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Manufacturing Processes
- 1. Basic Mechanical Engineering By NitinG Shekapure Unit III Manufacturing Processes (L18 To L23) N itin Shekapure
- 2. By: Nitin Shekapure UnitIII Manufacturing Processes Introduction to Manufacturing Processes and their Applications (Casting, Forging, Sheet metal working and Metal joining processes). Description of the Casting process: Sand casting (Cope & Drag), Sheet metal Forming (shearing, bending, drawing), Forging (Hot working and cold working comparison), Electric Arc welding, Comparison of— Welding, Soldering, Brazing. N itin Shekapure
- 3. Manufacturing – Needand concept The progress and the prosperity of human civilization are governed and judged mainly by improvement and maintenance of standard of living through availability or production of ample and quality goods and services for men’s material welfare (MMW) in all respects covering housing, clothing, medicine, education, transport, communication and also entertainment. The successful creation of men’s material welfare (MMW) depends mainly on Availability of Natural Resources (NR) Exertion of Human Effort (HE); both physical and mental Development and use of power tools and machines (Tools), This can be depicted in a simple form, MMW = NR(HE)TOOLS where, NR: refers to air, water, heat and light, plants, animals, solid and liquid minerals TOOLS: refers to power plants, chemical plants, steel plants, machine tools etc. which magnify human capability. This clearly indicates the important roles of the components; NR, HE and TOOLS on achieving MMW and progress of civilization. N itin Shekapure
- 4. Difference Between Manufacturing andProduction The two phrases ‘to produce’ and ‘to manufacture’ are often considered synonyms and are used as replacements for each other. Many a times, the use of the two has actually ben interchanged. However…But N itin Shekapure
- 5. Manufacturing Manufacturing is aprocess of producing something useful through raw materials with the help of machinery or by hands in factories. The term manufacturing is used in the industrial sector where the input is transformed into the output on a large scale. The input can be in the form of raw material, components, and parts. The most important feature of manufacturing is the men-machine setup. The product manufactured can either be directly sold to the final consumers or other manufacturing entities to produce other items like equipment, appliances, aircraft, household, etc. Arrived from the Latin word “manu factus”, meaning “made by hand”. N itin Shekapure
- 6. Production The activity oftransforming both material and non-material inputs into the output that create utility is known as Production. The transformation includes conversion of raw materials into work in progress and works in progress into finished goods ready for sale. Here, the material input includes raw material, components, partly finished goods, etc. and non-material goods include ideas, information, skill, art, talent, etc. The production of goods and services employs manpower and sometimes machines. The output generated should be used for consumption, or it must possess a value so that it can be sold to the consumer. In economics, the production of goods and services is done to satisfy human wants. There are five factors of production that are used in the activity; they are land, labor, capital and entrepreneur. The participation and coordination of all these factors can lead to a successful production. N itin Shekapure
- 7. The following arethe major differences between manufacturing and production: • When the raw material is used as input to produce goods with the use of machinery is known as a Manufacturing. The process of transforming resources into finished products is known as Production. • Manufacturing consists of the generation of all those goods that are suitable for use or it can be sold out. On the other hand, production involves the creation of the utility. • In manufacturing, the use of machinery is a must whereas production can be done with or without the use of machinery. • All types of manufacturing activities are used in production, but production may not necessarily be known as manufacturing. • In manufacturing, the output generated will be tangible in nature, i.e. goods only, but in the case of production it produces both tangible and intangible outputs, i.e. goods as well as services. • Men-machine setup should be there for manufacturing of goods, which is not in the case of production, the only man is sufficient for producing output. Key Differences Between Manufacturing and Production N itin Shekapure
- 8. So in simpleway Manufacturing is The process of converting raw materials, components, or parts into finished goods that meet a customer's expectations or specifications. N itin Shekapure
- 9. Classification of Manufacturing Processes Manufacturing Processes Cutting Lathe Drilling Milling Grinding Shaping Boring Sawing NCMachines Gear Cutting Finishing Non- Cutting Casting Rolling Forging Press Work Molding Wire Drawing Fabrication Welding Brazing Soldering Riveting Screw Fastening N itin Shekapure
- 10. Casting is amanufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting Non Cutting N itin Shekapure
