Module- 5

Manufacturing

• Manufacturing Processes: Basic processes like

machining, casting, forging etc. welding, brazing and

soldering.

1
 What is Manufacturing?
✔ The word manufacture is derived from two Latin words manus
(hand) and factus (make); the combination means “made by hand”

✔ “Made by hand” accurately described the fabrication methods that

were used when the English word “manufacture” was first coined
around 1567 A.D.

✔ Most modern manufacturing operations are accomplished by

mechanized and automated equipment that is supervised by
human workers

15-Nov-23 2
 What is Manufacturing?
The process of converting raw materials, components, or parts into finished goods that
meet a customer's expectations or specifications. (or)
Transformation of materials and information into goods for the satisfaction of human
needs.

Manufacturing

Technologically Economically

15-Nov-23 3
 Manufacturing

Manufacturing

Secondary
Primary
Final shape and size
Basic shape and size to with tighter control
the material on dimension, surface
characteristics etc.

Casting, forming,
powder
metallurgy Material removal
processes

4
 Technological Importance
Technology - the application of science to provide society and its
members with those things that are needed or desired

• Technology provides the products that help our society and its
members live better

• What do these products have in common?

– They are all manufactured

• Manufacturing is the essential factor that makes technology

possible
 Economical Importance
Indian Economy
Sector: %GDP Gross domestic product )
Agriculture and natural resources 17
Construction and public utilities 13
Manufacturing 16
Service industries* 54
100
* includes retail, transportation, banking, communication,
education, and government
 Manufacturing - Technological
• Application of physical and chemical processes to alter the
geometry, properties, and/or appearance of a starting material to
make parts or products

15-Nov-23 7
 Manufacturing - Economic
• Transformation of materials into items of greater value by one or

more processing and/or assembly operations

✔When iron ore is converted into steel,

value is added.
✔ When sand is transformed into
✔ glass, value is added.
✔ When petroleum is refined into plastic,
value is added.
✔ when plastic is moulded into the
complex geometry of a patio chair

15-Nov-23 8
 Manufacturing Process
Manufacturing Processes

Casting: Forming & Machining: Joining: Finishing:

Shaping:
Expendable Turning Welding Lapping
mold Rolling
Milling Brazing Polishing
Permanent Forging
mold Drilling Soldering Deburring
Extrusion
Boring Bonding Surface
Drawing treating
Grinding assembly
Sheet forming coating
Shaping
Broaching

15-Nov-23 9
 Manufacturing Processes

1. Welding
2. Casting
Fundamentals of Manufacturing
3. Forging Processes

4. Rolling (ZERO wastage of

5. Metal Forming parent material)

6. Extrusion

7. Machining Machining Processes

(Wastage of parent material)
 Casting of Metals
Process in which molten metal flows by gravity or other force
into a mold where it solidifies in the shape of the mold cavity
• The term casting also applies to the part made in the process
• Steps in casting seem simple:
1. Melt the metal
2. Pour it into a mold
3. Let it freeze

15-Nov-23 11
Introduction to casting

1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand
Metallic CUBE
5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop

12
 Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand
Metallic CUBE
5. Cope Box

6. Pouring basin and runner

7. Riser

Wooden CUBE 8. Mould cavity

9. Foundry Shop

13
Pattern
Mould Box

Mould Box

Flat Surface - Ground

14
Pattern
Mould Box

Mould Box

Pattern

Mould Box

Ground

Flat Surface - Ground

15
Mould box filled with Moulding SAND

18
Rammer

19
 Again add
Moulding SAND

20
Rammer

21
Invert the Mould Box with
pattern

22
Inverted Mould Box with
pattern

23
Another Mould BOX

Inverted Mould Box with

pattern

24
Conical Shaped Wooden
pieces

Inverted Mould Box with

pattern

25
Inverted Mould Box with
pattern

26
Moulding
Sand

Inverted Mould Box with

pattern

27
Rammers

Inverted Mould Box with

pattern

28
Rammers

Inverted Mould Box with

pattern

Sand

29
Sand

Inverted Mould Box with

pattern

Sand

30
 Inverted Mould Box with
pattern
Sand

31
Mould Box – 2 Sand

Mould Box – 1

32
Remove (Pull up) the pattern
with care
Sand

Pattern
Cavity
(Mould cavity)

33
Align the two mould boxes

Sand

Pattern
Cavity
(Mould cavity)

34
 Remove the Conical Shaped Wooden
pieces

Sand

35
Sand Mould Box – 2

Mould Box – 1

36
Sand Mould Box – 2

Mould Box – 1
(Drag BOX)

37
Sand Mould Box – 2
(Cope BOX)

Mould Box – 1
(Drag BOX)

38
 COPE
Sand

DRAG

39
 COPE
Sand

DRAG

40
 COPE
Sand

Mould
Cavity

DRAG

41
 Pouring basin and runner

COPE
Sand

Mould
Cavity

DRAG

42
RISER Pouring basin and runner

COPE
Sand

Mould
Cavity

DRAG

43
 Molten metal is poured through
the Pouring basin and runner

Sand

44
 Molten metal is poured through
the Pouring basin and runner

Sand

45
 Molten metal is poured through
the Pouring basin and runner

Sand

46
When the mould cavity is
full, excess molten metal Molten metal is poured through
rises through the RISER
the Pouring basin and runner

Sand

47
When the mould cavity is
full, excess molten metal Molten metal is poured through
rises through the RISER
the Pouring basin and runner

Sand Allowed to
solidify

48
Solidification complete

Break the mould

50
Solidified Metal

51
 Final Product

Solidified Metal

52
Remove the unwanted projections by machining

Final Product

53
 Final Product

Final Product or CASTING

54
 Cooling Curve for a Pure Metal

Pure metals solidify at a constant temperature. During freezing the

latent heat of solidification is given off. Most metals shrink on
solidification and shrink further as the solid cools to room
temperature.
15-Nov-23 55
 Nucleation and Growth

15-Nov-23 56
 Solidification of Pure Metals
• Due to chilling action of mold wall, a
thin skin of solid metal is formed at the
interface immediately after pouring
• Skin thickness increases to form a shell
around the molten metal as solidification
progresses
• Rate of freezing depends on heat transfer
into mold, as well as thermal properties
of the metal .
• randomly oriented grains of small size
near the mold wall, and large columnar
grains oriented toward the center of the
casting
15-Nov-23 57
 Solidification Patterns

Solidification patterns for gray cast iron in a 180-mm (7-in.) square

casting. Note that after 11 min. of cooling, dendrites reach each other, but

the casting is still mushy throughout. It takes about two hours for this

casting to solidify completely

58
 Advantages and disadvantages of Casting

• Can create complex part geometries

• Can create both external and internal shapes
• Some casting processes are net shape; others are near net shape
• Can produce very large parts
• Some casting methods are suited to mass production
Different disadvantages for different casting processes:
– Limitations on mechanical properties
– Poor dimensional accuracy and surface finish for some
processes; e.g., sand casting
– Safety hazards to workers due to hot molten metals
– Environmental problems

15-Nov-23 59
 Applications

• Big parts

– Engine blocks and heads for automotive vehicles, wood

burning stoves, machine frames, railway wheels, pipes,
church bells, big statues, pump housings
• Small parts

– Dental crowns, jewelry, small statues, frying pans

15-Nov-23 60