3. WHAT IS MANUFACTURING PROCESSES??
-> Manufacturing process, are the steps through which raw
materials are transformed into a final product. The manufacturing
process begins with the product design, and materials
specification from which the product is made. These materials
are then modified through manufacturing processes to become
the required part.
INPUT
Raw Materials
Manufacturing
Processes on
Materials
Output
Finished Products
4. IMPORTANCE OF MANUFACTURING PROCESSES
There are many importance and significance of manufacturing in our life as
follows:-
Manufacturing supplies the products which satisfy our basic needs, maintain
our good health and insure our safety and prosperity.
Manufacturing industry spends 73% of all private R&D expenditures in the U.S.
Manufacturing helps the country to increase their GDP(Gross Domestic
Product). For example, In 1996, manufacturing accounted for 21% of Gross
Domestic Product in the U.S.
Export of manufactured goods expands trade and commerce , and brings in
much needed foreign exchange.
5. CLASSIFICATION OF MANUFACTURING PROCESSES:-
1. On the basis of primary shaping processes:-
-> Casting.
-> Forging.
-> Powder metal forming.
-> Gas cutting.
-> Bending.
-> Shearing.
6. 2. On the basis of Machining processes:-
-> Drilling.
-> Grinding. Traditional Method.
-> Milling.
-> Electric Discharge.
-> Laser Beam. Non-Traditional and Advanced Method.
-> Electron Beam
3. On the basis of joining processes:-
-> Welding.
-> Brazing.
-> Soldering.
-> Riveting.
-> Adhesive joining.
7. 4. On the basis of Surface finishing processes:-
-> Polishing.
-> Plating.
-> Galvanizing.
-> Metal Spraying.
-> Painting.
5. On the basis of processes changing the properties:-
-> Heat Treatment.
-> Cold Working.
-> Hot Working.
9. ENGINEERING MATERIALS:-
Engineering materials refers to the group of materials
that are used in the construction of manmade
structures and components. The primary function of an
engineering material in to withstand applied loading
without breaking.
The major classification of engineering materials are as follows:-
-> Metals.
-> Polymers.
-> Ceramics.
-> Composites.
10. 1). METALS:-
• Metals used in manufacturing are usually alloys.
• Alloys are more important commercially than pure metals.
• Alloys are composed of two or more elements of which at least one
must be a metal.
• Metals and alloys can be divided into two groups;
(a) Ferrous.
(b) Non-ferrous.
2). POLYMERS:-
• Compound formed by repeating structural units called ‘mers’.
• Atoms share electrons to form very large molecules.
• Consists of carbon plus one or more of H, O, N, Halogens etc.
• It divided into three Categories;
(a) Thermoplastics , (b) Thermosetting , (c) Elastomers
11. 3). CERAMICS:-
• Crystalline:-
-> Manufactured by powder mixing, compacting and firing.
-> Compounds consisting of metallic and non-metallic components.
-> Typical non metallic elements are oxygen, nitrogen and carbon.
• Amorphous
->Manufactured by melting and casting.
4). COMPOSITES:-
• Consists of two or more phases that are processed separately and are
then bonded together.
• They have properties superior to their constituents.
• Properties of composites depend upon;
(1) Components
(2) Shape of the components
(3) Method of combining these phases
12. FERROUS MATERIALS/ALLOYS:-
Ferrous materials & alloys have iron as the base element. These alloys
include steels and cast iron.
Ferrous alloys are the most common metal alloys in use due to the
abundance of iron, ease of production and high versatility of the
material.
The biggest disadvantage of many ferrous alloys is low corrosion
resistance.
Carbon is an important alloying element in all ferrous alloys. In
general, higher levels of carbon increases strength and hardness, and
decreases ductility and weldability.
When alloyed with carbon , it acquires greater commercial value and
use than any other metal/alloy.
13. TYPES OF IRON:-
1) WROUGHT IRON:-
-> It is the purest form of iron.
-> It contain about 0.1% of carbon.
2) PIG IRON:-
-> The components of pig iron are as follows:-
(a) Carbon- 4%
(b) Silicon- 1.5%
(c) Manganese- 1%
(d) Sulphur- 0.04%
(e) Phosphorus- 0.4%
14. 3) CAST IRON:-
• Cast iron is a ferrous alloy containing. high level of carbon, generally
greater than 2%.
• Carbon Present in the cast iron can take the Form of graphite or carbide .
• Cast irons have a low melting temperatures which makes them well suited
to casting.
• Used primarily in sand casting.
• may also contain elements like Si, Mn, P, etc. to enhance various
properties.
• Grey cast iron is most commonly used.
• Used in making heavy machine casting, IC engine casting.
• Types of cast iron :
-> White cast iron – contains 1.7%-2.3% carbon in form of cementite.
