Manufacturing process

Contents
Manufacturing process
Casting
Types of Castings
Advantages


Manufacturing process
The knowledge of manufacturing processes is of great importance for
design engineer .
There are various manufacturing processes used in Industries.
1. Primary shaping processes
2. Machining processes
3. Surface finishing processes
4. Joining processes
5. Processes effecting change in properties
Manufacturing process
Primary shaping processes:
The Processes used for the preliminary shaping of the machine components are
known as primary shaping processes.
The common operations used for this process are casting, forging, extruding ,
rolling, drawing, bending , shearing , spinning, powder metal forming , squeezing
etc;
CASTING
It is one of the most important process used in Mechanical engineering.
The castings are obtained by re-melting of ingots in a cupola or some other foundry
furnace and then pouring this metal into metal or sand moulds.
Various Important casting processes are :
1. Sand mould casting.
2. Permanent mould casting.
3. Slush casting.
4. Die casting.
5. Centrifugal casting.
Cupola: Melting device used in foundries.
That can used to melt cast iron , ni-resist iron
and some bronzes.
Ingot : It is a material usually metal,
that is cast into a shape suitable for further
processing.
1.Sand Mould Casting
The casting produced by pouring molten metal in sand mould is called Sand Mould
Casting. It is particularly used for parts of larger sizes.
Sand casting, the most widely used casting process, utilizes expendable sand
molds to form complex metal parts that can be made of nearly any alloy. Because
the sand mold must be destroyed in order to remove the part, called the casting,
sand casting typically has a low production rate.
The sand casting process involves the use of a furnace, metal, pattern, and sand
mold. The metal is melted in the furnace and then ladled and poured into the
cavity of the sand mold, which is formed by the pattern. The sand mold separates
along a parting line and the solidified casting can be removed.

1.Sand Mould Casting

2.Permanent Mould Casting
The Casting Produced by pouring molten metal in metallic mould is called Permanent
Mould Casting. It is used for casting aluminum pistons, electric iron parts, cooking
utensils, gears etc., The Permanent Mould Casting has following advantage.
1. Shaping the sand : A wooden pattern cut to the shape of one half of the casting
is positioned in an iron box and surrounded by tightly packed moist sand.
2. Ready for the metal : After the wooden patterns have been removed, the two halves of
the mould are clamped together. Molten iron is poured into opening called the runner.

a. It has more favorable fine grained structure.
b. The dimensions may be obtained with close tolerances.
c. The holes up to 6.35mm diameter may be easily cast with metal cores.




2.Permanent Mould Casting
Permanent mold casting is a metal
casting process that shares similarities
to both sand casting and die casting. As
in sand casting, molten metal is poured
into a mold which is clamped shut until
the material cools and solidifies into
the desired part shape. However, sand
casting uses an expendable mold which
is destroyed after each cycle.
Permanent mold casting, like die
casting, uses a metal mold (die) that is
typically made from steel or cast iron
and can be reused for several thousand
cycles. Because the molten metal is
poured into the die and not forcibly
injected, permanent mold casting is
often referred to as gravity die casting.
3.Slush Casting
It is a special application of permanent metal mould casting. This method is used
for production of hollow castings without the use of cores.
As in permanent mold casting, the molten metal is poured into the mold and
begins to solidify at the cavity surface. When the amount of solidified material is
equal to the desired wall thickness, the remaining slush (material that has yet to
completely solidify) is poured out of the mold.
As a result, slush casting is used to produce hollow parts without the use of cores.

4.Die Casting
The casting is produced by forcing molten metal under pressure into a permanent
metal mould is called die casting.
Die casting is a manufacturing process that can produce geometrically complex
metal parts through the use of reusable molds, called dies. The die casting process
involves the use of a furnace, metal, die casting machine, and die. The metal,
typically a non-ferrous alloy such as aluminum or zinc, is melted in the furnace and
then injected into the dies in the die casting machine.
There are two main types of die casting machines
1. Hot chamber machines (used for alloys with low melting temperatures, such as
zinc) and
2. Cold chamber machines (used for alloys with high melting temperatures, such as
aluminum).



