MT Full

Manufacturing Technology
Asst. Prof Arun P Das

Credits : 3
Course Overview
Module 1 :- Metal Casting
Module 2 :- Rolling Process
Module 3 :- Forging
Module 4 :- Sheet metal forming
Module 5 :- Principles of clamping
Module 6 :- Welding Technology
Asst. Prof Arun P Das, ASIET kalady

Introduction to Manufacturing
Processes
What is manufacturing?
Raw materials Products
It encompasses
1. Design of products
2. Selection of raw materials
3. Sequences of processes through which
product is manufactured

Production Cycle

Module 1
CASTING
Expected outcomes:- At the end of this module the
students will be able to:
Acquire knowledge in various casting processes
and technology related to them

Module 1:- Metal Casting
Brief Introduction:-
What is casting?
Why it is a useful and important

manufacturing process?

Casting is the process whereby a part is produced
by solidification(of a molten metal) to take the
shape of a mold.

Why casting?
Versatile to many types of metals

Potential for rapid and cost
effective production
Wide range of length scale
(mm to m)
Complex part geometries
(Including internal cavities)
Classification of casting process

Sand casting

General sequence of all casting process
Pattern / mold making

Melt preparation
Mold filling
Cooling and solidification
Removal (Breakout) of the parts

Casting terminology

Sand Molds
1) Expandable Molds
2) Permanent Molds
3) Composite Molds

Patterns

Cores

Shell Mold Casting

Investment casting

Hot Chamber Die casting

Cold chamber Die casting

Module II:- Metal Rolling
Contents
Principles of Rolling Flat Rolling
Roll Force and Power Requirement
Hot and Cold Rolling
Defects in Rolled Plates - Rolling Mills
Ring Rolling Thread Rolling
Applications- Rolling of tubes, wheels, axles and
I-beams

Flat Rolling
Rolling is the process of reducing the thickness

by compressive applied through a set of rolls

Rolling Mills
The whole set up used for reducing the
thickness of w/p by rotating rollers are called
Rolling Mills
The different types of Rolling Mills are:-
Two High rolling mills
Three high rolling mills
Four high rolling mills
Cluster mill

Two High Rolling Mill

Three High Rolling Mill

Four High Mill

Cluster Mill

Rolling Defects
Rolling Defects
Surface defects Structural defects

Structural Defects
Structural Defects are on the Microscopic level
Structural defects are classified as
Wavy Edges
Edge Cracks
Zipper Cracks
Alligatoring

Wavy Edges and Zipper Cracks
Wavy Edges
Zipper Cracks

Edge Cracks and Alligatiroing
Edge Cracks
Alligatoring

Shape Rolling Process
Various shapes can be produced by shaping
rolling process, Like I beams, railroads, etc

1. Ring rolling process

2. Thread rolling

Module III
Metal Forging

FORGING
Forging - defined as metal working

process by which metals and alloys
are plastically deformed to the
desired shapes by the application of
compressive forces.
Classification:
Open Die Forging
Impression / closed die forging

Open Die Forging
Open die forging is performed between flat

dies with no precut profiles in the dies.
Larger parts over 200,000 lbs. and 80 feet
in length can be hammered or pressed into
shape this way.

Open Die Forging
It is used
- Number of components to be forged is
too small
- Size of the component is too large
Upper die
Billet
Lower die

Open Die forging steps
Starting stock Preliminary Upsetting
Progressive upsetting /forging to

disc dimensions

Impression Die Forging
Process Operations
In impression die forging, the work
piece acquires the shape of the die
cavities(impressions). Some of the
materials flows out and forms flash
The flash cools rapidly and presents
increased resistance to deformation and
helps build up pressure inside the bulk of
the work piece that aids material flow into
unfilled portions in the die cavity.
Closed die forging steps
Starting stock Initial upsetting
Flash

Forging Operation- Assignment
UPSETTING
HEADING
FULLERING
FLATTENING
EDGING
DRAWING OR NECKING
SETTING DOWN
SWAGING
PUNCHING
PIERCING
BENDING
Flash is to be removed
Punched holes may be needed
Improved surface finish or closer dimensional accuracy
may be desired.
Trimming Flash is trimmed before the forging is ready for
shipping.
Coining and ironing are essentially sizing operations with
pressure applied to critical surfaces to improve tolerances,
smoothen surfaces, or eliminate draft. Little metal flow is
involved in either operation and flash is not formed.
Coining is usually done on surfaces parallel to the parting

line.
Ironing is typified by the forcing of a cup-shaped component
through a ring to size on outer diameter.