- 11. Non Cutting Casting • MetalCasting is one of the oldest materials shaping methods known. • Casting means pouring molten metal into a mold with a cavity of the shape to be made, and allowing it to solidify. • When solidified, the desired metal object is taken out from the mold either by breaking the mold or taking the mold apart. • The solidified object is called the casting. • By this process, complex parts can be given strength and rigidity frequently not obtainable by any other manufacturing process. • The mold, into which the metal is poured, is made of some heat resisting material. • Sand is most often used as it resists the high temperature of the molten metal. Permanent molds of metal can also be used to cast products. N itin Shekapure
- 12. Types of Casting 1.Sand Casting 2. Investment Casting 3. Die Casting 4. Centrifugal Casting Casting N itin Shekapure
- 13. Features of castingprocess: • Cast Components are brittle. • Close dimensional controls are not expected • No restriction on the size of the component • No restriction on the type of metal or alloy used • Surface finish is un satisfactory, Machining is required • Extremely thin sections can not be cast • Large variations in section thickness of components are not allowed • Economically suitable for both job and mass production Casting N itin Shekapure
- 14. Applications of castingprocess 1. Automobiles Engine Blocks Cylinder blocks Pistons. Piston rings Clutch Housing, etc 2. Aircrafts Jet engine blades Gear box housing Gear blank, etc Pulleys. 3. Machine tool Machine tool beds Frames Gear box housing Gears Machine tool slides and heavy components, etc 4. Water Pump Casings 5. Turbine casings 6. Flywheels Casting N itin Shekapure
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- 16. Sand casting process Castingsare made by sand. Applications- Gear box housing. Bearing housing, machine tool frame, etc. Casting N itin Shekapure
- 17. Metal Casting: SandCasting • Steps in Sand Casting: 1. Pattern Making: • Pattern is replica of the part to be casted. • Initially pattern has to be made using different manufacturing process other than casting. • Draft/Taper is provided on pattern for its easy removal from sand mould • Commonly used materials for pattern making are- Wood, Plastic and metal N itin Shekapure
- 18. • Steps inSand Casting: 2. Mould Making: • Mould is a container made from green sand and which has cavity in which molten metal can poured. • Mould box has two splits, the upper one is called cope and lower one is called drag • Arrangement for metal pouring has to be made inside the mould N itin Shekapure
- 19. • Steps inSand Casting: 3. Core Making: • Core is a device used in sand casting to produce hollow castings • Generally core is made from same material as that of the mould i.e. sand • Supporting elements called chaplets are used to support core N itin Shekapure
- 20. • Steps inSand Casting: 4. Metal Melting and Pouring: • The raw material is melted using furnace. Furnace may be operated on electricity or fuel • The molten metal is poured into mould using ladle • Pouring basin, sprue, runner, gate are used to guide molten metal into the cavity N itin Shekapure
- 21. • Steps inSand Casting: 5. Solidification • Metal is allowed to cool to room temperature • During solidification the metal shrinks and the extra metal required compensate this shrinkage is obtained from the riser 6. Finishing • Undesired part which corresponds to gating system and riser has to be cut from main casting • The casted surface generally is rough and some finishing operation like grinding, machining, polishing are required 7. Inspection • Before dispatching the casted part has to be checked for desired dimensions. The part which doesn’t meet expected dimensions has to be scraped • Castings are also checked for various undesirable defects N itin Shekapure
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- 23. Steps in Sandcasting 1 2 3 4 5 6 N itin Shekapure
- 24. Advantages of sandcasting • Complex shapes component can be produced • Highly economical & cost of component is very low • Not require high initial investments • Not required highly skilled man power • Suitable for small job production Casting N itin Shekapure
- 25. Limitations of sandcasting • Poor dimensional accuracy. • It involves melting of metal, high energy consumption process. • Not suitable for highly complex shapes • Can not produce extremely thin sections. (less than 6 mm) • For each casting requires one mould hence this process requires large man power for mould making • Large working space, in addition storing raw material, installing furnace & molding sand • Environmental pollution is high. Casting N itin Shekapure
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- 30. Non Cutting Rolling Isthe process of plastically deforming metal by passing it between rolls. Is widely used to convert steel ingots into blooms, billets, and slabs, and subsequently into plates, sheets and strips Advantages • Provides high throughput (Material) • Provides good control over the dimensions of the finished product In Hot Rolling: • Metal is rolled at a temperature above its recrystallization temperature • Higher reduction in the cross-section is achieved In Cold Rolling: • Metal is rolled at a temperature below its recrystallization temperature • Better strength and control of dimensions are achieved N itin Shekapure
- 31. Non Cutting Forging isa metal forming process in which metal is first heated and then plastically deformed to the desired shape and size by the application of compressive force using hand hammer, or a press Ductile materials are required. (ability of material to sustain plastic deformation without failure.) • Alloy Steel, Low Carbon Steel, Medium Steel, Stainless steel • Copper Alloys • Aluminum Alloys etc. N itin Shekapure
