A course on

Manufacturing
Process
(Technical Studies)

By-
Praveen Srivastava
Assistant Professor
praveensrivastavacaet@gmail.com
What is manufacturing process?
• A sequence of operations, often
done on a machine or at a given
area to convert raw material or
semi finished product in to a final
product
Work Flow Of manufacturing process

Raw
material

Semi finished
product

Final product
Cement manufacturing process
Manufacturing process
 What is raw material?
• Materials used for manufacturing
process are raw materials
Examples-
• Ferrous metals
• Non ferrous metals
• Plastics
• Ceramics
• Composite materials etc.
Semi finished products
Semi finished products of fabrication
process
 Finished products
Forging final product Woolen final product
 Different manufacturing process
• Casting
• Forging
• Extrusion
• Injection moulding
• Wedging
• Slip casting
• Machining
• Welding etc.
 Properties of materials
• Mechanical properties
• Physical properties
Ex.-shape, size, weight and
behaviour in certain conditions etc.
• Chemical properties
Ex.-corrosion, resistance etc.
 Mechanical properties
• The mechanical properties of a metal
or those properties, which
completely define its behaviour
under the action of external loads or
forces.
 Loads
• Classification
-With respect to time
-With respect to direction
-With respect to area over which load is
acting
 Stress and strain
• Stress- the stress is defined as the internal
resistance set up by molecules of a material to
resist deformation
• Stress= P/A
where P= force or load applied, and
A= cross-section area
• Strain-he strain is defined as the deformation
or change in length per unit length
 According to nature of load types of
stress and strain
• Tensile stress and strain
• Compressive stress and strain
• Shear stress and strain
 Hooke’s law
• Hooke’s law states when a material is loaded
within elastic limit, stress is proportional to
strain.
• Hooke’s law holds good for tension as well as
compression
Stress-Strain curve (Mild steel)
Stress-strain curve (Brittle-Ductile
material)
 Failure of material
Failure of material Ductile fracture
Brittle failure
 Types of mechanical properties of
metals
• Toughness
• Resilience
• Elasticity
• Plasticity
• Ductility
• Malleability
• Brittleness
• Hardness
• Strength
• Stiffness
 Toughness and resilience
• Toughness-It is defined as the property of a
material by virtue of which it can absorb
maximum energy before fracture takes place.
• Resilience-It is defined as the property of a
material by virtue of which it stores energy up
to elastic limit.
Resilience Toughness
 Elasticity
•Elasticity of a material is its power of coming back
to its original position after deformation when the
stress or load is removed.
•Elasticity is a tensile property of its material.
•The greatest stress that a material can endure
without taking up some permanent set is called
elastic limit.
 Plasticity
• The plasticity of a material is its ability to
undergo some degree of permanent
deformation without failure.
• Plastic deformation will take place only after
the elastic range has been exceeded, beyond
yield point.
 Stiffness
• The resistance of a material to deflection
is called stiffness or rigidity.
• Steel is stiffer or more rigid than
aluminium.
• Stiffness is measured by Young’s modulus
E. The higher the value of the Young’s
modulus, the stiffer the material
 Ductility
• Ductility of a material enables it to draw out
into thin wire on application of the load.
• Mild steel is a ductile material.
• The wire of gold, silver, copper, aluminium, etc.
are drawn by extrusion or by pulling through a
hole in a die due to the ductile property. The
ductility decreases with increase of
temperature.
 Malleability
• Malleability of a material is its ability to be
flattened into thin sheets without cracking by
hot or cold working.
• Aluminium, copper, tin, lead, steel, etc. are
malleable metals.
 Brittleness
• The brittleness of a material is the property of
breaking without much permanent distortion.
• There are many materials, which break or fail
before much deformation take place. Such
materials are brittle e.g., glass, cast iron.
 Hardness
• Hardness is closely related to strength. It is the
ability of a material to resist scratching,
abrasion, indentation, or penetration
• It is directly proportional to tensile strength
and is measured on special hardness testing
machines by measuring the resistance of the
material against penetration of an indentor of
special shape and material under a given load
 Strength
• It is the resistance offered by a material when
subjected to external loading. So, stronger the
material the greater the load it can withstand
• The maximum stress that any material will
withstand before destruction is called its
ultimate strength
Creep failure
 Fatigue failure
S-N curve
 Ferrous and non ferrous metals
•Ferrous Metals-These are metals which
contain iron as the main constituent.
•They may have small amounts of other
metals or other elements added, to give the
required properties.
•All ferrous metals are magnetic and give
little resistance to corrosion
 Ferrous and non ferrous metals
•Non ferrous metals-These are metals which
do not contain any iron.
•They are not magnetic and are usually
more resistant to corrosion than ferrous
metals.
Examples are aluminium, copper, lead. zinc
and tin
 Hot Working and Cold Working
• Cold working refers to plastic deformation
that is usually, but not necessarily, carried out
at room temperature
• When the deformation is carried our above
recrystallization temperature, it is called hot
working
 Heat treatment process
•This process is controlled heating and cooling of
the alloys at various rates
•The effects of thermal treatment depend on the
alloy, on its composition and microstructure, on the
degree of prior cold work
Thermal treatment process-
•Recovery
•Recrystallization
•Grain growth
Different heat treatment processes
• Annealing
• Normalising
• Quenching
• Tempering
• Case hardening
 Annealing
• Method- Heating the metal above the
recrystallization temperature for a definite
time and cooling very slowly in the furnace
itself
• Time of soaking is 1 hour per inch thickness of
material
• Objectives-it makes the metal fine grained,
soft, ductile without internal stresses or
strains
• Ex. Tube drawing and wire drawing
 Normalising
• It consists Heating the metal above the
recrystallization temperature for a definite
time and cooling it in still air
• It produces harder and stronger steel
• It removes internal stresses
• Refine grain structure
• It increases the yield point, ultimate tensile
strength and impact values etc.
 Quenching
• It consists of heating the steel above
recrystallization temperature and then rapidly
cooling it in oil, water or brine
• It produces a fine grained structure, greater
hardness, maximum tensile strength,
minimum ductility and internal stresses
 Tempering
• After quenching process steel is reheated to
lower temperature and then then cooled at
room temperature
• This reheating and cooling is tempering
• It relieves the strain in hardened steel,
decreases brittleness and restores ductility
and reduces hardness
• It makes the steel tough
 Case Hardening
• In this process a hard wear resistant and shock
resistant surface is produced on steel having a
tough core inside
• It consists of carburising a piece of steel,
quenching either mildly or rapidly reheating again
to refine and harden the case, quenching rapidly
at a low temperature and cooling slowly.
• Carburising
• Nitriding
• Cynaiding