Swaging--This operation is related to the open die
forging process whereby the stock is drawn out
between flat, narrow dies. But instead of the stock,
the hammer is rotated to produce multiple blows,
sometimes as high as 2,000 per minute. It is a useful
method of primary working, although in industrial
production its role is normally that of finishing.
Swaging can be stopped at any point in the length of
stock and is often used for pointing tube and bar
ends and for producing stepped columns and shafts
of declining diameter.

Forging die design
Standard terminology for various features of a typical impression forging die

Forging Machines
Variety of forging machines with a range of
capacities, speeds and speed-stroke
characteristics are present
The general classification of forging machines
are:
Presses
Hammers

Presses
Hydraulic Presses:

Mechanical Press

Hammers
Hammers available in a variety of designs:
Gravity Drop Hammer Power Drop Hammer

Counter blow Hammers

Extrusion
A compression forming process in which the
work metal is forced to flow through a die
opening to produce a desired cross-sectional
shape

Types of extrusion
Direct Extrusion
The ram forces the work billet metal to move
forward to pass through the die opening.
Indirect Extrusion
The die is mounted to the ram rather than at the
opposite end of the extruder container housing.

Ram Force

Hydrostatic Extrusion
Using hydrostatic system to reduce the friction and

lower the power requirement.
Sealing is the major problem.

Extrusion Defects

Chevron Cracking
(a) Chevron cracking (central burst) in extruded round steel bars. Unless the
products are inspected, such internal defects may remain undetected and later cause
failure of the parts in service. This defect can also develop in the drawing of rod, of
wire, and of tubes. (b) Schematic illustration of rigid and plastic zones in extrusion.
The tendency toward chevron cracking increases if the two plastic zones do not
meet. Note that the plastic zone can be made larger either by decreasing the die
angle or by increasing the reduction in cross-section (or both). Source: After B.
Avitzur. Asst. Prof Arun P Das, ASIET kalady
Drawing Process
Drawing is a metalworking process which uses
tensile forces to stretch metal.
As the metal is drawn (pulled), it stretches

thinner, into a desired shape and thickness.
Drawing is classified in two types: sheet metal
drawing and wire, bar, and tube drawing
Wire Drawing

Difference between Extrusion and Drawing
The extrusion pushes, Drawing Pulls

Extrusion

Module IV
Work holding devices and Principles of

locating elements

Work Holding devices
Jigs and Fixtures

Degrees of Freedom
Is the number of independent coordinates required to
represent the motion of an object in space
The DOF of a body in space is 12

6 Linear motion
6 Rotational motion
Principle of Locating elements
Principle of Perpendicularity
Principle of Minimum number of Pins
Principle of Extreme Positioning

Jig and Fixtures
Jig :- Is a Device to hold and positioning the

workpiece and Guiding and Locating the tool
Fixture:- Is device used to holding and

positioning but not for guiding the tool, Fixture
is heavier in construction

3-2-1 principle

Module VI
Welding Technology
CO :- Make use of knowledge in Various types of welding
process for fabrications of different parts

Welding
Welding is the process of joining similar or
dissimilar metals by the application of heat, with
or without the application of pressure and
addition of filler material.
Assembly two parts together by creating a fusion and/or

deformation in the interaction area.
Classification of welding
Classified in to TWO
Plastic welding
Fusion Welding

Classification of welding process
Welding processes can be classified on the
basis of following technological criteria like:-
Welding with or without filler material

