BASIC MECHANICAL ENGINEERING-ME101

PART-B(PRODUCTION ENGINEERING)
 Books
➢Manufacturing Processes, By Kalpakjian

➢Manufacturing Technology-I, By P.N RAO

➢Workshop Practice-I&II, By Hazra Chaudhary

 NO OF UNITS
➢Introduction to Engineering Materials

➢Introduction to Manufacturing Processes

➢Introduction to Quality Measurement Manuf.

Processes
 Materials
➢ The substances which are useful in the field of
engineering materials.
➢ A particular material is selected on the basis of
following consideration
1. Properties of Materials
2. Cost of materials
3. Availability of Materials
Properties of Materials

➢ Strength
➢ Elasticity
➢ Plasticity
➢ Ductility
➢ Brittleness
➢ Hardness
➢ Toughness
➢ Creep
➢ Fatigue
 Engineering Materials

Metals Plastics / Ceramics Composites

Polymers

PMC

Non-Ferrous Alumina Silica Glass

Ferrous
Metals CMC
Metals

Cast Iron
MMC

Thermosets Thermo Plastics

Steel
Cast Iron
(e) Alloy Cast Iron
Cast Iron
Based on the percentage of carbon , classification
of steel according to iron carbon equilibrium are

1. Eutectoid steel : 0.8 % Carbon

2. Hypoeutectoid steel : less than 0.8 % carbon
3. Hypereutectoid steel : higher than 0.8 but less
than 2 %
GRAY CAST IRON
It is obtained by slow cooling of
molten metal, after it is melted in
Cupola furnance. It is name after
the gray color of the fracture it
forms, Which is due to the
presence of free Graphite.
GRAY CAST IRON
 White Cast Iron

White cast Iron is formed by more

rapid cooling of molten metal
after pouring in the mould cavity.

Figure
White Cast Iron
Malleable Cast Iron

Figure
Ductile (Nodular)Cast Iron
Effects of alloying elements on cast iron
INTRODUCTION TO
MANUFACTURING
PPROCESS
 SAND CASTING
• Sand casting uses ordinary sand as the primary mould
material.
The sand grains are mixed with small amounts of other materials, such as
clay and water, to improve mouldability and cohesive strength, and are
then packed around a pattern that has the shape of the desired casting.
• The pattern must be removed before pouring, the mold is usually made
in two or more pieces.
• An opening called a sprue hole is cut from the top of the mold through
the sand and connected to a system of channels called runners.
 Shell Moulding

• The sand is mixed with a thermosetting resin is allowed to

come in contact with a heated metal pattern
• A skin (shell) of about 3.5 mm of sand and plastic mixture
adhere to the pattern.
• Then the shell is removed from the pattern.
• The cope and drag shells are kept in a flask with necessary
backup material and the molten metal is poured into the
mold.
• Can produce complex parts.
• A good surface finish and good size tolerance reduce the
need for machining.
Advantages

1. Dimensional accuracy.
2. Smoother surface finish. (Due to finer
size grain used)
3. Very thin sections can be cast.
4. Very small amount of sand is needed.
Investment Casting
Investment casting process or lost wax process

Basic steps:
1. Produce expendable wax, plastic, or polystyrene patterns.
2.Assemble these patterns onto a gating system
3. Investing or covering the pattern assembly with refractory
slurry
4.Melting the pattern assembly to remove the pattern material
5. Firing the mould to remove the last traces of the pattern
material
6.Pouring molten metal