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MANUFACTURING PROCESSES

5 Essential Industrial Methods Explained
Casting Forging Welding Additive
"From raw materials to finished products."
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Classification

How Are Products Manufactured?

Manufacturing processes transform raw materials into finished products through controlled engineering operations.
1Shaping — casting, forging
2Material removal — machining
3Joining — welding, brazing
4Additive — 3D printing
5Surface treatment — coating
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Process 1

Casting

Casting transforms liquid material into a solid component using a mould.
1Pattern making
2Mould preparation
3Metal melting
4Pouring & solidification
5Casting removal & cleaning
Sand Investment Die Centrifugal Continuous
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Process 2

Forging

Forging shapes metal through compressive force.
Open-Die Forging
Flat or simple dies — large, simple shapes
Closed-Die Forging
Shaped dies — precise, complex parts
Press Forging
Continuous press — deeper penetration
Upset & Roll Forging
Increase cross-section / shape by rolling
Improves strength and toughness via grain-flow development.
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Process 3

Welding

Welding joins materials by producing a permanent bond, commonly through heat.
Arc / SMAW
MIG / GMAW
TIG / GTAW
Gas welding
Resistance
Laser / EB
Key Concept
Heat-Affected Zone (HAZ)
Quality depends on heat input, shielding and joint preparation.
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Process 4

Additive Manufacturing

Build complex components layer by layer using a digital 3D model.
FDM — Fused Deposition Modeling
Extruded thermoplastic filament
SLA — Stereolithography
UV laser cures liquid resin
SLS / DMLS
Laser sinters plastic or metal powder
Binder Jetting
Deposits binder on powder bed
ADDS MATERIAL — UNLIKE SUBTRACTIVE MACHINING
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Also Essential

More Ways to Manufacture

Machining
Turning · milling · drilling · grinding
Forming
Rolling · extrusion · stamping · bending
Powder Metallurgy
Compressing and sintering metal powder
Injection Moulding
Molten plastic or metal into moulds
Composite Manufacturing
Combining materials (e.g. fibre-reinforced)
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Selection

Which Process Is Right for Your Product?

Material Geometry Precision Quantity Cost Quality
Casting Complex, large shapes
Forging Strong metal components
Welding Permanent joints
Additive Complex custom geometries
Machining Precision & surface finish
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Formulas

5 Important Engineering Formulas

Casting tₛ = C × (V/A)ⁿ
Forging F = Y × A
Welding HI = (V·I·60) / (S·1000)
Additive t = L / (h × v)
Machining Vₘ = (π·D·N) / 1000
Use for estimation. Verify with process standards and manufacturer data.
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Worked Examples

Real Manufacturing Calculations

Casting Solidification
V=500, A=300, C=2.5, n=2
V/A = 1.667 cm
tₛ ≈ 6.95 s
Welding Heat Input
V=25V, I=200A, S=300 mm/min
HI = (25·200·60)/(300·1000)
HI = 1.0 kJ/mm
Forging Force
w=100, l=150, Y=200 MPa
A = 15,000 mm²
F = 3,000 kN
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Quality & Safety

Quality + Safety = Better Manufacturing

Quality
✓ Inspect components
✓ Monitor T & P
✓ Check dimensions
✓ Inspect welds
✓ Record parameters
Safety
✓ Wear PPE
✓ Ventilation
✓ Heat protection
✓ Fire safety
✓ Lockout/tagout
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Master Manufacturing Engineering

Understand the processes. Learn the formulas. Improve production knowledge.
Casting Forging Welding Additive Machining
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