1.
Casting
Casting is a process of pouring liquid metal into a mold containing the hollow shape of the
desired outcome.
Centrifugal Casting
Centrifugal casting is a process of pouring molten metal into a spinning die. Spinning die creates
high g-forces to the molten metal which gives it the cylindrical shape.
Example: Some examples of centrifugal casting include jet engine compressor cases, military
products and other high-reliability applications.
Die Casting
Die casting is a manufacturing process used for producing metal parts where high precision is
required. This process is accomplished by forcing molten metal under high pressure into reusable
metal dies.
Example: Die casting process is used for producing precise non-ferrous metal parts. Some
examples of die casting include engines, clutch housings.
Sand Casting
Sand casting is a metal casting process that uses sand as the mold material. This process has a
low production rate as the sand mold must be destroyed in order to remove the part.
Example: More than 70% of all metal castings are produced via sand casting process. Some
examples of sand casting process include engine blocks, machine tool bases, cylinder heads,
pump housings, valves, gears, pulleys, crankshafts, connecting rods, and propellers.
2. Molding
Molding is a manufacturing process that uses a rigid frame to shape hot liquid or a ductile raw
material. It is mostly used to manufacture plastic products. The different types of manufacturing
processes under molding are: –
Blow Molding, Compression Molding, Injection Molding.
3. Forming
Forming is a manufacturing process that uses suitable stresses such as compression, tension or
shear to deform the material and get the desired shape.
Forging
Forging is a manufacturing process that uses compressive forces to shape the material. This
process is accomplished with the help of a hammer, press or a special forging machine.
Bending
Bending is a manufacturing process used to deform metal into the desired shape by using a die
and punch. This process is most commonly used for sheet metal products to get the required U-
shape, V-shape or the channel shape.
4. Machining
Machining is a manufacturing process used to cut a piece of raw material into the desired shape
and size with the help of controlled material-removal process.
Milling – Milling is a process of removal of material from a workpiece using rotary cutters and
getting the desired shape.
Turning -Turning is a process of removal of unwanted material from circular parts using a
cutting tool. This process requires a lathe, workpiece, fixture, and a cutting tool.
Shaping – Shaping process uses a cutting tool that reciprocates against a stationary workpiece
producing a plane or a desired surface.
Drilling – Drilling process uses a drill bit to make a hole of circular cross-section into the solid
material
5. Joining
Joining or assembling process are part of every production processes where two or more parts
are combined together to get the required product.
Welding – Welding process is used to heat and melt two or more parts and force them together
making a single functional part. Arc welding, resistance welding, oxyfuel gas welding are few
types of welding operations.
Soldering – Soldering process is also used to join two or more metal items by melting and
putting a filler metal (solder) into the joint. It differs from welding as it does not involve melting
of the workpieces.
Brazing – Brazing process is used to join two or more metal items together by melting and
flowing a filler metal into the joint. Brazing uses higher temperatures for a similar process as
compared to soldering. Also, it requires much more closely fitted parts than in soldering.
6. Coating or Plating
This process is defined as a method of covering the part surface with powder or zinc or other
chemicals to protect it from corrosion, wear and other defects. It is also done to improve the
electrical conductivity or magnetic response of the material. The main types of manufacturing
processes under the coating process are powder coating, electroplating, sputter deposition.
7. Additive Manufacturing
Additive manufacturing is the process reversible to subtractive manufacturing i.e. machining. It
is a manufacturing process that builds 3D objects by adding layer-upon-layer of material,
whether the material is plastic, metal or concrete. Additive manufacturing comprises many
technologies such as 3D printing, rapid prototyping, direct digital manufacturing, layered
manufacturing and additive fabrication. This technology is growing at a very fast speed due to its
high-efficiency and accuracy.
Fig: Single point cutting tool
Metal Fabrication Processes: Understanding the Different Types
Casting.
Forming. ...
Forging.
Drawing. ...
Machining