2. Casting
⢠Pouring of
metal into
mould
⢠Sand
casting Die
casting
centrifugal
casting
Machining
⢠Material
removal by
cutting tool
⢠Turning
shaping
milling
drilling
boring.
Surface
finishing
⢠Surface
finishing
by tool
⢠Grinding,
honing
lapping,
buffing,
polishing.
Power
metallurgy
â˘Pressing and
heating of
metal
powder
mixture
Sheet
metal
working
â˘Making
components
from metal
sheets
â˘Bending,
drawing,
blanking,
punching
Metal
joining
â˘Joining of
the
components
â˘Welding,
brazing,
soldering,
Reverting
screw
fastening
pressing.
Process
effecting
change in
properties
⢠Change of
properties
⢠Heat
treatment
hot
working,
cold
working
Metal
forming
â˘Plastic
Deformation
into desired
shape
â˘Forging press
work, rolling,
extrusion
Manufacturing Processes
3. Casting Process
It is the process in which the molten metal is poured into a mould or cavity
Casting process
ďMelting the metal such as cast
iron, copper, brass, aluminum.
ďPouring the molten metal into
cavity or mould.
ďAllowing the molten metal to
cool and solidify in the mould.
ďRemoving the component from
mould
4. Casting Process
Sand Casting
Process
Special Casting
Process
Plaster mould
Casting Process
Permanent
mould Casting
Process
Die-Casting
Process
Shell mould
Casting Process
Centrifugal
Casting Process
Continuous
Casting Process
Types of Casting Process
5. ⢠Pattern is model or replica of a
casting used for making a cavityPattern Making
⢠It is the process of making a cavity
which confirm to the shapeMould Making
⢠Core is pre defined shape made
from the sand and placed into
mould
Core Making
⢠Metal is melted in furnace and
poured in to mould cavity
Melting and
Pouring of metal
⢠Molten metal is allowed to cool
and solidify in the mould.
Cooling and
Solidification
â˘After solidification the sand mould is
broken to take out casting is then mould
cavity. The cleaned and inspected.
Cleaning and
Inspection
SandCasting Process
It is the process in which the casting are made using sand mould.
6. Special Casting Process
Permanent mould Casting process
ďź In this process permanent mould is
used
ďźCasting are made by poring the molten
metal into mould under gravity.
Thereforee it is also called as gravity die-
casting process.
ďźAdvantage of this process is it gives very
high dimension accuracy and surface
finishing
ďźDue to this process production rate
become high and it require low work
space
ďźLimitation of this process is high initial
cost
ďźDue to metallic mould it is mot suitable
for large size and high melting point
casting
7. Special Casting Process
Die-Casting process
ďźit is done by injecting the molten
under high pressure of 10-210MPa,
into permanent mould.
ďźIt is also called as gravity die-casting
process.
ďźAdvantage of this process is it can
produce highly intricate shapes.
ďźIt produces extremely thin section
ďźIt require also high initial cost so
that process is economical for mass
production only.
ďźApplication of this process is used to
making electrical as well as
automobile components.
8. Advantages
⢠No restriction of shape
⢠No restriction on the
type of metal or alloy
⢠Economical suitable for
both small and big size
component
⢠Cost of component is
very low
⢠Good dimension
accuracy
⢠High production rate
⢠Better in daming
property.
Limitation
⢠Restrictions on the
minimum thickness of
component, less then
6mm cannot be
manufactured.
⢠Casting process require
melting metals so it is
high power consuming
process.
⢠In this process
environment pollution
is very high.
⢠The blow holes, gas
cavity and non-metallic
insursions in process
reduce the strength of
component.
Application
⢠Automobiles:- Engine
block, piston cylinder,
piston ring , gear box,
gear blanks, etc
⢠Aircraft:- Jet engine
blades gearbox, etc
⢠Machine tools:-
machine tools beds,
frames, gear box
housing, gears, etc.
⢠Turbines:- wheels and
housings of steam and
hydraulic turbine,
turbine vanes etc.
⢠Piping:- water supply,
sewer pipes, etc
Casting Process
9. Metal Forming process
It is the process in which the component of desire size and shape is obtained
through the plastic deformation of metal or alloy under extremely applied force.
General forging process
ď in this process the material is
deformed into desired shape
between two parts called dies.
ďThe forging press consist of
lower die fix. Upper die
connected motor through crank
rod shaft and gear.
