Fabrication is an integral part of manufacturing, where raw materials are transformed into functioning products. The fabrication process itself is versatile, allowing for adaptability and customization to meet various production and industrial requirements.
Let us start by understanding what is fabrication. Fabrication is the process of transforming raw metal materials into finished or semi-finished products. Cutting, shaping, or molding metal are just some of the fabrication processes used in the industry. It can be carried out either on-site or in specialized workshops equipped with advanced machines and tools.
The manufacturing sector is expectedto reach 1 trillion USD in revenue by 2025, which means the demand for skilled fabricators will increase exponentially.In this blog, we delve into the commonly used fabrication processes that have been a driving force in the manufacturing industry.
1. Cutting process
The cutting process is a fabrication technique where work-pieces are cut into small pieces of the required shape and size. Cutting is a crucial step in the fabrication process because it allows for the precise cutting of material, removing waste material, preparing material for weld joints, and removing defects.
Common cutting techniques used in metal fabrication are sawing, milling, turning, and drilling. Fabrication workshops use cutting tools such as blades, drills, and bits to get the desired shape. In case you require on-site cutting you can opt for gas cutting.
Fabricators use different machines for cutting, such as computer numerically controlled machines (CNC), hand-held tools, power tools, or high-tech machinery. Advanced cutting techniques include lasers, plasma arc cutting, power scissors, and water-jets.
When selectinga cutting method, it is important to consider feasibility, cost-effectiveness, and specific requirements. The choice of equipment will depend on factors like thematerialof construction, thickness, job complexity, production volume, and precision required.
2. Forming processes
Forming is a fabrication process that uses mechanical forces to deform objects. No material is added or removed during the forming process. It involves applying the proper stresses, such as compression, shear, and tension, to materials (mainly metals), causing them to deform physically, and obtaining the desired forms and sizes.
Some forming processes include:
2.1. Rolling
Rolling is the process of passing a metal sheet through two or more rollers. The rollers move in the opposite direction to reduce the thickness of the workpiece through compression. Rolling is commonly used in the manufacturing industry to produce a variety of metal products, including sheets, plates, bars, and rods. It is a versatile process that can be used to produce a wide range of materials, including steel, aluminum, copper, and nickel. Rolling is a cost-effective process that can produce high-quality products with a consistent thickness and shape. It is also a relatively energy-efficient process, which makes it a sustainable manufacturing option.
2.2. Extrustion
Extrusion is the process of forcing a workpiece (either hot or cold) through a die. The extruded metal acquires the die shape as it moves through the cavity. Extrudate refers to the product that comes out of the die. The metal flows through the die opening sometimes with the help of a RAM. Fabricators use compressive and shear stresses to shape the metal, and elevated temperatures ensure it does not become brittle. Some commonly extruded materials include aluminum, steel, magnesium, and lead. Non-metals like plastics and ceramics are extruded extensively. Extrusion is used in the production of pipes, tubes, frames, and profiles.
2.3. Die Forming
Die-forming is the process of stamping the material with a press. The workpiece (usually metal sheets) is permanently reshaped around on onto a die through plastic deformation. It is subject to compressive forces to take the shape of the die. Fabricators use mechanical or hydraulic presses depending on the scale and complexity of the process.
2.4 Forging
Forging uses compressive forces to shape and deform metals at high temperatures (600-1250 oC) to make the metal stronger and more durable. Common metals used in forging include alloy steel, stainless steel, aluminum, brass, copper, and carbon steel. The high temperatures in forging make the metal more malleable, and heavy hammers or presses create extreme pressure. This force causes the metal to take on the shape of the die or mold, resulting in a finished product with improved mechanical properties.
Various industries like automotive, aerospace, consumer goods, construction, and manufacturing use the forming process. The processes selected will depend on the raw material and the final product.
3. Joining processes
The joining process is the manufacturing process of joining two or more metals permanently or temporarily linked together to form a single unit. Here are a few of the most popular joining procedures:
3.1. Welding
Welding is a fabrication process where two or more metals (sometimes thermoplastics) are fused with the application of heat, pressure, or both, forming a joint when the part cools. The welding joint is permanent and is called weldment.
Welding can broadly be divided into two categories - fusion welding and solid-state welding. Fusion welding heat is applied to melt the base metals, allowing them to join. Sometimes a filler metal is added to the molten pool to improve the strength of the bond. MIG (metal inert gas), TIG (tungsten inert gas), and oxy-fuel welding are types of fusion welding.
