Manufacturing process FE

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
•Pressing and
heating of
metal
powder
mixture
Sheet
metal
working
•Making
components
from metal
sheets
•Bending,
drawing,
blanking,
punching
Metal
joining
•Joining of
the
components
•Welding,
brazing,
soldering,
Reverting
screw
fastening
pressing.
Process
effecting
change in
properties
• Change of
properties
• Heat
treatment
hot
working,
cold
working
Metal
forming
•Plastic
Deformation
into desired
shape
•Forging press
work, rolling,
extrusion
Manufacturing Processes

4. Casting Process
It is the process in which the molten metal is poured into a mould or cavity
Casting process
Melting the metal such as cast
iron, copper, brass, aluminum.
Pouring the molten metal into
cavity or mould.
Allowing the molten metal to
cool and solidify in the mould.
Removing the component from
mould

5. 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

6. • 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
•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.

8. Special Casting Process
Permanent mould Casting process
 In this process permanent mould is
used
Casting are made by poring the molten
metal into mould under gravity.
Thereforee it is also called as gravity die-
casting process.
Advantage of this process is it gives very
high dimension accuracy and surface
finishing
Due to this process production rate
become high and it require low work
space
Limitation of this process is high initial
cost
Due to metallic mould it is mot suitable
for large size and high melting point
casting

9. Special Casting Process
Die-Casting process
it is done by injecting the molten
under high pressure of 10-210MPa,
into permanent mould.
It is also called as gravity die-casting
process.
Advantage of this process is it can
produce highly intricate shapes.
It produces extremely thin section
It require also high initial cost so
that process is economical for mass
production only.
Application of this process is used to
making electrical as well as
automobile components.

10. 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

11. 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
 in this process the material is
deformed into desired shape
between two parts called dies.
The forging press consist of
lower die fix. Upper die
connected motor through crank
rod shaft and gear.
During downward stoke of ram
the upper die exert the sudden
compressive force on the hot
material. Then it converted into
desired shape.

13. 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

14. Forging process based on Types of dies
Open forging Process Closed forging Process
In this process the material
is deform between the two
flat dies
In this process the material is
deform between the two dies
which have the impression of
desired shape

15. Hand forging process Drop forging process
Forging process based on mode of
application of compressive force
It is process of deforming the
hot material into desired shape
by applying the repeated blow
of hand held hammer.
It is process of deforming the hot
material into desired shape by
rising die and allowing it to fall so
impact the blow on material

16. Press forging process Machine forging process
It is process of deforming the
hot material into desired shape
by slow squeezing action
It 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
It is similar press forging
process but difference is it is in
horizontal direction.

17. 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

18. 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
The pieces of metal sheer which
is to be given a shape is kept
over the die.
The force is applied through the
punch.
Small clearance is kept between
the punch and die for the
thickness of metal-sheet.
The tool used on the press for
carrying out the sheet metal
working are called die and punch

20. 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

21. • 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

22. • 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

24. 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
It is process of forming flat metal-
sheet into a three dimensional
hallow shape by means of punch
and die
Example:- drums, cans etc
It is the process of shaping a metal-
sheet into a surface of desired
profile
In this process shape of die and
punch is directly reproduced.
Ex:- aircraft parts, steel furniture,
toys, etc.

25. Sheet Metal Forming Process
3)Coining (squeezing) 4) Embossing
It is process of cold squeezing of
metal in which all the surface are
confined within a set of dies
Example:- coins, medals, badges
It is the process of producing the
depressed or raised impression of
letter figure or design on metal
sheet.
It is used in production of name
plate identification tags etc.

26. Sheet Metal Forming Process
5)Bending
It is a metal forming process by
which a straight length metal
sheet is transformed into a
curved length.
Bending methods
1. V-bending
2. U-bending
3. Edge bending
4. Angle bending
5. Curling

27. 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 doesn’t 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)

28. 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

29. 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)

30. Welding
process
Pressure
welding
Forge welding
Electric
resistance
Spot welding
Seam welding
Projection
welding
Pressure
welding
Non-pressure
welding
Non-pressure
thermit welding
Electric arc
welding
Shlelded Metal
arc welding
Tugston insert
gas arc welding
Metal insert gas
arc welding
Carbon arc
welding
Gas welding
Types of
Welding

32. Pressure (Plastic) welding
Forge welding
 Forge welding is the pressure welding
process in which heating and
external pressure require.
 No need of filler metal
 The heating is followed by upsetting
of edge and finally complete by
hammering.
 The forge welding process is used by
black-smith to make domestic articles
and farm tools
Resistance welding
 it is the pressure welding process in
which heating and external pressure
require.
No need of filler metal
In resistance welding the amount of
heat generated is given by H=I2RT
Types of resistance welding is
1. Spot Welding
2. Seam welding
3. Projection Welding
 The advantage of this welding is
very fast so production rate
becomes high
 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.

33. Non-Pressure (Fusion) welding
Electric arc welding
 It is non-Pressure welding in which heating is
done due to electric arc and no need of
external pressure but require filler material.
 Advantages:- the process can be used for any
complicated shape.
 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
 it is the non-pressure welding
process in which heating is done due
to combustion of gas
filler metal is generally used
In resistance welding the amount of
heat generated is given by H=I2RT
Types 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

34. 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

35. 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

36. Types of joints

37. BRAZING
Brazing is the process of joining two
workpieces, made of similar or
dissimilar materials, by heating them to
specified temperatures above 450°C but
below the melting temperature of the
workpieces and using a non famous
filler material.
The filler materials used are usually
alloys of copper, silver or nickel.

38. Advantages Limitations Applications
•Can join a large variety of
dissimilar metals with
dissimilar thickness.
•Thin sheets and pipes can
be joined
•Non metals too can be
joined
•Process can be automated
for mass production.
•Produces pressure tight
and corrosion resistant
joints.
•Requires little or no
furnishing other than flux
removal.
Strength of brazed joint is
lessr than the welded joint.
To obtain the desired fit
cost of machinery is high.
Cost of filler material is
high.
Large surfaces cannot be
brazed easily.
Fabrications of various
systems.
Joining of carbide tips with
mild steel shanks in cutting
tools.
Steam turbines.
Joining of dissimilar metals
and non metals of
nonuniform thickness.

39. Soldering
• Soldering is the process of joining two
workpieces, made of similar or dissimilar
materials, by heating them to specific
temperature below 450°C and using a non
ferrous filler material.
• Commonly used filler material is tin-lead alloy.

41. Advantages Limitations Applications
•Joins variety of dissimilar
materials,
•Joins workpieces of
different thickness.
•Process is simpler and
cheaper.
•Soldered joints require no
finishing
•Strength of soldered joint
is very less.
•Large surfaces cannot be
soldered.
•Lead in the filler material
is toxic.
•In electric circuits and
components.
•Joining thin sheets not
subjected to load.
•Joining wires.