • The angle of the welding torch should be 15-20 degrees apart from the direction of the welding. This is to be ensured otherwise the visibility of the welding path will be a problem. The quality of the welding will not be up to the mark without this technique.
  • The filler metal should be kept at a distance from the tungsten electrode. Otherwise, there is a possibility of the contaminating the electrode. So filler should be kept at a very low angle.
  • The torch will be melting the base metal and the melted base metal will be performing the fusion of the filler metal. The tendency to melt the filler metal with the torch should be avoided.
  • The preparation of the tungsten electrode should be carefully done with the grinding wheel. It will be like sharpening the pencil. But for welding of the softer metal like Aluminium the tip should be flattened. The tungsten electrode tip just has to be touched against the grinding wheel.
  • You have to be very careful when welding the stainless steel. Too much heat can deteriorate the welding quality. The welding flame colour should be in the range flaxen to salmon. Too much oxidized dark greyish and dirty flame is undesirable. This colour resembles too much flame. With increasing travel speed and lesser current flow, the problem of overheating of the flame can be avoided. Reducing the diameter of the filler metal can also solve this problem.

Basic Principles of TIG welding

TIG welding Advantages in manufacturing

  • TIG is free from flux. So the TIG welded parts are totally free from corrosion. It is the very clean form of welding.
  • Metals like Aluminium are very delicate and care should be taken at the time of welding. Normal welding is not suitable for Aluminium as it is can deform the metal as a result of thermal stress generation.
  • TIG welding can be performed in any suitable positions- vertical, horizontal or overhead. Due to its general arrangement, it gives a better view to the welder to complete the job. You can complete the job within a very short time in comparing to the other welding processes.
  • Pressure tight joints like Gas pipelines can be welded with ease. TIG provides great strength with very negligible distortion.
  • It is a high-speed method and very clean with great precision. The quality of the welding is superb.
  • The electrode is non-consumable. So the welding is flawless as there is no need to change the electrode.
  • Thinner parts can be welded without any deformation. The finish is superior.
  • The welding can be done without the inclusion of the filler metal.

TIG Disadvantages

  • The filler deposition rate is very low in TIG welding method. As a result, it can be a slower process in comparison with electric arc welding.
  • As the welding is complicated, highly skilled technicians are needed to successfully complete the job.
  • GTAW produces intense rays of light which can be very dangerous for the eyesight of the welder or the surrounding people.
  • The initial cost of the machine and a man-power appointment can be high.
  • You cannot join thicker sheet metal parts with TIG welding.
  • TIG welding needs clean and tidy metal surface for a better weld quality. So surface preparation can be a time-consuming It can cost some money too.

TIG Application

  • TIG or GTAW is used frequently in welding lightweight aircraft. MIG almost serves the purposed of the TIG. But in case of lightweight aircraft manufacturing, you have to use TIG welding. Complex but light elements of the aerospace industry can be welded with TIG.
  • Stainless steel, Aluminium, high carbon steel, gold, bronze, nickel, copper and many unconventional metals can be welded in this process.
  • Automobiles work with sheet metals. The sheet metals welding of the automobile is done with TIG. The automotive vehicles have to endure a lot of stress in their lifespan. So the precision, as well as strength, is needed to be ensured. The welded joints are not rusted and also corrosion free.
  • Repairing tools without the trace of repair joints can be made by the TIG. Toys, Aluminium tools, metal parts, car parts all can be repaired through the TIG welding method.
  • The use of TIG is not limited to industrial works. It is also used in arts.

Using TIG or GTAW in your manufacturing plant depends upon the type of prototype or final product you are building. Advantages and disadvantages are there. A manufacturing plant needs to go through these points and act accordingly. TIG is high-quality welding with affordable price but at the same time, it needs a skilled technician and some preparation of the metal surfaces.

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casting process
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Casting – the Most Significant Manufacturing Processes for the Modern Manufacturers

by norwegianprototypes
written by norwegianprototypes

Manufacturing is the technique that converts the raw materials into finished goods through some continuous processes which involve special knowledge, manpower, equipment and machinery. Modern day manufacturing is not possible without having a good knowledge of these processes. A complete man-machine setup with the division of labour is involved in these processes. Almost any raw material can be converted into finished goods by means of these significant manufacturing processes. Modern day manufacturing is not possible without these processes –

  • Casting
  • Moulding
  • Forming
  • Machining and
  • Joining
  • Imaging and Coating
  • Additive manufacturing