- 32. Two types ofForging by working process • Hot Forging: It is Defined as the deformation of the material into predetermined shape carried out at a temperature above its recrystallation temperature • Cold Forging: It is Defined as the deformation of the material into predetermined shape carried out at a temperature below its recrystallation temperature (usually room temperature). Forging N itin Shekapure
- 33. Difference between Cold& Hot Working Forging Parameters Hot Working Forging Cold Working Forging Force & Energy required Low High Dimensional accuracy Poor (due to thermal contraction during cooling) Good Machine requirement Light Heavier and Powerful Ductility of component Increases Decreases Type of materials Need not be soft Soft like Aluminum Strain Hardening effect Absent Present Forging N itin Shekapure
- 34. Types of Forging Hammer Forging Drop Forging Press Forging Upset Forging Roll Forging Forging N itin Shekapure
- 35. • Open-Die Forging •Oldest Style • Free Fall or Steam Driven • Low Rate and Accuracy Hammer Forging Pressure or load applied on hot metal part by hand Forging N itin Shekapure
- 36. Drop Forging •Aligned Cavity Dies • Horizontal Impact Forging • High Accuracy • High Tensile Strength Forging Pressure or load applied on hot metal part by impacting ram. Ram is fall under gravity from certain height N itin Shekapure
- 37. Press Forging • LargeForgings Produced • Slow, Steady Pressure • Uniform Deformation • Mechanical or Hydraulic Forging The hammering action is relatively slow squeezing instead of delivering heavy blows N itin Shekapure
- 38. Upset Forging • MachineForging • Common • Hot or Cold Forging The cross section of the hot material or workpiece is increased locally with a corresponding reaction in it’s length by slow squeezing action. N itin Shekapure
- 39. Roll Forging •Fast • Widely Used • Long, Tapered or Symmetrical Sections Forging N itin Shekapure
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- 41. Advantages • High dimensionalaccuracy and good surface finish. • Forging process reduces the grain size, which improve the strength and toughness of the forged components. • Thin sections are possible without reducing strength, which results in light weight components. • Produces the components without shrinkage cavities, blow holes, machining scratches, which increases the endurance strength. • Better withstand the external load. • Better resistance to shock and vibrations. Forging N itin Shekapure
- 42. Limitations Applications • Brittle materialscan not be used. • Complex components with intricate shapes can be produced by casting and not by forging process. • Forged component cost is more than cast components. • Cost of forging dies is high. • I C Engine parts like crankshafts, connecting rods, rocker arms, etc. • Small tools • Gear blanks, Levers. • Automobile and Aircraft components. N itin Shekapure
- 43. Sheet Metal Workingis the process of manufacturing the components from the sheet metal of thickness ranging from 0.1 mm to about 8 mm. It is carried out by a machine tool called press (Press working).N itin Shekapure
- 44. Sheet Metal Working SheetMetal Cutting (Shearing) Operations • Punching (Piercing) • Punching • Blanking • Perforating • Notching • Lancing • Slitting Sheet Metal Forming Operations • Bending • Drawing & Deep Drawing • Embossing • Forming • Coining (Squeezing) N itin Shekapure
- 45. Metal Cutting (Shearing) Processes Piercing Producing a hole of any desired shape in metal. Punching Producing a circular hole in metal Blanking The metal punched out is the required component, called blank. Sheet Metal Cutting Processes N itin Shekapure
- 46. Metal Cutting (Shearing)Processes Notching Removal of a small part of a metal sheet of any desired shape Perforating Producing no of evenly spaced holes in a metal sheet Sheet Metal Cutting Processes N itin Shekapure
- 47. SlittingCutting a metalsheet in a straight line along a length Metal Cutting (Shearing ) Processes Lancing Cutting a part of metal sheet through some portion of its length and then bending of cut portion Sheet Metal Cutting Processes N itin Shekapure
- 48. Metal Forming Processes Itis a process in which flat plate metal sheet is converted into a desired shape without wasting the material. Drawing and deep drawing Bending Forming Coining Embossing Sheet Metal Forming Processes N itin Shekapure
- 49. V Bending U Bending BendingMethods Sheet Metal Forming Processes N itin Shekapure
- 50. Angle Bending Bending andwiping/ Edge bending Sheet Metal Forming Processes N itin Shekapure
- 51. Forming Process offlat metal sheet into a surface of a desired profile Sheet Metal Forming Processes N itin Shekapure
- 52. Curling an edgeof circular cross section is formed along a sheet or at the end of the tube. Sheet Metal Forming Processes N itin Shekapure
- 53. Embossing is theprocess producing depressed or raised impression of letters figures or designs on metal sheet. Sheet Metal Forming Processes N itin Shekapure
- 54. Coining (Squeezing) isthe process of cold squeezing of metal sheet in which all the surface are confined within a set of dies. Metal Forming Processes N itin Shekapure
- 55. Metal Forming Processes Wiredrawing is a metalworking process used to reduce the cross- section of a wire by pulling the wire through a single, or series of, drawing die(s). N itin Shekapure
- 56. Sheet Metal Working Advantages •Components produced are light in weight • Cheap • Rate of production is high • High dimensional accuracy • Not required skilled man power Limitations • Limitation of thickness of metal sheet • Components have low strength • Not suitable for job production • Vibrations are more during operations • Noisy in operation • Dies are costly N itin Shekapure
