The document discusses various manufacturing processes including casting, machining, surface finishing, sheet metal working, metal forming, and metal joining processes. It provides details on the key steps and types of processes for casting such as sand casting and die casting. It also summarizes metal forming techniques like forging, extrusion and rolling. Furthermore, it covers sheet metal processes involving cutting, piercing, punching and forming. Metal joining methods like welding, brazing and soldering are also summarized.
Analysis of machining parameters using MQL conditionPadmalochan Nanda
In this project an investigation is done related to the role of MQL on tool wear and surface roughness in turning operation at industrial speed-feed combination
Analysis of machining parameters using MQL conditionPadmalochan Nanda
In this project an investigation is done related to the role of MQL on tool wear and surface roughness in turning operation at industrial speed-feed combination
Basic concepts of forging process are included.Forging is a very important production process as we know.To learn about forging,this slides would help you a lot.
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
Basic concepts of forging process are included.Forging is a very important production process as we know.To learn about forging,this slides would help you a lot.
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
Chapter 3: Metal Works, Casting & Heat Treatmentsyar 2604
This topic explains the processes of metal works and casting. It also describes the types and purpose of heat treatment for steels and the effects of heat treatment on mechanical properties of steels.
Event Management System Vb Net Project Report.pdfKamal Acharya
In present era, the scopes of information technology growing with a very fast .We do not see any are untouched from this industry. The scope of information technology has become wider includes: Business and industry. Household Business, Communication, Education, Entertainment, Science, Medicine, Engineering, Distance Learning, Weather Forecasting. Carrier Searching and so on.
My project named “Event Management System” is software that store and maintained all events coordinated in college. It also helpful to print related reports. My project will help to record the events coordinated by faculties with their Name, Event subject, date & details in an efficient & effective ways.
In my system we have to make a system by which a user can record all events coordinated by a particular faculty. In our proposed system some more featured are added which differs it from the existing system such as security.
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
Presented at NUS: Fuzzing and Software Security Summer School 2024
This keynote talks about the democratization of fuzzing at scale, highlighting the collaboration between open source communities, academia, and industry to advance the field of fuzzing. It delves into the history of fuzzing, the development of scalable fuzzing platforms, and the empowerment of community-driven research. The talk will further discuss recent advancements leveraging AI/ML and offer insights into the future evolution of the fuzzing landscape.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdf
Unit 3 manufacturing process3
1.
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
3.
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.
7.
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.
12.
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
19.
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
23.
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)
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
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.
40.
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.