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    Basic Manufacturing Processes

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    Partho Roychoudhury
    Basic Manufacturing Processes involves obtaining a desired product from raw materials through various processes like metal casting, fabrication, metal forming, and machining. Metal casting involves melting metals and pouring them into molds to solidify into shapes. Fabrication joins materials through processes like welding and riveting. Metal forming shapes materials through plastic deformation using tools like dies and punches in processes like rolling, forging, extrusion, and sheet metal forming. Machining removes material through cutting processes like turning, milling, drilling, boring, and planning to achieve the final shape and dimensions.

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    Basic Manufacturing Processes

    Uploaded by

    Partho Roychoudhury
    5K views72 pages
    Basic Manufacturing Processes involves obtaining a desired product from raw materials through various processes like metal casting, fabrication, metal forming, and machining. Metal casting involves melting metals and pouring them into molds to solidify into shapes. Fabrication joins materials through processes like welding and riveting. Metal forming shapes materials through plastic deformation using tools like dies and punches in processes like rolling, forging, extrusion, and sheet metal forming. Machining removes material through cutting processes like turning, milling, drilling, boring, and planning to achieve the final shape and dimensions.

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    Basic Manufacturing Processes involves obtaining a desired product from raw materials through various processes like metal casting, fabrication, metal forming, and machining. Metal casting involves melting metals and pouring them into molds to solidify into shapes. Fabrication joins materials through processes like welding and riveting. Metal forming shapes materials through plastic deformation using tools like dies and punches in processes like rolling, forging, extrusion, and sheet metal forming. Machining removes material through cutting processes like turning, milling, drilling, boring, and planning to achieve the final shape and dimensions.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    5K views72 pages

    Basic Manufacturing Processes

    Uploaded by

    Partho Roychoudhury
    Basic Manufacturing Processes involves obtaining a desired product from raw materials through various processes like metal casting, fabrication, metal forming, and machining. Metal casting involves melting metals and pouring them into molds to solidify into shapes. Fabrication joins materials through processes like welding and riveting. Metal forming shapes materials through plastic deformation using tools like dies and punches in processes like rolling, forging, extrusion, and sheet metal forming. Machining removes material through cutting processes like turning, milling, drilling, boring, and planning to achieve the final shape and dimensions.

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    At a glance
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    The key takeaways are the different manufacturing processes like metal casting, forming, joining and machining are discussed along with their classification.

    The main manufacturing processes discussed are metal casting, forming, joining and machining.

    The main types of metal casting processes mentioned are sand casting, shell moulding, centrifugal casting and pressure die casting.

    Basic Manufacturing Processes

    By
    P.V.R.Ravindra Reddy
    Associate Professor
    Department of Mechanical Engineering
    Chaitanya Bharathi Institute of Technology
    Definition

    It is the process of obtaining


    desired product from raw
    material
    Classification
    • Metal casting :Making the desired product by
    melting and pouring the metal in desired cavity made
    in a mould.

    • Fabrication: Joining Process. Welding, riveting etc


    comes under fabrication processes.

    • Metal forming: due plastic deformation by the


    application of load with the tools called dies and
    punches.

    • Machining : getting the desired shape by removal


    of material
    Metal Casting
    Metal Casting : classification
    • Sand Casting
    •Green sand Moulding
    •Dry sand Moulding
    • Special Moulding/casting processes
    • Shell Moulding
    • Centrifugal Casting
    • Continuous casting
    • Pressure die casting
    • Investmest casting
    Sand Casting
    Processes in sand casting

    •Pattern Design & Development


    •Moulding
    •Melting
    •Pouring
    •Knockout
    •Felting
    •In process and final inspection
    •Packing and dispatch
    Pattern : The replica of casting