-> Grey cast iron - contains 3%-3.5% carbon in form graphite.
-> Nodular cast iron – contains 3.2%-4.4% carbon.
-> Malleable cast iron – contains 2%-3% carbon.
-> Mottled cast iron – contains upto 2.75% carbon in form of graphite.
15. 4) STEEL:-
• An iron-carbon alloy containing 0.02% -2.11%. (carbon).
• They most important category within the ferrous metal group.
• May also contain elements like Si, Mn, Cr, Mo, Ni, W etc. to enhance various
properties.
• Applications:-
-> construction.
-> Transportation.
-> customer goods.
• Most of steel are plain carbon steels.
16. CLASSIFICATION OF STEEL:-
1) Based on percentage of carbon:-
(a) Low Carbon Steel:-
->It contains Carbon upto 0.3%.
-> It has high Ductility, malleability formability and weldability.
-> It has low strength, Hardness and corrosion Resistivity.
-> It is also known as mild Steel.
-> It doesn't respond to Heat treatment.
(b) Medium Carbon Steel:-
->The Percentage of carbon is 0.3%-0.6%
-> It has high strength and hardness in Comparison to Low carbon steel.
-> It has low malleability, Ductility, formability and weldability .
-> It has high corrosion resistance.
-> It is used for axes, gears, shafts, and machine parts.
17. (c) High Carbon Steel:-
-> It contain 0.6%-1.5% Percentage Carbon in high carbon steel.
-> It has high strength, hardness and corrosion resistance.
-> It responds excellently to the Heat treatment.
-> It common uses are cutting tools, drills, springs etc.
-> It has less Ductility, malleability, formability and weldability.
2) Based on the Alloying Elements Contained:-
(a) Silicon Steel:-
->It contains more than 0.8% Silicon
-> It has high yield strength and Toughness.
-> If we add 1-2% Si then it is known as Navy steel.
-> If we add 3% Si then it is known as Hadfield silicon steel.
1.1 It has high magnetic property.
1.2. It is used in armatures, cores and Pores of electric motors.
18. (b) Manganese Steel:-
-> It contains more than 5% manganese.
-> It has high toughness and eliminate Red Shortness of steel.
-> If we add 17% Mg then it is known as Hadfield Manganese steel.
1.1 It retain Hardness by work Hardening.
1.2 It is used to make shuffel bucket.
(c) Chromium Steel:-
-> It is carbide former.
-> It has high Strength and hardness.
->If in steel, chromium is Present more than 10.3% then,it is form stainless steel.
19. 5) STAINLESS STEEL:-
• Stainless steel have good corrosion resistance, mostly due to
addition of chromium as an alloying ingredient.
• Stainless steels have a Chromium compositions of at least 11%.
Chromium forms a Protective inert film of chromic oxide over the
material and Prevents oxidation.
• If steel contain Cr greater then 10.3% then it is known as stainless
steel.
• If steel contain more carbon then we have to increase the
percentage of chromium in steel.
20. CLASSIFICATION OF STAINLESS STEEL:-
1) Ferritic Stainless Steel:-
• The % of Cr in ferritic stainless Steel is 16-18%.
• Percentage of carbon should not exceed 0.35%
• It has how weldability, and machinability.
• They can be cold worked.
• It is used to make deep drawn vessels for Chemical industry.
• Iron Present in form of α-Ferritic.
• It Present in BCC Lattice.
• It is soft, and It has magnetic Property.
• The main component of ferritic Stainless steel is ferrite.
21. 2) Martensitic stainless steel:-
• The Percentage of Chromium is 18-24% and of carbon is 0.8-1.2%.
• It has high hardenability and strength.
• It has low weldability, Formability, Machinability.
• It is used to make cutlery, surgical instrument.
• It responds to the Heat treatment.
• It is present in BCC Lattice.
• The main component of martensite stainless steel is martensitic.
• It has magnetic property.
3) Duplex Stainless Steel:-
• It is the combination of 50% of austenite stainless steel and 50% of ferritic
stainless steel.
• It contain 21%-25% chromium and 5%-7% nickel.
22. 4) Austenite Stainless Steel:-
• Main component is Austenite.
• It has high weldability, for malleability, machinability.
• It is stable only at temp greater than 723°C. hence, we Place Ni in
Austenite then it will drop down the temperature of Austenite to room
temperature.
• It is costliest than martensitic and ferritic stainless steel.
• The Percentage of carbon is 18% and of nickel is 8%.
• The corrosion Resistance is best because of Presence of Ni and austenite.
• It is used in chemical industries which uses strong chemical.
• It is present in FCC type. And It has not magnetic Property.
• Types of ASS are 304, 302, 301, 316, where 316 is Costly among them
because it is used in food grade.
