Student Name: Tinashe C Maunga

Reg Number: C24158839E

Program: BEMC5

Module Name: Introduction to

Manufacturing Processes

Module Code: CUPE 129

School: School of Engineering

Assignment Question: Highlight 6

classes of manufacturing processes
INTRODUCTION TO MANUFACTURING and with the aid of clearly labelled
diagrams briefly explain 3
PROCESSES manufacturing processes found
within each class

ASSIGNMENT 1 Due Date: 23/08/2024

Manufacturing processes involve converting raw materials or components into finished products. The
methods vary widely, depending on the product’s complexity, materials, and production volume.

The 6 classes of manufacturing processes are:

1. Forming
2. Casting
3. Molding
4. Machining
5. Joining
6. Additive Manufacturing

FORMING
Forming is a process of applying force or pressure to a material and plastically deforming it to get the
desired shape. The material under forming is heated first to make it easily or more malleable. It is
frequently used on metals. There are types of manufacturing processes which fall in the class of forming
and these are forging, rolling and extrusion.

FORGING

Forging is a manufacturing process in which compressive forces are used to shape a metal slug into a
near-net shape product with the use of a tool. The method is adaptable for a range of shapes, from
simple to the very complex; for intricate geometries, forging is performed using several tool sets
(multistep process). Forgings are typically classified according to the type of tooling used in the forging
process; these include open-die forging, closed-die forging, and impression-die forging. (Kridli &
Boileau,2021)

ROLLING
Rolling is the most widely used deformation process. It consists of passing metal between two rollers,
which exert compressive stresses, reducing the metal thickness. Where simple shapes are to be made in
large quantity, rolling is the most economical process. Rolled products include sheets, structural shapes
and rails as well as intermediate shapes for wire drawing or forging. Circular shapes, ‘I’ beams and
railway tracks are manufactured using grooved rolls. Initial breakdown of an ingot or a continuously cast
slab is achieved by hot rolling. Mechanical strength is improved and porosity is reduced. There is cold
rolling which is often used in the final stages of production. Sheets, strips and foils are cold rolled to
attain dimensional accuracy and high-quality surface finishes. With softer metals such as lead and
copper, a succession of cold-rolling passes can impose very large deformations. For many materials,
however, the rolling sequence has to be interrupted for intermediate annealing in order to prevent
fracture. (Lovatt et al,)

EXTRUSION

The extrusion process is one of the types of bulk-forming processes in which work metal is forced or
compressed through a die hole to achieve a certain required cross-sectional shape. (Ar.Amrit Kumar,
2022)

CASTING

Casting is a process of putting liquid metal into a mold and allowing it to cool and solidify. This is referred
to as the main shaping process. Usually, a secondary process such as machining is required to provide
the appropriate surface polish. Casting is usually done on metals just like forming. There are some
common types of casting which are die casting, sand casting and invest casting.

DIE CASTING

Die casting is an automated casting process in which the liquid melt is pressed into a mold under high
pressure (150 to 1200 bar) and at a high filling speed (up to 540 km/h). Usually alloys with a low melting
point are used. This casting process is particularly suitable for series and mass production of components
because, unlike sand casting, for example, permanent metal molds are used which do not have to be
destroyed after casting. It is possible to produce large and complex components with low wall
thicknesses. (Alexander Stack, 2019)

SAND CASTING

Sand casting is a process that utilizes non-reusable sand molds to form metal castings. On one hand,
casting is a deceptively simple manufacturing process: anyone who has formed castles at the beach
knows sand can be used to make detailed shapes.(Ryan Fisher, 2023)

INVESTMENT CASTING
Investment casting is a manufacturing process that uses a wax or plastic to create a mold. The pattern is
surrounded by a refractory material and then heated to melt the pattern to produce a cavity. Molten
metal is poured into the cavity and allowed to cool. After cooling the mild is broken away to review the
casting (K.S.Ma 2009).

MOLDING

Molding is process which involves using a mold to shape a liquid or flexible substance. It is quite similar
to casting since the substances need to be left to cool down and solidify. Molding is usually used to
shape polymers. The common types of molding are injection molding, compression molding and blow
molding.

