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1. BASIC MECHANICAL ENGINEERING
Dr. G.Praveen Kumar
Assistant Professor
Department of Mechanical Engineering
Unit-II
MANUFACTURING PROCESSES

2. Course Outcomes:
CO1: Understand the different manufacturing processes.
CO2: Explain the basics of thermal engineering and its applications.
CO3: Describe the working of different mechanical power transmission systems
and power plants.
CO4: Describe the basics of robotics and its applications.

3. BASIC MECHANICAL ENGINEERING
Unit-II
Manufacturing Processes:Principles of Casting, Forming,
joining processes, Machining, Introduction to CNC
machines, 3D printing, and Smart manufacturing.
Thermal Engineering – working principle of Boilers, Otto
cycle, Diesel cycle, Refrigeration and air-conditioning
cycles, IC engines, 2-Stroke and 4-Stroke engines, SI/CI
Engines, Components of Electric and Hybrid Vehicles.

4. Manufacturing
Manufacturing basically implies making of goods or articles and
providing services to meet the needs of mankind.
Manufacturing process Manufacturing is the process of turning raw
materials or parts into finished goods through the use of tools,
human labor, machinery, and chemical processing.

5. Classification of manufacturing processes

6. Principles of Casting
• The casting process is the manufacturing process in which molten material
such as metal is poured into the casting cavity or mold of the desired shape
and allowed to harden or solidify within the mold, after solidification the
casting is taken out by ejecting or by breaking the mold.

7. Casting Terminology
• Pattern: An approximate duplicate or true replica of required product of casting
• Flask/Box: The rigid metal or a wooden frame that holds the moulding material
• Cope: Top half of the moulding box
• Drag: Bottom half of the moulding box
• Core: As and shape that is inserted into a mould to produce internal features of a casting such as
holes.
• Gating System: Channels used to deliver the molten metal to the mould cavity
• Sprue: The vertical passage in the gating system
• Runner: The horizontal channel of the gating system
• Gate: Channel which connects runner and mould
• Riser: A vertical opening in the mould
• Act as a vent for gases
• Helps to confirm that the mould is completely filled
• Act as a reservoir of molten metal to feed and compensate for shrinkage during solidification of a
casting

8. Have you seen any similar process before?
 What do we control?
1. Size & shape of cavity and mold
2. Mixture composition
3. Temperature
4. Cooling time
5. Carefully remove it

9. Basic steps in Casting
1. Pattern making
2. Mold making
3. Melting of metal and pouring
4. Cooling and solidification of metal
5. Cleaning of casting and inspection

10. Basic Casting Process

11. Basic Casting Process

14. Advantages
• Product can be cast as one piece and hence the metal joining process
is eliminated.
• Very heavy and bulky parts can be manufactured
• Metals difficult to be shaped by other manufacturing processes may
be cast (eg: Cast Iron)
• Casting can be employed for mass production as well as for batch
production.
• Complex shapes can be manufactured

15. Disadvantages of Casting
• Casting process is a labour intensive process
• Not possible for high melting point metals
• Dimensional accuracy, surface finish and the amount of defects
depends on the casting process
• Allowances required.

16. Applications
• Transportation vehicles(eg.:engines)
• Machine tool structures.
• Turbine vanes
• Mill housing
• Valves
• Sanitary fittings
• Agricultural parts
• Construction &atomic energy applications.

17. Types of the casting process:
 Shell Casting
 Investment Casting
 Full Molding
 CO2 Molding
 Sand Casting
 True Centrifugal Casting
 Gravity Die Casting
 Pressure Die Casting
 Hot Chamber Die Casting
 Cold Chamber Die Casting and
 Slush Casting

18. Forming
Forming is a mechanical process used in manufacturing industries wherein materials
(mostly metals) undergo plastic deformations and acquire required shapes and sizes by
application of suitable stresses such as compression, shear and tension.

19. Types
The type of Forming Operations is as follows
•Rolling
•Forging
•Extrusion
•Wire Drawing
•Roll forming
•Stamping

20. Rolling

22. Rolling
Roll forming is a continuous process which converts sheet metal into an
required shape using consecutive sets of mated rolls, each of which
makes only incremental changes in the form. The sum of these small
changes in form is a complex profile. The Forming Process.

24. Forging
Forging is a manufacturing process involving the shaping of
metal using localized compressive forces. The blows are
delivered with a hammer or a die. Forging is often classified
according to the temperature at which it is performed: cold
forging, warm forging, or hot forging.

25. Extrusion
Extrusion is a metal forming process in which metal or work piece is
forced to flow through a die to reduce its cross section or convert it
into desire shape. This process is extensively used in pipes and steel
rods manufacturing. The force used to extrude the work piece is
compressive in nature.

27. Wire drawing 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).
Wire Drawing

28. Roll forming
Roll forming is a continuous process which
converts sheet metal into an engineered
shape using consecutive sets of mated rolls,
each of which makes only incremental
changes in the form. The sum of these small
changes in form is a complex profile. The
Forming Process.

29. Stamping
Stamping is the process of placing flat sheet metal in
either blank or coil form into a stamping press
where a tool and die surface forms the metal into a
net shape.