    Pattern
    Pattern : The replica of casting
    • Pattern Allowances
    • Shrinkage Allowance
    • Draft Allowance
    • Machining Allowance
    • Rapping & Tapping Allowance
    • Distortion allowance
    • Pattern Materials
    • Wood : Teak, Deodar, Pine, Mahogany Wall nut etc.
    • Metals & Alloys : CI, Steel, Aluminum, Brass etc.
    • Plasters : Plaster of Paris
    • Plastics : Epoxy resin.
    • Expendable materials: Wax, Mercury etc.
    Moulding
    Moulding: Making the cavity
    • Sand Mix
    • Sand
    • Clay
    • Additives
    • Water
    • Desired properties of Moulding sand
    • Refractoriness
    • Permeability
    • Adhesiveness & Cohesiveness
    • Strength (GCS,GSS,DCS,DSS,Hot strength)
    • Plasticity
    • Collapsibility
    • Bench Life
    Core : For a cavity in casting
    • Sand Mix
    • Sand
    • Binder: Core oil, Dextrin etc.
    • Preparation
    • Preparation using core boxes
    • Backing – 200-240 0C for 1-3 hrs.

    Core
    Types of cores
    Gating System
    Melting & Pouring

    • Melting furnaces
    • Cupola
    • Arc furnace
    • Induction furnace
    • Metal is tapped in ladles
    • Poured in the mould
    Knockout & Fetling
    • Breaking the mould
    • Removing the gating system
    • With hammer
    • With hacksaw machine
    • With flame cutting
    • Cleaning the castings
    • Shot blasting
    • Sand blasting
    • Tumbling
    • Tumbling with hydro blast
    Inprocess & final inspection
    • Visual inspection
    • Percussion test
    • Dye penatrant test
    • Florescent powder test
    • Magnetic particle test
    • Ultrasonic test
    • Radiography
    Shell Moulding
    Centrifugal Casting

    • True Centrifugal casting


    • Semi centrifugal Casting
    • Centrifuging
    True Centrifugal casting
    Semi Centrifugal casting
    Centrifuging
    Pressure die casting

    • Hot chamber process

    • Cold chamber process


    Hot chamber Process
    Cold chamber Process
    Investment Casting
    Casting Defects
    • Blow holes
    • Pin holes
    • Shrinkage cavity
    • Cold shut
    • Misrun
    • Scab
    • Mould drop
    • Hot cracks
    • Cold cracks
    Advantages of casting Process
    • No limitation of Weight
    • Complex shapes
    • Cheapest manufacturing process
    • Hardness, brittleness does not matter
    • Suitable for mass production or
    jobbing work
    • No directional properties
    Welding

    Welding is a process used to join similar


    or dissimilar metals with the help of
    heat and with or without the application
    of Pressure
    Welding Positions
    Types of Joints
    Types of Welding Processes

    • Gas Welding
    • Arc Welding
    • Resistance Welding
    • Thermo-chemical Welding
    • Radiant energy welding
    • Solid state welding process
    Gas Welding

    • Oxy-Hydrogen Welding
    • Air-Acetylene Welding
    • Oxy-Acetylene Welding
    Oxy Acetylene Welding Setup
    Types of flames
    Arc Welding Processes
    • Carbon Arc Welding (CAW)
    • Shielded Metal Arc Welding (SMAW)
    • Submerged Arc Welding (SAW)
    • Tungsten Inert Gas Welding (TIG)
    • Metal Inert Gas Welding (MIG)
    • Plasma Arc Welding (PAW)
    • Electro Slag Welding (ESW)
    Arc
    • Contains electrons and ions
    • Electron emission is thermionic.
    • K.E of is converted to heat.
    • 66.6% heat at anode and 33% at
    cathode.
    • Work piece is heated more in DCSP
    • Electrode consumption is more in
    DCRP.
    Carbon Arc Welding
    • First invented arc welding
    • Graphite electrodes are used
    • No weld pool protection
    • Almost obsolete .
    Shielded Metal Arc Welding
    Coating ingredients
    • Arc Stabilizers • Binding Agents
    • Titania TiO2 • Sodium Silicate
    • Gas-Forming Materials • Asbestos
    • Wood Pulp • Starch
    • Sugar
    • Limestone CaCO3
    • Alloying and Deoxidizing Elements
    • Slag-Forming Materials • Si, Al
    • Alumina Al2O3
    • TiO2
    • SiO2
    • Fe3O4
    • Slipping Agents to Aid Extrusion
    • Clay
    • Talc
    • Glycerin
    Submerged Arc Welding
    Tungsten Inert Gas Welding
    Metal Inert Gas Welding
    Plasma Arc Welding
    Electro slag welding process
    Resistance Welding