Source of energy for welding
Arc and non-arc welding
Fusion and pressure welding

Welding with or without filler material
A weld joint can be developed just by melting
of the edges of plates
Such welding is called autogenous weld
Autogenous weld can be crack sensitive during
solidification . temperature range of the base
metal is about 750 -100 deg.C
Laser beam welding
Electron beam welding
Resistance welding,
Friction stir welding
Some of the welding processes are designed to
produce a weld joint by applying heat for
melting base metal and filler metal both
These processes are mostly used for welding
of thick plates (usually > 5mm)
Metal inert gas welding
Submerged arc welding
Flux cored arc welding
Electro gas/slag welding

Source of energy for welding
Almost all weld joints are produced by making a
atomic/metallic bond between metals , the same is
achieved either by melting the surfaces using heat or
applying pressure
Based on the type of energy being used for creating metallic
bonds between the components to be welded, welding
processes can be grouped as under:
Chemical energy: Gas welding, explosive welding,
thermite welding
Mechanical energy: Friction welding, ultrasonic welding
Electrical energy: Arc welding, resistance welding
Radiation energy: Laser beam welding, electron beam
welding
Arc and non-arc welding
Welding processes in which heat for melting
the surfaces is provided after establishing an
arc either between the base plate and an
electrode is called Arc welding
Shielded Metal Arc Welding: Arc between base metal and covered
Electrode
Gas Tungsten Arc Welding: Arc between base metal and tungsten
Electrode
Plasma Arc Welding: Arc between base metal and tungsten electrode
Gas Metal Arc Welding: Arc between base metal and consumable
electrode
Flux Cored Arc Welding: Arc between base metal and consumable
Electrode
Submerged Arc Welding

Non Arc welding
welding processes in which metallic bond is
produced using pressure or heat generated from
sources other than arc, like chemical reactions or
frictional effect etc., are called non-arc based
welding processes
Resistance welding processes: uses electric resistance
heating
Gas welding: uses heat from exothermic chemical reactions
Thermit welding: uses heat from exothermic chemical
reactions
Ultrasonic welding: uses both pressure and frictional heat
Diffusion welding: uses electric resistance/induction heating
to facilitate diffusion
Explosive welding: involves pressure
Gas welding
Gas welding is a fusion-welding process. It joins
metals using the heat of combustion of an
oxygen/air and fuel gas.
The fuel gases used are Acetylene, Hydrogen,
Propane or Butane.
Temperature produced ranges from 2600 C to
3300C.
The intense heat produced melts and fuses
together the edges of parts to be welded,
generally with the addition of filler material.
Working principle

Important types of gas welding are:
Oxy- acetylene gas welding - 32000C
Air- acetylene gas welding -25000C
Oxy- hydrogen gas welding -25000C

Oxy acetylene Gas Welding Set up

Filler metal
Filler metals are additional metal added to the
weld.
The composition of filler rod is same or nearly
the same as that of the part being welded.
Filler metal is usually available in the rod form.

Fluxes
During welding, if the metal is heated/melted in
air, oxygen from air combines with the metal to
form oxides
which result in poor quality, low strength welds.
The flux is fusible and is non-metallic.
Fluxes are available as powders, pastes or liquids.
Flux chemically reacts with the oxides and a slag
is formed.
Slag floats over the molten metal which is later
removed
Requirement of a good flux :
1. Should have a lower melting point than the

base metal.
2. Should protect the weld from surroundings.
3. Should not cause corrosive action to the weld.
4. Should help the formation of slag

Types of flame in Oxy-Acetylene gas
welding
The ratio of acetylene and oxygen in the gas
mixture are an important factor in gas welding.
At a ratio 1:1 , when there is no excess oxygen, it
is considered to be Neutral flame
When there is a greater oxygen supply, it becomes
Oxidizing flame
If the ratio of oxygen is deficient, the flame
becomes reducing or Carburizing flame

