Introduction

Manufacturing is a word derived from a Latin word ‘Manu and factus’, i.e., made by hand. In the later stage of the industrial development, it is meant for the conversion of raw materials into finished goods to fulfil the requirement of the social need of the human beings. The raw material cannot be used directly to fulfil the needs of the human beings, but it has to be processed into a particular form. This processing of the materials involves different types of manufacturing processes. Manufacturing process is a way to convert the a material from its raw form to the usable form; this may be shaping processes, joining processes, cutting processes or the processes involved in changing the properties of the materials.

What Are Manufacturing Processes?

There are various manufacturing processes involved within the processes that serve to transform raw materials or components into finished products. These processes are a sequence of steps, for example, cutting, formatting, connecting, aligning or uniting materials. The goal is therefore to manufacture goods that will adhere to the standards, for quality, cost effectiveness and performance.

The Significance of Manufacturing Processes

Economic Growth: The success of manufacturing drives the growth of our economy. It not only creates employment but fosters development and increases economic development.
Quality Control: Amongst the key features of manufacturing is strictness towards quality control. This ensures that level of quality for products is constant and meets desires of customers.
Innovation: Manufacturing works are the vanguards of progress and have given birth to the new and revolutionary materials, products and technologies. Such breakthroughs include 3D printing and nanotechnology that have changed the entire industry.
Customization: Enjoy the joys of contemporary manufacturing, where customization is an essential part of it. Starting from customized clothes and ending up with individually programmed smartphones, manufacturing companies now have an opportunity to modify their output according to the needs and likes of the consumers and make them feel being more than satisfied.

Classification of Manufacturing Processes

The manufacturing processes can be broadly classified into four classes: primary shaping process, machining or cutting processes, joining processes, and the processes affecting change in properties, i.e., heat treatment processes.

Primary Shaping Processes

Primary shaping processes are concerned with the processes that are used to change the shape and size of the product, i.e., deformation of the materials into desired shape and size. These processes may involve casting, metal forming, powder metallurgy, etc. Casting is the processes in which metal is melted in the form of liquid metal with the application of heat and moulded/ poured in a cavity of required shape and size, so that after solidification it may get the shape of the cavity. Then some of the secondary processes may be used for cleaning and surface finishing of the castings.
In case of the metal forming, plastic deformation of the metal is used. In this process, the metal is deformed in the shape and size which is required using the external force. The forming process may be of either hot forming or cold forming depending on the properties of the material's. For brittle material, hot forming processes are required whereas in the case of ductile material's hot as well as cold forming may be used.
In case of hot forming, the material is heated above the recrystallization temperature (up to plastic state) and then deformed by the application of external force. Recrystallization temperature is the temperature at which the crystal structure of the metal starts to change. Sometime metal may be heated below the recrystallization temperature and above the ambient or room temperature to make it soft for the forming process.
This is called warm forming. Some of the important metals forming processes are: Hot working, processes forging, rolling, hot spinning, extrusion, hot drawing and hot spinning. Some of the cold working processes are: cold forging, cold rolling, cold heading, cold drawing, wire drawing, stretch forming, sheet metal working processes such as piercing, punching, lancing, notching, coining, squeezing, deep drawing, bending etc.

Similarly, powder metallurgy is also part of primary forming processes, in this process the metal particles with binders are compacted and sintered to get the proper shape of the product. Sintering is the process in which a product of powder metallurgy is heated after compacting to remove the moisture and make the uniform strength. Gas cutting is also used for the shaping purposes.

Machining Processes

Machining is the process of removing the unwanted part of the material by cutting processes, i.e., application of cutting force by sharp edged cutting tool for severe plastic deformation in the shear plane. Some of the common machining processes are: turning, threading, knurling, milling, drilling, boring, planning, shaping, slotting, sawing, broaching, hobbing, grinding, and unconventional machining processes namely electrochemical machining, laser beam machining, abrasive jet machining, ultrasonic machining, electron beam machining, etc. Many surface finishing processes like honing, lapping, polishing etc., work on the principle of metal machining principles.

Joining Processes

Joining processes are used to make a joint between the components. These joints may be permanent joint or temporary joint. For example, welding is a permanent joint whereas soldering, screwing, and riveting are the temporary joints. Sometimes riveting is also considered as semi-permanent joint for a particular application like joining of the boiler plates, thick metal plates, etc. Welding is a process in which two metal pieces are joined using the application of heat with pressure or without pressure.
This may be fusion welding or pressure welding depending on the requirements. Welding may be classified on the basis of the source of the heat used like gas welding, arc welding, resistance welding, friction welding, etc. Soldering is the process of joining two metal pieces by filling the groove of molten metal without heating the edges of the parent metal sheets. Brazing is the processes of having both the application of welding and soldering.
In this process, molten metal is poured in the groove by heating the edges of the parent metal pieces but below the melting point whereas in the case of welding, the edges of the parent metal pieces are heated up to melting points for proper fusion. Many other types of joints may be used for the assembly purposes like keys, coupling, knuckle joint, cotter joint and etc.

Processes Effecting Change in Properties

Processes effecting change in properties are generally employed to provide certain specific properties to the metal workpieces for making them suitable for particular use or application. Some important mechanical and electrical properties of the materials like hardening, softening and grain refinement are needed and hence are imparted by heat treatment. Heat treatment affects the physical properties and also makes a change in the internal structure of the metal. Some of the commonly used heat treatment processes are: annealing, normalizing, hardening, case hardening, flame hardening, tempering, shot peeing, grain refining and age hardening.

Important of machine tools in Manufacturing Processes

Machine tools that give a shape to parts/products by removing metal chips from a workpiece include lathes, shapers and planers, drilling machines, boring machines, milling machines, grinders, etc. Before the Industrial Revolution of the 18th century, hand tools were used to cut and shape materials for the production of goods such as cooking utensils, wagons, ships, furniture, and other products. After the advent of the steam engine and material; goods were produced by power-driven machines that could only be manufactured by machine tools. Jigs and fixtures (for holding the work and guiding the tool) were the indispensable innovations that made interchangeable parts realities in the 19th century.

The Role of Automation and Robotics Manufacturing Processes

Advancements in automation and robotics have transformed manufacturing processes. Automated systems improve efficiency, reduce errors, and enhance productivity. Robots can perform tasks that are repetitive, dangerous, or require precision, making them invaluable in manufacturing.

Sustainability in Manufacturing Processes

In the years there has been a growing emphasis, on sustainability in the manufacturing industry. The main objectives now include minimizing waste preserving resources and reducing our impact, on the environment. Its becoming more and more common to see manufacturers adopting practices recycling initiatives and incorporating eco materials into their processes.

Conclusion

The manufacture’s processes contribute to building our world by developing products. They can range from manufacture of items for everyday use right up to manufacturing of aerospace parts. These practices are the base of society. Will likely see additional developments as technology improves. This leads to sustainable and personalized methods of production. Now more than ever if you are an engineer a consumer or just a person fascinated with the world we live in knowing how manufacturing processes work is important in today’s technologically fused globe.

The Role of Manufacturing Processes in mechanical engineering