4.Die Casting
4.Die Casting
1. Hot chamber machines : Hot chamber
machines are used for alloys with low
melting temperatures, such as zinc, tin, and
lead. The temperatures required to melt
other alloys would damage the pump, which
is in direct contact with the molten metal.
4.Die Casting
Cold chamber machines are used for
alloys with high melting
temperatures that cannot be cast in
hot chamber machines because they
would damage the pumping system.
Such alloys include aluminum, brass,
and magnesium. The molten metal is
still contained in an open holding pot
which is placed into a furnace, where
it is melted to the necessary
temperature.
Advantages of Die casting Process
i. The Production rate is high , ranging up to 700 castings per hour .
ii. It gives better surface smoothness
iii. The dimension may be obtained within tolerances .
iv. The Die retains its trueness and life for longer periods. For example , The life of
die for zinc base castings up to one million castings, for copper base alloys up to
75 000 castings and for aluminum base alloys up to 500 000 castings.
v. It requires less floor area for equivalent production by other castings methods.
vi. By Die Casting , thin and complex shapes can be easily produced.
vii. The holes up to 0.8mm can be cast .
Dis-Advantages of Die casting Process
i. The Die casting units are costly .
ii. Only non ferrous alloys are casted more economically,.
iii. It requires special skill for maintenance and operation of a die casting machine
5. Centrifugal casting
Centrifugal casting, sometimes called rotocasting, is a metal casting process that
uses centrifugal force to form cylindrical parts. This differs from most metal casting
processes, which use gravity or pressure to fill the mold.
In centrifugal casting, a permanent mold made from steel, cast iron, or graphite is
typically used. However, the use of expendable sand molds is also possible. The
casting process is usually performed on a horizontal centrifugal casting machine
(vertical machines are also available).
Centrifugal casting is used to produce axi-symmetric parts, such as cylinders or
disks, which are typically hollow. Due to the high centrifugal forces, these parts
have a very fine grain on the outer surface and possess mechanical properties
approximately 30% greater than parts formed with static casting methods.
These parts may be cast from ferrous metals such as low alloy steel, stainless steel,
and iron, or from non-ferrous alloys such as aluminum, bronze, copper,
magnesium, and nickel.
Centrifugal casting is performed in wide variety of industries, including aerospace,
industrial, marine, and power transmission. Typical parts include bearings,
bushings, coils, cylinder liners, nozzles, pipes/tubes, pressure vessels, pulleys,
rings, and wheels.

5. Centrifugal casting
Casting Design
An engineer must know how to design the Castings so that they can effectively and
efficiently render the desired service and can be produced easily and economically.
In order to design a casting , the following factors must be taken into
consideration:
1. The Function to be performed by the casting ,
2. Soundness of the casting
3. Strength of the casting
4. Ease in its production
5. Consideration for safety And
6. Economy in production
In order to meet these requirements an engineer should have thorough
knowledge of Production methods including pattern making , moulding , Core
making , melting and pouring etc.,
One should be able to make a proper selection of methods for casting .
To be continued..
FORGING
Contents
Forging
Types of forging processes
Sub types of Forging Processes
FORGING
Forging is the working of metal into a useful shape by hammering or pressing.
It is the process of heating a metal to a desired temperature in order to acquire
sufficient plasticity, followed by operations like hammering , bending and
pressuring etc., to give it a desired shape .
It is probably the oldest method of metal forming.
Various forging processes:
i. Impact Forging
ii. Press Forging
FORGING
i. Impact Forging : The Load is applied by an impact and the deformation takes
place over a very short time .
Impact forging can be further subdivided into three types:
Smith forging,
Power Forging,
Drop forging,
Upset forging.


ii. Press Forging : Impact forging usually involves a mechanical press, press forging,
on the other hand, requires hydraulic power.

The largest forgings are invariably produced on large hydraulic presses. These have
vertically moving rams, which move down slowly under considerable pressure.

A typical press forge would be capable of loads of the order of 6000 to 10000 tons.

Forgings up to 100 tons weight can be handled easily in this forge and the highest
quality products are manufactured by this technique.

FORGING
1. Smith Forging or Hand Forging :
It is Done by means of hand tools and its usually employed for small jobs.
The impact force for deformation is applied manually by the blacksmith by means
of a hammer. The piece of metal is heated in a forge and when at the proper
temperature is placed on an anvil.

FORGING
2. Power Forging :
When the forging is done by means of Power Hammers ,it is then known as Power
Forging . It is used for medium size or large articles requiring very heavy blows .

FORGING
3. Machine Forging or Upset
Forging : It is done by means of
forging machines.
This process was developed
originally to gather, or upset
metal to form heads on bolts.
Today the purpose of this
machine has been broadened to
include a wide variety of forgings.

It is essentially a double-acting
press with horizontal motions
rather than vertical

FORGING
4. Drop Forging : It is carried out with the
help of drop hammers and is particularly
suitable for mass production of identical
parts .
It is the modern equivalent of smith
forging where the limited force of the
blacksmith has been replaced by the
mechanical or steam hammer.
The process can be carried out by open
forging where the hammer is replaced by a
tup and the metal is manipulated manually
on an anvil.


FORGING
Advantages of Forging process
i. It refines the structure of the metal.
ii. It renders the metal stronger by setting the direction of grains
iii. It effects considerable saving in time, Labour and material as compared to the
production of the similar item by cutting from a solid stock and then shaping it .
iv. The reasonable degree of accuracy may be obtained by Forging.
v. The Forgings May be welded .