Neutral flame(1:1 ratio)
Neutral Flame is produced when equal volumes
of oxygen and acetylene are mixed in the
welding torch and burnt at the torch
The Temperature of the flame is of the order
about 3260C
The flame has distinct inner cone which is light
blue in color. It is surrounded by an outer flame
envelop which is darker blue

Oxidizing Flame
This is produced when excess of oxygen and
acetylene are mixed in the welding torch.
Oxygen to Acetylene ratio is 1.5 to 1
The Temperature of the flame is of the order about
3482 C.
Only in the welding of copper and copper based alloys
oxidizing flame is desirable, flame is harmful for
steels, because it oxidizes the steel

Carburizing flame
Reducing Flame is produced when oxygen supplied is
reduced.
The Temperature of the flame is of the order about 3037
C.
The temp of reducing flame is lower, so it is suitable for
applications require low heat, such as brazing, flame
hardening ..

Different flame in gas welding

Arc Welding
In arc welding the heat required is obtained from
the electrical energy
It involves either consumable or a non
consumable electrodes
It uses both AC or DC power supply
This arc produces temperatures of about 30,0000

Arc welding Set Up

Electrodes used in ARC Welding
consumable Non consumable
Non-consumable electrodes :
Non-consumable electrodes are those electrodes, which do not
consumed during the welding process.
Separate filler metals are necessary to fill the gap between the
joints.
Non-consumable electrodes are made up of higher melting
point materials like carbon , graphite etc
Consumable electrodes :
Consumable electrode possess more thermal efficiency than non-
consumable electrode.
Are consumed during welding operation. May be made of various
metals depending upon the purpose and chemical composition of
the metals to be welded.
Bare electrodes are used in coil form with out coating in MIG
Welding.
Metal Arc welding make use of coated electrode.
Commonly used core wire materials are : mild steel,
low alloy steel, nickel steel etc. Consumable Electrodes may be
classified into
Consumable electrodes:
Shielded Metal Arc welding
Submerged arc welding
Gas metal arc welding/Metal Inert gas
welding(MIG)
Flux cored arc welding
Electroslag welding
Non Consumable electrodes:
Gas Tungsten arc welding/Tungsten Inert gas
welding(TIG)
Plasma arc welding
Electron beam welding
LASER beam welding
Shielded Metal Arc Welding

Submerged Arc Welding

Gas-Tungsten-Arc Welding(GTAW)/
TIG welding

Plasma Arc Welding

Solid state welding
The joining Take place without fusion of the work
pieces
The principle is
If two clean surfaces are brought into
atomic contact with each other under
sufficient pressure, the form bond and produce
a strong joint

Ultrasonic welding

Friction welding(FRW)
In friction welding the heat required for
welding is generated through, friction at the
interface of the two components
One of the components remains stationary
while the other is placed in a chuck and rotated
at a high constant speed
After sufficient contact is established, the
rotating member is brought to a quick stop ,
while the axial force is increased
Sequence of operation of FRW

Resistance welding
The process in which the heat required for
welding is produced by means of electrical
resistance across the two components to be
joined
These process have major advantages, such as
not requiring consumable electrodes, shielding
gases, or flux

Major resistance welding techniques are:
Resistance Spot Welding
Resistance Seam Welding
Stud Welding
Percussion Welding

Resistance spot welding
Spot welding is a process of joining
overlapping sheets by the heat generated by
resistance to the flow of electric current
through the work-pieces held together under
force by two pointed electrodes

Sequence of operation

Resistance seam welding
Seam welding is a process of joining
overlapping sheets by the heat generated by
resistance to the flow of electric current
through the work-pieces held together under
force by two rotating circular electrodes

Two types of seam welding are:
1. Stitch welding
2. Roll Spot welding

Percussion welding
The Projection welding is similar to Spot
welding except that pointed electrodes are
replaced by flat and relatively large electrodes
and electrical and mechanical power applied is
more compared to Spot Welding.