- 57. Applications Sheet Metal Working •Automobile body parts (bike , car , buses etc), aircraft body parts. • Steel furniture, Utensils • Electronics appliancesN itin Shekapure
- 58. • Joining includeswelding, brazing, soldering, adhesive bonding of materials. • They produce permanent joint between the parts to be assembled. • They cannot be separated easily by application of forces. • They are mainly used to assemble many parts to make a system. Joining of materials N itin Shekapure
- 59. Welding is amaterials joining process which produces merging of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material. Welding Welding AWS distinguishes the welding processes according to: • Mode of energy transfer • Influence of capillary attraction in effecting distribution of filler metal in the joint The American Welding Society N itin Shekapure
- 60. Advantages of welding Welding •Welding provides a permanent joint. • Welded joint can be stronger than the parent materials if a proper filler metal is used that has strength properties better than that of parent base material and if defect less welding is done. • It is the economical way to join components in terms of material usage and fabrication costs. Other methods of assembly require, for example, drilling of holes and usage of rivets or bolts which will produce a heavier structure. N itin Shekapure
- 61. Welding Disadvantages of welding •Labour costs are more since manual welding is done mostly • Dangerous to use because of presence of high heat and pressure • Disassembly is not possible as welding produces strong joints • Some of the welding defects cannot be identified which will reduce the strength • Heat generated due to welding produces metallurgical changes hence, the structure of welded joint is different than that of parent metal. • Before welding, generally edge preparation of the workpieces is required N itin Shekapure
- 62. Welding Applications of welding Someof the important applications of welding process are as follows : • Aircraft construction (Welding of engine parts, turbine frame, ducts, etc.) • Rail-road equipment's (Air receiver, engine, front and rear hoods, etc.) • Pipings and pipelines (Open pipe joints, oil and gas pipelines, etc.). • Pressure vessels (boilers) and tanks Qoining of nozzles, ends, tanks, etc.). • Buildings and bridges (Columns base plates, erection of structures, etc.). • Automobile parts (Trucks, buses, cars, cranes, bikes parts, etc.). • Machine parts (Frames, beds, tools, dies, etc.). N itin Shekapure
- 63. Types of WeldingJoint Welding N itin Shekapure
- 64. Groups of weldingprocesses • Electric Arc welding • Brazing • Oxyfuel Gas Welding • Resistance Welding • Solid State Welding • Soldering • Other Welding N itin Shekapure
- 65. There are differentways of classifying welding and allied processes. Modern methods of welding may be classified under two broad categories i.e. plastic (Pressure) welding and fusion (non-pressure) welding. Classification of Welding processes In general, welding and allied processes are classified as follows Arc welding : 1. Gas tungsten arc welding (TIG) 2. Gas metal arc welding (MIG) 3. Electro-slag welding 4. Stud arc welding 5. Shielded metal arc welding 6. Submerged arc welding 7. Plasma arc welding N itin Shekapure
- 66. Resistance welding : 1.Spot welding 2. Seam welding 3. Projection welding 4. Percussion welding 5. Resistance butt welding Gas welding: 1. Oxy-acelylene welding 2. Oxy-hydrocarbon welding 3. Air acetylene welding 4. Pressure gas welding Classification of Welding processes N itin Shekapure
- 67. Welding • Pressure Welding(Plastic Welding) In this process, metal pieces to be welded are heated to a temp. so as to make them plastic and then forced together by external pressure. This process does not require additional metal for completing the weld. For example, forge welding, electric resistance welding, etc. • Fusion Welding (Non-Pressure Welding):- In this process, metal pieces to be welded are heated to molten (fusion) state & allowed to solidify. No pressure is required in this process. Additional metal is generally supplied by filler rod (welding rod) to complete the joint. For example, arc welding, gas welding, etc. N itin Shekapure
- 68. Arc Welding Electric ArcWelding • It is a fusion welding process, in which welding heat is obtained from an electric arc between electrode & work. • The electrode is first allowed to touch the work to form an electric circuit and then separated by a small distance ( 4 to 6 mm), so that current continuous to flow through the gaseous medium. • The temp. produced by an electric arc is about 5500 °C. • The base metal is melted by the temp. of the arc, forming a pool of molten metal which is forced out of the pool by blast from the arc. • Metal of the electrode also gets melted & deposited at the weld. • Either A.C. or D.C. is used for arc welding. N itin Shekapure
- 69. Electric Arc Welding ArcWelding N itin Shekapure
- 70. Arc Welding Advantages, Disadvantagesand Applications of Arc Welding Process Advantages • It is the most versatile process which can be applied for thin and thick sections. • Welding of complicated shapes can also be done. • Welding can be done in any position with high weld quality. • Very neat appearance and smooth weld shapes can be obtained. • Generally, edge preparation is not required. • The equipment's are portable and less expensive. N itin Shekapure
- 71. Arc Welding Disadvantages • Asthe electrodes are coated, the chances of slag entrapment and their related defects are more. • Welding control is difficult. • The process needed filler material. • It is a slow process. Applications Arc welding is commonly used in the manufacturing of following parts : • Air receiver, boilers, pressure vessels fabrication. • Automobile, chemical and aircraft industry. • Ship buiding and bridge construction. N itin Shekapure