INJECTION MOLDING

The injection molding process is suitable for all materials, only the tool design having to be changed
depending on the shrink characteristics of the polymer/polymer combinations. Injection molding is a
process which converts polymer granules into one of the most dimensionally accurate
molded thermoplastic parts possible.(A.Riley, 2012)

COMPRESSION MOLDING
Compression Molding is a molding method in which the molding material (especially Thermoplastics or
Thermoset plastics) is generally preheated and is placed in a mold cavity. The heating or cooling given to
the cavity depends upon the type of plastic used. Pressure is then applied by pressing to make sure that
the make sure that the material fills the cavity to take the required shape. (M Shafi, 2013)

BLOW MOLDING

Blow molding is a manufacturing process that shapes hollow plastic parts, including bottles, containers,
and automotive components, by inflating a heated plastic tube, known as a parison or preform, inside a
mold. Air is blown into the tube, causing it to expand and take the shape of the mold. After cooling, the
product is ejected, trimmed, and ready for further processing.(Alepo, 2024)

MACHINING

Machining is a material removal technique in which material is removed from the block material item
using a tool. It is frequently used for secondary shaping after a primary technique like casting has been
employed to produce the part. Machining can be utilized on a variety of materials such as polymers,
metal and wood. The most common types of machining are drilling, turning, reaming and milling.
DRILLING

Drilling is a cutting process where a drill bit is spun to cut a hole of circular cross-section in solid, used to
create holes or wells in the earth’s surface for various purposes such as extracting oil and gas, mining
minerals, or accessing water sources. (Conoco Phillips, 2024). Other materials are drilled for decorations
or to make holes which accommodate some joining equipment like screws, rivets or bolts.

TURNING

The turning process can be described as the machining of a piece of material that is rotating, using a
single pointed tool that is stationary, to produce a smooth and straight outside or inside radius on the
piece. (Sousa & Silva, 2020)

MILLING
Milling is the machining process of using rotary cutters to remove material from a workpiece. It covers a
wide variety of different operations and is one the most the commonly used processes in industries and
machine shops today. (M. Ramirez, 2015)

JOINING

Joining is the process of assembling numerous independent components into a bigger and single
component. Joining is a secondary process just like machining since they both require already made
objects. Joining can be done on any material. The most common joining techniques are welding, riveting,
soldering, brazing and fastening.

WELDING

Welding is the process of joining metals by softening them using heat and uniting them by pressure with
or without the addition of metal to form a homogeneous joint (R.T.Gara 2007).
RIVETING

Riveting is a semi-permanent and non-thermal joining method that involves using a mechanical
fastener/rivet (a metallic part with a dome-shaped head) to join sheet metal parts. Riveting involves
drilling a hole in the two sheet metal parts you want to join together and installing a rivet. Installation
depends on the type of rivets you are working with, as you might have to place, drill, or punch the rivets
into the hole. After installing the rivets in the hole, you have to deform the rivet’s tail. This is achievable
by pounding or smashing it. Together with the shaped head, the flattened tail prevents the removal of
the rivets. (rapiddirect.com, 2022)

SOLDERING

Soldering is the major micro-joining process for assembling printed circuit boards of electronic products
and is an important method of joining two metals without melting of base metals. (Hiroshi Nishikawa,
2019)

ADDITIVE MANUFACTURING

Additive manufacturing id a process that involves layering materials to get the desired item. Additive
manufacturing processes include 3D printing, selective laser sintering and vat polymerization

3D PRINTING
Three-dimensional (3D) printing is an additive manufacturing process that creates a physical object from
a digital design. The process works by laying down thin layers of material in the form of liquid or
powdered plastic, metal or cement, and then fusing the layers together. (Adam Hayes, 2021)

SELECTIVE LASER SINTERING

Selective laser sintering (SLS) is a layer manufacturing process involving complex 3D parts that could be
generated through the successive addition of powder layers (Kruth et al., 1996; Kruth et al., 2001). In
SLS, the addition of powder layers during manufacturing is consolidated by focusing on selected areas
using the thermal energy supplied by a focused laser beam. Sintering between powder particles is
performed by raising the temperature above the softening temperature (Agarwala et al., 1995).

VAT POLYMERIZATION

Vat Photopolymerization (VPP), a process which utilizes light to induce controlled polymerization, is the
most mature of the Additive Manufacturing processes. VPP currently has four generations in terms of
overall throughput innovations: stereolithography (SLA), digital light processing (DLP), continuous DLP
(CDLP), and, most recently, volumetric DLP (VDLP). (Ware et al., 2023)
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