Solid-state welding creates a welding joint without melting the base metal. It uses pressure or a combination of heat and pressure. No filler metal is used. Welding workshops have welding machines, torches, wire feeders,protective gear, gases, and consumables. Welders are skilled professionals who have received training and certification to ensure the safety and quality of the weld. Welders need to upgrade their certifications periodically.
3.2. Soldering
Soldering is a fabrication process that joins different metals together by melting solder. Solder is usually an alloy of tin and lead has a melting point of 2350 C and 350 0 C. The technician uses a soldering iron to melt the solder. A strong electrical and mechanical bond is created when the solder cools down. The bond allows the metal parts to achieve electric contact.
The electronics industry uses soldering for electrical connections. It is used in PCB fabrication. The plumbing and jewelry industries use soldering extensively.
3.3. Brazing
Brazing is achieved by melting and pouring a filler metal into the joint, that has a lower melting point than the adjacent metal. Two or more metal objects are linked together. Capillary action helps to join the two metals together. The melting point of the filler metal is above 450 o C.
3.4 Fasteners
Fasteners are tools used to connect two or more things mechanically. Popular fasteners used are nut bolts, nails, hooks, clips, clutches, and zippers. They are used in the manufacturing, construction, and automotive sectors. The choice of fastener used will depend on factors such as the joint strength required and environmental factors.
3.5 Adhesive Bonding
Adhesive bonding is the process of using an adhesive agent to join two surfaces to create a smooth surface. The adhesive agent may be glue, epoxy, or any other plastic adhesive that adheres either by evaporation of a solvent or through curing via heat, pressure, or time.
4. Machining
Machining is the process of shaping metal by removing unwanted components from it. It is done manually or using CNC machines. Common machining processes used are:
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4.1. Drilling
Drilling uses a rotary cutting tool or drill bit to cut a hole in the material. The drill bit rotates rapidly on the workpiece, creating circular holes on the workpiece. You can drill using a handheld drill, standard machines, or CNC machines for automated and precise drilling operations. Operations that can be performed on a drilling machine include drilling, reaming, tapping, boring, counterboring, countersinking, and spot facing.
4.2. Turning
Turning uses a lathe to rotate the workpiece while the cutting tool moves linearly to remove metal along the diameter to create a cylindrical shape. You can place the cutting tool at different angles to produce different shapes. The operator can select the surface speed on CNC lathes with constant surface speed control, and the machine will automatically adjust the rpm when the cutting tool travels through the various diameters along the outside profile of the workpiece.
4.3. Milling
Milling uses a rotating multi-point cutting tool to remove material from the workpiece to get the required shape. The workpiece is fed slowly into the machine, or the tool moves across the stationary workpiece. Manufacturers generally use milling as a finishing or secondary process; we can use it from beginning to end. Face milling, plain milling, angle milling, climb milling, and form milling are a few of the several forms of milling.
5. Casting
Metal casting involves heating a metal to its melting point and then pouring it into a specially designed mold. Once the metal cools and solidifies, it can be refined to remove any minor flaws and enhance its surface quality.
The primary advantage of casting is its ability to produce complex shapes in a single operation. This makes it suitable for manufacturing various products in industries such as automotive, aerospace, agriculture, and computer equipment, among others.
However, casting has a drawback because the heating and cooling processes can introduce internal stresses to the metal's crystal structure. Therefore, manufacturers must carefully execute casting procedures to prevent the formation of cracks and damage to the metal.
6. Advantages of fabrication as a service
Several fabrication companies offer fabrication services to create products and parts. They offer services like structural fabrication, custom fabrication, module fabrication, or assembly operations and work with metals like mild steel, stainless steel, or aluminum. Some of the advantages of fabrication services are:
Fabrication as a service has become a popular trend with several businesses offering on-demand fabrication services. FAAS has several benefits over traditional services. One of the biggest advantages ofopting for FAAS is that you have access to a variety of fabrication tools and knowledge without having to make substantial upfront investments in tools, Businesses can rely on their core competencies while outsourcing their fabrication demands.
7. How do I select the right fabricator service?
You must select the right fabrication company to fulfill your project requirements effectively. Venwiz can help you find the ideal fabricator.Venwiz’s discovery module is ideal for shortlisting fabricators based on experience, the skill r, industries served, location, and turnover. The Venwiz platformis a one-stop shop for vendor management.Some factors to consider are:
The fabrication processes discussed in this blog are an integral part of the production process. By effectively understanding and utilizing the fabrication process, manufacturers can unlock new possibilities, streamline their processes, and deliver high-quality products. Visit Venwiz and register to look for qualified vendors for your job. - www.venwiz.com