- 72. Arc Welding Types ofArc welding : The main types of welding process are as follows 1. Shielded metal arc welding 2. Gas tungsten arc welding (TIG) 3. Gas metal arc welding (MIG) 4. Electro-slag welding 5. Plasma arc welding 6. Stud arc welding N itin Shekapure
- 73. Arc Welding Shielded MetalArc Welding (SMAW) Process It is also called as Flux shielded metal arc welding and as Manual Metal Arc welding (MMA or MMAW) SMAW is an arc welding process where coalescence (blend) is produced by heating the workpiece with an electric arc set up between the flux coated electrode and the workpiece. Due to arc heat, the flux covering decomposes and performs functions of arc stability, weld metal protection, etc. The electrode itself melts and supplies the necessary filler metal. N itin Shekapure
- 74. Arc Welding Shielded MetalArc Welding (SMAW) Process Principle • Required heat for welding is obtained from the arc struck between the coated electrode and the workpiece. • By employing higher or lower currents, the arc temperatures and thus arc heat can be increased or decreased. • Generally, the arc temperature is about 2400 °C to 2600 °C • A high current with a smaller arc length produces very intense heat. • The arc melts the electrode and the workpiece. • Material droplets are transferred from the electrode to workpiece through the arc and are deposited along the welded joint. • The coating of flux melts and produces a gaseous shield and slag to prevent atmospheric contamination of the molten weld metal. N itin Shekapure
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- 76. Arc Welding Shielded MetalArc Welding (SMAW) Process Advantages • It is the simplest of all arc welding processes. • The equipment is portable and less expensive. • Various metals and their alloys can be welded. • Welding can be done in any position with high weld quality Limitations • Due to limited length of electrode and brittle flux coating on it, mechanization is difficult. • It is a slow process. • Because of flux coated electrodes, the chances of slag entrapment and other related defects are more. • Welding control in this process is difficult. N itin Shekapure
- 77. Arc Welding Shielded MetalArc Welding (SMAW) Process Applications 1. Used for all commonly used metals and their alloys. 2. It is used as a fabrication process and for maintenance and repair jobs. 3. Also used in, • Air receiver, boiler and pressure vessel fabrications • Automotive and aircraft industry • Ship building and bridge construction. N itin Shekapure
- 78. Arc Welding Gas TungstenArc Welding (GTAW) Process (TIG) • It is also called as Tungsten Inert Gas (TIG) Welding. • It is an arc welding process where coalescence (blend) is produced by heating the workpiece with an electric arc struck between tungsten electrode and workpiece. • To avoid atmospheric contamination of the molten weld pool, a shielding gas is used. • If required, a filler metal may be added. N itin Shekapure
- 79. Arc Welding Gas TungstenArc Welding (GTAW) Process Principle • To start the process, welding current, water and inert gas supply are turned on. • The arc is struck by touching the electrode with a scrap metal tungsten piece. • Then the welding torch is brought near to the workpiece. • When electrode tip reaches within a distance of 2 to 3 mm from the workpiece, spark jumps across the air gap between the electrode and the workpiece. • Then the air path gets ionised and arc is established. • The welding continues by moving the torch along the joint and at the far end of the workpiece arc is broken by increasing the air gap. • To avoid atmospheric contamination, a shielding gas is impinged on the solidifying part for a few seconds. • The welding torch and the filler rod are generally kept inclined at an angle of 70° to 80° with weld plane. • For welding, a leftward technique is used. N itin Shekapure
- 80. Arc Welding Gas TungstenArc Welding (GTAW) Process N itin Shekapure
- 81. Arc WeldingGas TungstenArc Welding (GTAW) Process • No flux is used; hence there is no danger of flux entrapment. • The operator can exercise a better control on the welding process as there is clear visibility of the arc and the workpiece. • This process produces smooth and sound welds with fewer spatters. • No weld cleaning is required. • It produces high quality welds in non-ferrous metals. Advantages • Cost of equipment is very high. • By chance, if a filler rod end comes out of the inert gas shield, then it can cause weld metal contamination. • It is a slow process. • Separate filler rod is required. Disadvantages N itin Shekapure
- 82. Arc WeldingGas TungstenArc Welding (GTAW) Process Applications • Welding of sheet metal and thinner sections. • Precision welding in aircraft, chemical and instrumental industries. • Welding of expansion bellows, instrument diaphragms and transistor cases. • Welding of Al, Mg, Cu, Ni and their alloys, alloy of stainless steel, etc. N itin Shekapure
- 83. Arc Welding Gas MetalArc Welding (GMAW) Process (MIG) • This process is also called as Metal Inert Gas (MIG) Welding. • It is an arc welding process where coalescence (blend) is produced by hearing the workpiece with an electric arc generated between a continuously fed metal electrode and the workpiece. • Flux is not used, but the arc and molten metal are shielded by an inert gas. • The inert gas may be argon, helium, carbon dioxide or a gas mixture. N itin Shekapure