    •Spot Welding
    •Seam Welding
    •Projection Welding
    •Resistance Butt
    Welding

    •Percussion Welding
    Thermo-Chemical Welding
    Fe2O3 + 2Al 2Fe + Al2O3 + 181.5 kcal

    3Fe3O4 + 8Al 9Fe + 4Al2O3 + 719.3 kcal


    Radiant Energy Welding Processes

    Electron beam welding Laser Beam Welding


    Solid State Welding Processes

    • Cold welding
    • Forge welding
    • Friction Welding
    • Ultrasonic welding
    • Explosion Welding
    • Diffusion welding
    Weld Defects
    Metal Forming

    It is the process of obtaining


    desired shape due to plastic
    deformation by the application of
    load with the tools called dies
    and punches.
    Types of Metal forming processes
    • Bulk Deformation Processes:
    • Rolling
    • Forging
    • Extrusion
    • Wire drawing
    • Sheet Metal Forming :
    • Shearing : Blanking, piercing, lancing, shaving,
    notching, Perforating.
    • Cup drawing
    • Stretch forming
    • Spinning
    Rolling
    Forging
    • Open die forging
    • Closed die forging
    Extrusion
    Wire Drawing
    Cup Drawing
    Drawing is a sheet metal
    forming operation used
    to make cup-shaped,
    box-shaped, or other
    complex-curved, hollow-
    shaped parts. It is
    performed by placing a
    piece of sheet metal
    over a die cavity and
    then pushing the sheet
    into the opening with a
    punch. The blank is held
    down flat against the die
    by a blankholder.
    Bending
    Two common bending methods are:
    • V-bending
    • Edge or wipe bending.
    V-bending: In the sheet metal blank is
    bent between a V-shaped punch and
    die.
    Edge or wipe bending: involves
    cantilever loading of the material. A
    pressure pad is used to apply a Force to
    hold the blank against the die, while the
    punch forces the work piece to yield and
    bend over the edge of the die.
    Spinning
    Machning

    Machining is the process removal of


    material from a raw material, by
    cutting small chips, in order to obtain
    the desired shape and dimensions for
    final part.
    Classification of machining processes

    Machining types
    (Cutting processes types)

    Traditional machining Non-Traditional machining

    Cutting with Conventional Tools Cutting with Non-Conventional Tools Machining by:
    (Single point or multi point cutting tools (Abrasive tools that have a random
    having a cleary defined geometry) geometru of cutting part)

    Sloting/ Turning Milling Drilling Grinding Honning Lapping Water Electro/ Laser Ultra
    Shaping jet Chemical beam sonic
    erosion
    Turning
    Operations on lathe
    Boring
    Planer
    Shaper
    Drilling
    Milling
    Milling is a machining operation in which a workpart is
    fed past a rotating cylindrical tool usually with multiple
    cutting edges.

    The cutting tool in milling is called a milling cutter and


    cutting edges are called teeth.

    The geometric form created by milling is a plane surface.


    Other geometries can be created either by means of the
    cutter path or cutter shape.
    Types of Milling operations

    Peripheral milling: the axis of


    the cutter is parallel to the
    surface being machined, and
    the machining is performed by
    cutting edges on the outside
    periphery of the cutter.
    Face milling: the axis of the
    cutter is perpendicular to the
    surface being milled, and
    machining is performed by
    cutting edges on both the end
    and outside periphery of the
    cutter
    Types of Peripheral Milling
    • Up (conventional) milling:
    the direction of motion of
    the cutter teeth is opposite
    the feed direction when the
    teeth cut into the work.
    • Down (climb) milling: the
    direction of motion of the
    cutter teeth is the same as
    the feed direction when the
    teeth cut into the work.
    Reaming and Tapping
    Thank you

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