ďDuring downward stoke of ram
the upper die exert the sudden
compressive force on the hot
material. Then it converted into
desired shape.
10. Forging Process
Based on die of
forging process
Open die
forging
process
Closed die
forging
process
Based on mode of
application of
compressive force.
Hand
Forging
Process
Drop Forging
Process
Press
Forging
Process
Drop Forging
Process
Machine
Forging
Process
Types of Forging Process
11. Forging process based on Types of dies
Open forging Process Closed forging Process
ďźIn this process the material
is deform between the two
flat dies
ďźIn this process the material is
deform between the two dies
which have the impression of
desired shape
12. Hand forging process Drop forging process
Forging process based on mode of
application of compressive force
ďźIt is process of deforming the
hot material into desired shape
by applying the repeated blow
of hand held hammer.
ďźIt is process of deforming the hot
material into desired shape by
rising die and allowing it to fall so
impact the blow on material
13. Press forging process Machine forging process
ďźIt is process of deforming the
hot material into desired shape
by slow squeezing action
ďźIt is process in which the cross-
section of the hot material or
work piece is increased locally
with corresponding reduction
in is length by slow squeezing
ďźIt is similar press forging
process but difference is it is in
horizontal direction.
14. Advantages
⢠High dimensional
accuracy and surface
finish.
⢠Reduce the grain size
due to this it improve
the strength.
⢠Produces high strength
and weight ratio.
⢠Produce the component
with thin section without
reducing strength.
⢠Produces the component
without shrinkage
cavities blow holes and
machine scratches.
⢠Component offers better
resistance to shock and
vibration.
Limitation
⢠Brittle material like cast
iron cannot be forged
⢠Complex component
with intricate shapes
can't be produced by
this process.
⢠Normally forged
component cost more
than cast component
⢠The cost of forging dies is
high.
Application
⢠It is use for making I.C.
engine parts like
crankshafts, connecting
rods, rocker arms etc
⢠It is use for making gear
blanks, levers
⢠it also use for making
automobile and aircraft-
component.
Metal forging process
15. Sheet Metal Process
⢠It is the process of manufacturing of component or parts from the sheet metals
⢠It is carried out with the machine tool called as press therefore it is called as Press working
Sheet metal process
ďThe pieces of metal sheer which
is to be given a shape is kept
over the die.
ďThe force is applied through the
punch.
ďSmall clearance is kept between
the punch and die for the
thickness of metal-sheet.
ďThe tool used on the press for
carrying out the sheet metal
working are called die and punch
16. Sheet-Metal cutting or shearing
process
Piercing
Punching
Blanking
Performing
Slitting
Lancing
notching
Sheet-Metal forming
process
Drawing and deep
drawing
Bending
Forming
Coining
embossing
Sheet Metal Working Process
17. ⢠It is the operation of
producing a hole of any
desired shape in metal sheet
by using a punch and die
Piercing
⢠It is the operation of
producing a cicular hole in a
metal sheet using punch and
a die
Punching
⢠It is the operation of cutting
out a piece of required shape
from a metal sheet using
punch and a die
Blanking
Sheet Metal cutting Process
It is the process in the metal-sheet is cut using punch and die and desire part of
sheet is used and remaining part of metal-sheet is discarded
18. ⢠It is the operation of producing a
number of evenly spaced holes in
metal sheet by using a punch and
die
Perforating
⢠It is the operation of cutting metal
sheet in a straight line along the
length
Slitting
⢠It is the operation of cutting out
part of metal sheet through some
portion of its length and then being
the cut portion
Lancing
⢠It is the operation of removal of
small part of the metal sheet of the
desired shape from the edge of the
metal sheet.
Notching
19. Sheet Metal Forming Process
It is the process in in which the flat plate of metal sheet is converted into a desired
shape without wasting material.
1) Drawing and deep drawing 2) Forming process
ďźIt is process of forming flat metal-
sheet into a three dimensional
hallow shape by means of punch
and die
ďźExample:- drums, cans etc
ďźIt is the process of shaping a metal-
sheet into a surface of desired
profile
ďźIn this process shape of die and
punch is directly reproduced.
ďźEx:- aircraft parts, steel furniture,
toys, etc.