- 84. Arc WeldingGas MetalArc Welding (GMAW) Process Principle * In this process, the wire is fed continuously from a reel through a gun at constant rate, which also imparts current to the wire. * The current ranges from 100 to 400 Amp. depending upon the wire diameter and melting point of the wire. * Depending upon the current being used, the welding gun can be either air or water cooled. * Bare electrodes are generally used for MIG welding. * The electrode wire is generally in diameters of a 0.09 to 1.6 mm however sizes up to 3.2 mm are made. * In MIG welding, the welding area is flooded with an inert gas which will not combine with the metal. * The flow rate of this gas flow is sufficient to keep oxygen of the air away from the non-metallic surface while welding is being done. N itin Shekapure
- 85. Arc Welding Gas MetalArc Welding (GMAW) Process N itin Shekapure
- 86. Arc WeldingGas MetalArc Welding (GMAW) Process • Because of continuously feeding electrode, it is a faster process. • It can produce joint with deep penetration. • Both thin and thick workpieces can be welded. • Higher metal deposition rates are achieved by using MIG welding and this processcan be easily mechanised. • As flux is not used, MIG welding produces smooth, neat, clean and • spatter free welded surfaces. Advantages Disadvantages • This process is more complicated. • Welding equipments are more complex, costly and less portable. • As air drafts may disperse the shielding gas, MIG welding is not used for outdoor applications. N itin Shekapure
- 87. Arc Welding Gas MetalArc Welding (GMAW) Process • For welding of tool steels and dies. • For manufacturing of refrigerator parts • Also used in industries such as aircraft, automobile, pressure vessel and ship building. • Welding of carbon, silicon and low alloy steels, stainless steels, Al, Mg, Cu, Ni and their alloys can be done. Applications N itin Shekapure
- 88. Arc Welding Comparison betweenTIG and MIG Welding Processes Sr.No. TIG MIG 1. Non consumable electrodes are used. Consumable electrode wires are used. 2 Electrodes are made of tungsten or tungsten alloys. Bare welding wire is made of desired composition. 3. Electrode only generates an arc and does not melt. Electrode generates an arc and melt also. 4. Easier for thin plates and small parts. Widely used for thick plates (above 4 mm). 5. Welding torch is water cooled. Welding torch is air or water cooled. 6. Used for joining dissimilar metals. Used for joining similar metals. 7. It is a slow process. It is a faster process. 8. During the process, separate filler material is used. In this process, metal electrode will act as a filler material. 9. Cost of equipment is low. Cost of equipment is high. N itin Shekapure
- 89. Brazing It is ajoining process in which a filler metal is melted and distributed by capillary action between the faying (contact) surfaces of the metal parts being joined. Base material does not melt in brazing, only the filler melts. In brazing, the filler metal has a melting temperature (liquidus) above 450°C, but below the melting point (solidus) of base metals to be joined. Brazing N itin Shekapure
- 90. Filler materials usedfor brazing Brazing N itin Shekapure
- 91. Advantages of brazing •Brazing can be used to join a large variety of dissimilar metals. • Pieces of different thickness can be easily joined by brazing • Thin-walled tubes & light gauge sheet metal assemblies not joinable by welding can be joined by brazing. • Complex & multi-component assemblies can be economically fabricated with the help of brazing. • Inaccessible joint areas which could not be welded by gas metal or gas tungsten arc spot or seam welding can be formed by brazing. Brazing N itin Shekapure
- 92. Application of brazing •Fabrication of heat exchangers, pipe fitting, electric repair work. • Joining of carbid tips with mild steel shanks in cutting tool • Steam turbine • Joining dissimilar material • Joining non-metals to metals Brazing N itin Shekapure
- 93. Soldering Soldering • Soldering issimilar to brazing and can be defined as a joining process in which a filler metal with melting point (liquidus) not exceeding 450°C is melted and distributed by capillary action between the faying surfaces of the metal parts being joined. • As in brazing, no melting of the base metals occurs, but the filler metal wets and combines with the base metal to form a metallurgical bond. • Filler metal, called Solder, is added to the joint, which distributes itself between the closely fitting parts. N itin Shekapure
- 94. Advantages of Soldering •Soldering can be used to join a large variety of dissimilar metals. • In soldering process, the temperature is below the melting temperature of the workpiece, so there is no radical change in mechanical properties of the workpiece • Soldering can join the worpieces of different thinkness • Process is simple and chipper than brazing • Soldering joint require no finishing Soldering N itin Shekapure
- 95. Application of Soldering •For joining the components of electric circuits. • For joining thin sheets which are not subjected to load • Soldering can join the worpieces of different thinness • For joining the wires Soldering N itin Shekapure
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- 97. MCQ: 1. The manufacturingprocess can be defined as the a) Process of converting the semi finished product into finished product b) Process of converting the raw material into finished product using machines c) Process of assembling the components into a product d) Process of creating new product N itin Shekapure