Modern Casting Techniques

Different Types of Casting Processes Explained

Casting

Casting is a process of manufacturing in which molten metal is poured into the mould having the cavity of the desired shape. After the metal solidifies the total solid metal is taken out of the mould. This solid part is called the cast part or the casting. The final product is machined if necessary otherwise used as it is. With casting, you can make any finished goods of any shape. Different casting processes involve sand casting, die casting, centrifugal casting and lost wax casting. Each of the casting processes has their merits and limitation. Let’s discuss the different casting techniques.

casting process in manufacturing

Sand Casting

Materials of any melting point can be cast in the sand casting process. It is very cheap but to get desired finishing extra care should be taken. A typical sand casting process involves a furnace to melt the metal, the pattern and the sand mould. Generally, green sand with some natural binders is used to make the sand mould. Any kind of porosity in the sand should be removed. Proper ramming of the sand is necessary. The sand and the binder ratio should be accurate. Different types of sands are available for casting. Suitable sand selection is also a very important task in the process.

Advantages of Sand Casting

  • It is very cost efficient
  • Metals or alloys of any melting point can be used.
  • Any shape can be obtained.
  • Very less wear and tear of the pattern. The pattern used is also of very low cost as it is mainly made of wood.
  • Ferrous parts can be easily manufactured. Materials of the high melting point can be used.

Disadvantages of Sand Casting

  • Extra machining work is required in this process. After the metal solidifies some extra metal needs to be cut by machining process because of the runner and the riser shapes.
  • Surface finish is not always up to the mark.
  • Dimensional accuracy is difficult to achieve. The parts in which the dimensional accuracy is not that important can be easily manufactured by sand casting.
  • Materials may have low mechanical strength due to some faults in the casting technique as the process is totally manual.

 

Die Casting

Die casting is another casting method that involves permanent die. The die or permanent reusable moulds are used in die casting. As a result, the finished product is geometrically accurate in shape and dimension. It involves high pressure inside the casting chamber so the castings are accurate in size and shape. Mainly non-ferrous metal parts are manufactured in die casting method. Electrical equipment, motor parts, telecommunication materials, automobile parts and many other assembly parts are frequently manufactured using die casting.

Advantages of Die Casting

  • Manufacturers can get complex shapes with close tolerances.
  • It is suitable for rapid mass production. All the parts will have same dimensions and sizes.
  • Very less surface preparation is needed for making the castings.
  • The uniform design is one of the great features of die casting.
  • High mechanical strength is obtained by die casting

 

Disadvantages of Die Casting

  • It is not suitable for small-scale production.  To make the process cost-effective, the mass production of the materials is needed.
  • High initial cost of the materials and setup is observed.
  • There are some limitations of the dimensions of the finished goods. So goods having any dimensions and shapes are not suitable to manufacture in die casting.
  • Materials having lower melting points are only suitable for die casting.

Centrifugal casting

Centrifugal casting is another precision casting process. In centrifugal casting, the molten material/metal is poured into the spinning chamber. The chamber orientation can be vertical or horizontal. It depends on the size and shape of the product needed by the manufacturer. If the material is tubular then the horizontally rotating chamber is used. When ring-shaped materials are needed as the finished goods vertical chambers are used. Centrifugal castings are used for that parts that can symmetrically rotate on the same axis. For more knowledge about Centrifugal casting please visit the link:

Advantages of Centrifugal Casting

  • Excellent surface finish for the round shafts, tubes, cylinder and ring-shaped materials.
  • Excellent mechanical strength due to the fine-grained structure of the materials.
  • High production rates.
  • Hollow interiors in the products like tubes and rings can be done easily without the application of the core.
  • Lighter impurities.

Disadvantages of Centrifugal Casting

  • Not all metals are suitable for centrifugal casting.
  • The initial setup cost can be higher.

 

Lost Wax Method or investment casting

In investment or lost wax casting the molten metal is poured into the mould that is made of wax. It is also called the lost wax method. The wax patterns are prepared by injection moulding. The outer part is made of a harder shell. When the molten metal is poured, the wax is melted and drained away. The metal sample solidifies and finished good is obtained. Aerospace industries, computer parts manufacturers, food and beverage makers as well as jewellers are using lost wax methods.

Advantages

  • Superb intricate designs can be obtained.
  • Excellent surface finish is obtained and no parting line is present.
  • High accuracy can be obtained for the complicated designs.
  • Very less machining is required for the finished goods.

Disadvantages

  • It is a very costly process.
  • The parts that can be cast should be of very low weight.

These are some of the major casting processes involved in modern-day manufacturing process. For more knowledge have a look at the casting classifications.

 

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