20. Sheet Metal Forming Process
3)Coining (squeezing) 4) Embossing
ďźIt is process of cold squeezing of
metal in which all the surface are
confined within a set of dies
ďźExample:- coins, medals, badges
ďźIt is the process of producing the
depressed or raised impression of
letter figure or design on metal
sheet.
ďźIt is used in production of name
plate identification tags etc.
21. Sheet Metal Forming Process
5)Bending
ďźIt is a metal forming process by
which a straight length metal
sheet is transformed into a
curved length.
ďźBending methods
1. V-bending
2. U-bending
3. Edge bending
4. Angle bending
5. Curling
22. Advantages
⢠Component produced
by sheet-metal working
are light in weigh.
⢠The Component
produced by sheet-
metal working are
cheap.
⢠The rate of production
is high.
⢠It gives high
dimensional accuracy
and good surface
finishing
⢠It doesnât require skill
labour
Limitation
⢠There is limitation on
the thickness of metal-
sheet is used
⢠The sheet metal
component have
relatively low strength.
Application
⢠Automobile
⢠Aircraft body parts
⢠Steel furniture
⢠Utesils
⢠Electronic appliances
Sheet-metal working
(Press working)
23. Metal Joining Processes
It is the process in which the various parts are joined together to form product.
Welding
Brazing
Soldering
Mechanical Fasteners
Adhesive Bending
24. Welding
It is the process of joining two metallic part together by heating them to a plastic or
semi molten state .
Welding process require three input
1. Heat :- heat is required for fusing
the two part. It is essential for
welding
2. Application of pressure :- the
application of pressure is an
optional input element in
welding process.
3. Filler Material:- it is also optional
input. In some welding process it
supplied by welding rod.
Welding
Application
of Pressure
(Optional)
Filler
Material
(Optional)
Heat
(Essential)
26. Pressure (Plastic) welding
Forge welding
ďź Forge welding is the pressure welding
process in which heating and
external pressure require.
ďź No need of filler metal
ďź The heating is followed by upsetting
of edge and finally complete by
hammering.
ďź The forge welding process is used by
black-smith to make domestic articles
and farm tools
Resistance welding
ďź it is the pressure welding process in
which heating and external pressure
require.
ďźNo need of filler metal
ďźIn resistance welding the amount of
heat generated is given by H=I2RT
ďźTypes of resistance welding is
1. Spot Welding
2. Seam welding
3. Projection Welding
ďź The advantage of this welding is
very fast so production rate
becomes high
ďź Limitation is it require high initial
cost and high current supply.
The two metal part to be joined are heated to a plastic state and forced together by an
external pressure to make the joint.
27. Non-Pressure (Fusion) welding
Electric arc welding
ďź It is non-Pressure welding in which heating is
done due to electric arc and no need of
external pressure but require filler material.
ďź Advantages:- the process can be used for any
complicated shape.
ďź Some common electric arc welding process
are
1. SMAW (Shield Metal Welding)
2. TIG (tungsten inert gas) arc welding
3. MIG (metal inert gas) arc welding
4. Carbon arc welding
Gas welding
ďź it is the non-pressure welding
process in which heating is done due
to combustion of gas
ďźfiller metal is generally used
ďźIn resistance welding the amount of
heat generated is given by H=I2RT
ďźTypes of Gas welding is
1. Oxyacetylene gas welding
2. Ox hydrogen gas welding
3. Air acetylene gas Welding
The two metal part to be joined are heated to molten state and allowed to solidify to
make the joint with out external pressure
28. Uses an electric arc to coalesce metals
Arc welding is the most common method
of welding metals
Electricity travels from electrode to
base metal to ground
29. Advantages
⢠Gives light weight
construction .
⢠High strength joint
⢠High rate of production
⢠Mechanization and
automation possible
⢠Ability to produce
complicated shapes.
⢠Used effectively for
repeating broken parts
⢠Low cost process
⢠Ability to produce fluid
tight joints.
Limitation
⢠Not possible to
disassemble the parts.
⢠Joint weak against
vibration
⢠Quality and strength of
joint is operated
depend
⢠Result is residual
stresses distortion
⢠Gives harmful
radiations
Application
⢠Fabrication of bridges
electric and
transmission towers
⢠Manufacturing of
automobile bodies
⢠Building of ships and
aircrafts
⢠Manufacturing of
boilers, pressure
vessels, storage tanks,
pipelines
⢠Manufacturing of steel
furniture, window and
doors frames, grills
Welding