- 98. MCQ: 2. The processin which molten metal is poured into mould of desired shape is called as a) Metal forming b) Metal forging c) Casting d) Injection moulding N itin Shekapure
- 99. MCQ: 3. The followingmaterial is not suitable for casting a) Aluminium b) Plastic c) Copper d) Alloy steel N itin Shekapure
- 100. MCQ: 4. The followingmaterial is suitable for casting a) Aluminium alloy b) Cast iron c) Copper alloy d) All of the above N itin Shekapure
- 101. MCQ: 5. The exampleof component manufactured by casting is a) Machine tool bed b) Nut c) Shaft d) Ball bearing N itin Shekapure
- 102. MCQ: 6. The followingcomponent cannot be manufactured by casting a) Flywheel b) Gears c) Machine tool bed d) Connecting rod N itin Shekapure
- 103. MCQ: 7. The metalforming process is also known as a) Deformation process b) Casting process c) Metal cutting process d) All of the above N itin Shekapure
- 104. MCQ: 8. In metalforming process a) A molten metal in semifinished condition is converted to finished product. b) A molten metal is poured into the mould of desired shape. c) A metal in hot or cold condition is plastically deformed into desired shape. d) B and c N itin Shekapure
- 105. MCQ: 9. The followingis not a metal forming process a) Forging b) Casting c) Rolling d) Drawing N itin Shekapure
- 106. MCQ: 10. The followingis a metal forming process a) Casting b) Turning c) Forging d) All of the above N itin Shekapure
- 107. MCQ: 11. The ________isan example of a metal forming process a) Forging b) Rolling c) Drawing d) All of the above N itin Shekapure
- 108. MCQ: 12. The followingcomponent cannot be manufactured by metal forming process a) Connecting rod b) Machine tool bed c) I-sections d) Crankshaft N itin Shekapure
- 109. MCQ: 13. In metalforming process, a) Substantial material is removed from the raw material to convert it to finished product. b) Fine material is removed from the semifinished raw material to convert it to finished product. c) No material is removed from the raw material. d) The removed material can be processed again and reused, N itin Shekapure
- 110. MCQ: 14. The followingis an example of metal forming process a) Milling b) Forging c) Shaping d) Grinding N itin Shekapure
- 111. MCQ: 15. The followingis an example of metal cutting process a) Drilling b) Forging c) Grinding d) Extrusion N itin Shekapure
- 112. MCQ: 16. The metalcutting process is also known as _______ a) Machining b) Metal forming c) Metal deformation d) All of the above N itin Shekapure
- 113. MCQ: 17. The __________isa metal cutting process a) Forging b) Grinding c) Turning d) All of the above N itin Shekapure
- 114. MCQ: 18. In castingprocess the cavity is called as a) Cast b) Pattern c) Mold d) Drag N itin Shekapure
- 115. MCQ: 19. The componentsof intricate shape can be easily manufactured by a) Forging b) Casting c) Sheet metal working d) Grinding N itin Shekapure
- 116. MCQ: 20. A componentobtained by pouring the molten metal into a mould and allowing it to solidify, is called a) Mold b) Pattern c) Casting d) Cope N itin Shekapure
- 117. MCQ: 21. A plantwhere the castings are produced is called a) Machine shop b) Foundry c) Mould shop d) Casting plant N itin Shekapure
- 118. MCQ: 22. ________ isthe upper part of the casting flask a) Drag b) Cope c) Mold d) Pattern N itin Shekapure
- 119. MCQ: 23. Cope isthe ________ a) Mould cavity b) Casting c) Lower part of the casting flask d) Upper part of the casting N itin Shekapure
- 120. MCQ: 24. Drag isthe ________ a) Mould cavity b) Lower part of the casting flask c) Upper part of the casting d) Pattern N itin Shekapure
- 121. MCQ: 25. Find theodd term out from the following a) Drag b) Cope c) Pull d) Foundry N itin Shekapure
- 122. MCQ: 26. Which ofthe following statement is incorrect ? a) Casting can produce components of high strength. b) Casting can produce components of intricate shapes. c) Casting produce gas cavities and blow holes inside the component. d) Aluminium components can be produced by casting process. N itin Shekapure
- 123. MCQ: 26. In_________ process,environmental pollution is high a) Forging b) Casting c) Machining d) None N itin Shekapure
- 124. MCQ: 27. I.C. engineblocks are manufactured by a) Forging b) Casting c) Shaping d) Both a and b N itin Shekapure
- 125. MCQ: 28. The firststep in casting process is a) Mould making b) Core making c) Pattern making d) Pouring of metal N itin Shekapure
- 126. MCQ: 29. _______ isthe replica of casting, used for making a cavity a) Mold b) Workpiece c) Pattern d) Cope N itin Shekapure
- 127. MCQ: 30. In castingprocess, the pattern is nothing but a) A final component produced. b) A mould made from sand. c) The replica of a casting used for making the mould. d) A design on the component N itin Shekapure
- 128. MCQ: 31. The followingstatement about casting process is correct a) The pattern is made by using mould. b) The final cast component is converted to pattern by machining process. c) The mould is made by using pattern. d) The pattern is required only for complicated shapes for comparison N itin Shekapure
- 129. MCQ: 32. In sandcasting, the pattern is made from a) Sand b) Clay c) Plaster of pans d) Wood N itin Shekapure
- 130. MCQ: 33. The followingmaterial cannot be used for pattern a) Wood b) Hastic c) Aluminium d) Sand N itin Shekapure
- 131. MCQ: 34. The processof making the model of a casting used for making a cavity or mould is called as a) Molding b) Modeling c) Pattern making d) Casting N itin Shekapure
- 132. MCQ: 35. In castingprocess, the mould is commonly made from a) Sand b) Cast iron c) Wood d) Plastic N itin Shekapure
- 133. MCQ: 36. In castingprocess, the mould is commonly made from a) Mold making b) Pattern making c) Core making d) Cope making N itin Shekapure