Brazing and soldering
These two joining process permit lower
temperature than welding
These process require filler metals and external
source of heat
Brazing and soldering are arbitrarily
distinguished by temperature.
The temperature for soldering are lower than
for brazing , and the strength of the soldered
joint is much lower

Brazing
Brazing is a joining process in which a filler
metal is placed at or between the faying
surface to be joined, and the temp is raised
enough to melt the filler metal but not the
work pieces
The two main types of brazing processes are:
a) Ordinary brazing
b) Braze welding
The temp employed in brazing are below the
melting point of the base metal
The melting point of filler metals used for
brazing are generally 4500C
Brazing and braze welding

Filler metals used in Brazing

Fluxes used in brazing
The use of flux is essential in brazing, in order
to prevent oxidation and to remove oxide films
from work piece
Brazing flux are generally made of borax,
boric acid, borates fluorides and chlorides
Wetting agents are added to improve the
wetting characteristics of molten filler metal

Brazing Methods
Brazing is classified based on the heating
method
Torch brazing
Furnace brazing
Induction brazing
Resistance brazing
Dip brazing
Infrared brazing
Diffusion brazing

Torch Brazing
Torch Brazing is used to join both ferrous and
non ferrous metals. Heating is done by ordinary
gas welding equipment by burning gases such as
Air and Acetylene, oxygen and acetylene and
hydrogen and air and propane. Air gas torches
provides the lowest flame temperature. Oxy-
hydrogen torches are often used for brazing
aluminum and other non-ferrous alloys.

Induction brazing
In Induction Brazing, the parts to be welded are flux
coated along with the filler metal are properly
positioned and is then placed in an induction coil.
High frequency current is then passed through the
induction coil heating the parts to be welded. As the
melting point of filler metal is lower than the base
metals, filler metal melts and upon solidification
result in the joint

Soldering
In Soldering the metal pieces are joined by
heating the closely placed parts and then filler
alloy called Solder applied in the molten state
which upon solidification produces the desired
joint
During the process the filler alloy flows
between the two closely adjacent surfaces of
the work-pieces by capillary action.

Types of soldering
Soldering can be classified into two
Soft soldering : Used for joining of sheet
metals. Parts to be soldered are not exposed to
high temperatures and produces a less stronger
joint compared to Hard Soldered part.
Hard soldering : Also called as Silver
Soldering is used when strong joint is required
and hence exposed to high temperatures

Soldering fluxes

Different soldering methods are :
1. Soldering Iron Method
2. Torch method
3. Dip and wave method
4. Induction method
5. Resistance method
6. Furnace and hot plate method
7. Spray method
8. Ultrasonic method
9. Condensation method

Soldering iron method
Soldering iron method is the traditional tool for
soldering. Soldering iron has a soldering iron has a
copper tip which may be heated electrically or
coke or gas flame.
Soldering iron may vary in size depending up on
the use.
Tip of the soldering iron conducts heat from the
heat source to the components being joined. It
stores can conveys molten solder also.
Soldering iron are not limited to electrical
soldering.
Large cans and similar assemblies can be soldered
by Soldering Iron.

Dip and wave method
Dip soldering consist of dipping the assembled,
flux coated joints into the molten solder.
Dip soldering is used for mass production of joints.
Wave soldering is used to eliminate the drawbacks
of dip soldering, in wave soldering the parts to be
soldered are carried by a conveyor

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Manufacturing Technology

Asst. Prof Arun P Das

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Why it is a useful and important

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Versatile to many types of metals

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Pattern / mold making

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Rolling is the process of reducing the thickness

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Surface defects Structural defects

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Forging - defined as metal working

Asst. Prof Arun P Das, ASIET kalady

Open die forging is performed between flat

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Starting stock Preliminary Upsetting

Progressive upsetting /forging to

Asst. Prof Arun P Das, ASIET kalady

Starting stock Initial upsetting

Asst. Prof Arun P Das, ASIET kalady

Coining is usually done on surfaces parallel to the parting

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Standard terminology for various features of a typical impression forging die

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Gravity Drop Hammer Power Drop Hammer

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Asst. Prof Arun P Das, ASIET kalady

Using hydrostatic system to reduce the friction and