Conventional manufacturing refers to traditional manufacturing processes that have been used for many years and are still widely used today. It is characterised by a highly structured and sequential production process, with clear stages of production and well-defined roles for workers.
Conventional manufacturing processes have advantages, such as being well-established and having a long track record of producing reliable products. However, they can also have some drawbacks, such as being time-consuming, requiring a lot of manual labour, and producing waste.
Conventional manufacturing processes refer to various traditional techniques used to produce products and components in large quantities. These processes have been around for centuries and remain relevant today, playing a crucial role in modern manufacturing. The main conventional manufacturing processes include casting, forging, stamping, and machining, each with unique advantages and limitations.
Did You Know? Despite these limitations, conventional manufacturing remains a significant part of the modern manufacturing landscape.
Types of Conventional Manufacturing Process
Conventional manufacturing methods have been the mainstay of the manufacturing industry for many decades and are still widely used today. Understanding these processes is essential for anyone interested in manufacturing, as they provide a foundation for more advanced techniques used in modern manufacturing.
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Following are a few types of conventional manufacturing processes:
1. Casting
Casting involves pouring liquid metal or plastic into a mould and allowing it to cool and solidify into the desired shape. The mould is typically made from a refractory material such as sand or ceramic and is designed to withstand the high temperature of the liquid material. Once the material has cooled and solidified, the mould is removed to reveal the final product.
There are several casting processes, including sand casting and die casting. Sand casting, for example, is a relatively inexpensive process well-suited to manufacturing large, complex parts. Die casting, however, is a high-pressure process ideal for producing small, precise parts with tight tolerances. Casting is used to produce large and complex parts and is ideal for low-volume production.
2. Forging
Forging involves heating metal to a high temperature and then shaping it using hammering or pressing techniques. The process is commonly used to produce high-strength parts, especially in high-stress applications such as the aerospace, automotive, and defence industries. Several types of forging processes exist, such as open-die forging, closed-die forging, and roll forging. Open-die forging involves shaping the metal between two flat dies, while closed-die forging involves shaping the metal in a mould with two or more matching dies. Roll forging involves shaping the metal by passing it through a set of rolls.
One of the key advantages of forging is its ability to produce parts with high strength and toughness. This makes it ideal for use in applications where high stress and strain are expected. The process also allows the production of complex shapes and designs. It also allows the ability to produce parts with a uniform grain structure. This helps improve their overall strength and toughness.
3. Machining
Machining is a conventional manufacturing process involving various cutting tools and techniques to shape metal or plastic into the desired shape. There are several machining processes, such as turning, milling, drilling, and grinding. Turning, for example, involves rotating the workpiece and using a cutting tool to shape the material, while milling involves using a rotating cutter to remove material from the workpiece.
4. Stamping
Stamping involves using a stamping press to form metal or plastic into a desired shape. The process involves placing a sheet of metal or plastic between a punch and a die. Then, using a stamping press to apply pressure to the material, causing it to take on the shape of the die. Stamping is used to produce large quantities of simple, flat parts, such as auto body parts or electronic enclosures.
There are several stamping processes, including progressive stamping, blanking, and forming. For example, progressive stamping involves several stages to produce a final product, while blanking involves cutting the material into a desired shape. Forming involves shaping the material into a more complex shape. The coating can protect against wear, corrosion, and other environmental factors. For example, a coating of paint can protect against rust and weathering, while a ceramic coating can provide heat resistance and improve the hardness of a surface.
5. Coating
Coating involves the application of a thin layer of material to a surface. The purpose of the coating is to provide protection, enhance the appearance, or improve the functional properties of the coated surface. There are a variety of coating techniques and materials that can be used, including paint, plastic, metal, and ceramics. The most common coating forms include spray, dip, and electroplating. In spray coating, a spray gun is used to apply the coating material to the surface.
Dip coating involves immersing the surface in the coating material, while electroplating involves applying a metal coating using an electrical current. The coating can protect against wear, corrosion, and other environmental factors. For example, a coating of paint can protect against rust and weathering, while a ceramic coating can provide heat resistance and improve the hardness of a surface.
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Advantages of the Conventional Manufacturing Process
These methods are well-established, reliable, and proven effective in producing a wide range of products. Here are some of the advantages of conventional manufacturing processes
1. Cost-effective
Conventional manufacturing processes often involve fewer high-tech machines and automated systems, making them more cost-effective than their advanced counterparts. This makes it a great option for small and medium-sized businesses and for producing low-to-medium-volume products.
2. High Customisation
Conventional manufacturing processes offer high levels of customisation, making it easier to produce products tailored to specific customer requirements. This can be particularly important for businesses that cater to niche markets or need to produce specialised products.
3. Skilled Labour
Conventional manufacturing processes often rely on skilled workers to operate machinery, perform assembly and inspection, and carry out other tasks. This means there is a demand for skilled workers in the manufacturing industry, providing employment opportunities and promoting the development of technical skills.
4. Reliability
Conventional manufacturing processes have been used for many decades, so their reliability and stability are well established. The machinery and equipment used in these processes are also readily available and often come with a long lifespan, making them a low-maintenance option.
Limitations of the Conventional Manufacturing Process
While conventional manufacturing processes offer several advantages, they are also limited in certain ways. Here are some of the limitations of conventional manufacturing processes:
1. Low-efficiency
Conventional manufacturing processes are often less efficient than advanced ones, such as 3D printing or robotics. This means they can take longer to produce products, resulting in longer lead times and higher production costs.
2. Limited Production Capabilities
Conventional manufacturing processes often have limited production capabilities and may not be able to produce complex or intricate products. Businesses may need to turn to advanced manufacturing techniques or outsource production to meet their production needs.
3. Labour Intensity
It often requires high manual labour, which can be physically demanding and time-consuming. This can result in increased production costs and health and safety concerns for workers.
4. Quality Control Challenges
Conventional manufacturing processes may be more prone to human error, leading to quality control challenges and the need for more manual inspection and testing. This can increase the time and cost associated with the production process.
5. Technological Obsolescence
Conventional manufacturing processes are often based on older technologies, which can become obsolete. This means that businesses may need to invest in new equipment and processes as technology evolves, increasing their costs and requiring them to retrain their workers.
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Application of the Conventional Manufacturing Process
Conventional manufacturing processes are still widely used in various industries and applications, despite advancements in advanced manufacturing technologies.
Here are some of the common applications of conventional manufacturing processes:
1. Woodworking
Woodworking is an application of conventional manufacturing processes, where raw materials such as lumber are transformed into finished products such as furniture, cabinetry, and flooring.
2. Textile Manufacturing
Conventional manufacturing processes are also used in textile manufacturing, where raw materials such as cotton and wool are transformed into finished products such as clothing and linens.
3. Assembly
Conventional manufacturing processes are often used to assemble products, such as electronic devices, household appliances, and toys. This involves using manual labour and machinery to fit together different parts and components to create a finished product.
4. Sheet Metal Fabrication
Sheet metal fabrication is another common application of conventional manufacturing processes and is used to produce parts such as brackets, panels, and enclosures.
Conclusion
Conventional manufacturing processes are critical in modern manufacturing, providing various techniques for transforming raw materials into finished goods. From casting and forging to stamping and machining, these processes allow manufacturers to produce products with varying complexity, precision, and accuracy levels.
One of the key benefits of conventional manufacturing processes is their ability to produce parts with high precision and accuracy. This is critical in many applications, such as clothing, wood and furniture work, and more.
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