- 134. MCQ: 37. In casting,the material used for mould making is a) Cast iron b) Aluminium c) Sand d) Wood N itin Shekapure
- 135. MCQ: 38. In casting,the process of making a cavity which conforms to the shape of the desired component is called as a) Mold making b) Cavitation c) Pattern making d) Case making N itin Shekapure
- 136. MCQ: 39. In castingprocess, the holes or hollow spaces are obtained by using a) Drills b) Core c) Moulds d) Cavaties N itin Shekapure
- 137. MCQ: 40. The furnaceis essential for the following process a) Forging b) Shaping c) Casting d) None of the above N itin Shekapure
- 138. MCQ: 41. The moltenmetal is required in a) Forging b) Shaping c) Casting d) None of the above N itin Shekapure
- 139. MCQ: 42. _____________is ahole cut in a moulded sand to permit the molten metal to rise above the highest point in the casting. a) Riser b) Runner c) Cavity d) Basin N itin Shekapure
- 140. MCQ: 43. From pouringbasin, the molten metal is carried to the mould cavity through the _______ a) Riser b) Runner c) Cope d) Pipe N itin Shekapure
- 141. MCQ: 44. ________ helpsin escaping of the air, gas and steam from mould cavity a) Ventilator b) Runner c) Riser d) Both b and c N itin Shekapure
- 142. MCQ: 45. In sandcasting process, the metal is melted in a) Furnace b) Boiler c) Oven d) All of the above N itin Shekapure
- 143. MCQ: 46. The sequenceof steps in casting process is a) Core making - mould making - pattern making b) Mould making - core making - pattern making c) Pattern making - mould making - core making d) Mould making - pattern making - core making N itin Shekapure
- 144. MCQ: 47. The followingstatement is incorrect a) The components produced by sand casting have poor dimensional accuracy. b) The sand casting can produce extremely thin sections. c) In sand casting, each casting requires one mould. d) The components produced by sand casting have poor surface finish. N itin Shekapure
- 145. MCQ: 48. The followingstatement is correct: a) The sand casting can produce components with good dimensional accuracy. b) The sand casting can produce extremely thin sections. c) The sand casting process requires furnace. d) All (a), (b) and (c). N itin Shekapure
- 146. MCQ: 49. In sandcasting, core is made of a) Steel b) Wood c) Cast iron d) None of the above N itin Shekapure
- 147. MCQ: 50. In metalforming process, the component of desired shape and size is obtained through a) Pouring of molten metal in to cavity b) Machining of material c) Elastic deformation of metal d) Plastic deformation of metal N itin Shekapure
- 148. MCQ: 51. For metalforming process a) Force is necessary b) Both force as well as heat are necessary c) Heat is necessary d) Both force as well as heat are not necessary N itin Shekapure
- 149. MCQ: 52. The followingis not an example of metal forming process a) Extrusion b) Bending c) Forging d) Shaping N itin Shekapure
- 150. MCQ: 53. The processperformed by blacksmith is known as a) Casting b) Shaping c) Rolling d) Forging N itin Shekapure
- 151. MCQ: 54. The forgingoperation is performed under a) Breaking range of material b) Elastic state of material c) Plastic state of material d) Molten state of material N itin Shekapure
- 152. MCQ: 55. In _________process, the material is deformed to desired size and shape by the sudden application of force. a) Casting b) Forging c) Metal cutting d) Both a and b N itin Shekapure
- 153. MCQ: 56. The plasticityof material plays important role is _______ process a) Forging b) Casting c) Metal cutting d) welding N itin Shekapure
- 154. MCQ: 57. In forgingprocess, the material deforms a) Due to fracture b) Due to melting c) Without fracture d) Both b and c N itin Shekapure
- 155. MCQ: 58. In ancientdays, the implements of war such as : swords, knives, arrows were made by a) Casting process b) Shaping process c) Forging process d) Both b and c N itin Shekapure
- 156. MCQ: 59. The forgingprocess requires application of a) Tensile force b) Compressive force c) Shear force d) Constant force N itin Shekapure
- 157. MCQ: 60. In forgingpress, _________is fixed. a) Upper die b) Lower die c) Ram d) Both b and c N itin Shekapure
- 158. MCQ: 61. The mechanicalpress is used in ___________ operation a) Forging b) Casting c) Machining d) None of the above N itin Shekapure
- 159. MCQ: 62. The materialused for forging process a) Must be the brittle material b) Must be the ductile material c) Can be ductile or brittle material d) Must be the ferrous N itin Shekapure
- 160. MCQ: 63. The processused by blacksmith is a) Drop forging b) Casting c) Press forging d) None of the above N itin Shekapure
- 161. MCQ: 64. The dieand punch are used in a) Casting b) Punching c) Sheet metal work d) Both b and c N itin Shekapure
- 162. MCQ: 65. The sheet-metalwork is carried out at ______ temperature a) Recrystallization b) Melting c) 100°C d) Room N itin Shekapure
- 163. MCQ: 66. Piercing issimilar to ______________ a) Blanking b) Punching c) Slitting d) Notching N itin Shekapure
- 164. MCQ: 67. The nameplatescan be manufactured by the process known as a) Coining b) Forming c) Blanking d) Embossing N itin Shekapure
- 165. MCQ: 68. In weldingprocess, the essential elements is /are a) Filler material b) Pressure c) Heat d) Both a and c N itin Shekapure
- 166. MCQ: 69. The weldingis used in a) Manufacturing of crankshaft b) Manufacturing of engine cylinder c) Manufacturing of boilers, pressure vessels d) all of the above N itin Shekapure
- 167. MCQ: 70. The mostwidely used type of welding is a) Gas welding b) Electric arc welding c) Electric resistance welding d) A and B N itin Shekapure