Manufacturing Processes

• Manufacturing processes :
It is a process of converting raw material into finished product using machines.
Processes means various available engineering methods we have to select the
proper methods to get the fastest, easiest, high strength, high quality & least
expensive product.

Manufacturing Processes

Sheet
Metal Surface Powder Metal Metal Surface
Casting Machining
forming Finishing Metallurgy Working Joining treatment
• Casting processes: The casting is a process of melting or liquefying the
metal such as cast iron, copper or aluminium , alloys, plastics & pouring it into
mould to get the final product after solidification.
• The various casting processes are :
1) Sand mould casting 2) Permanent mould casting 3) Die casting 4) Centrifugal
casting.
• Metal Forming : In metal forming process, a metal in hot or cold condition is
plastically deformed into desired shape by application of external load. In this
process no metal is removed or waste, it is only displaced & deformed in to desired
shape.
Some of the metal forming processes are : Forging, rolling, drawing & extrusion.
• Machining Processes : In this process , a metal is removed by means of
cutting tools so as to get the desired shape & size.
Various machining processes are : Turning, milling, drilling, boring, shaping.
• Surface finishing processes : It is the process of removing the small amount of material
from the surface to get the high dimensional accuracy & surface finish to the components. Some of the
surface finishing operations are : Grinding, Honing, Lapping, Buffing, Polishing, electro plating.

• Powder Metallurgy : It is the process of mixing the fine powder of different material in to
required proportion , pressing & heating the compact in a die. The heating is done at below the melting
temperature of powder material. This heating process is known as sintering.

• Sheet Metal Working processes : Sheet metal working includes the process of
manufacturing the components from the sheet of thickness 0.1 mm to 6 to about 6 -8 mm. The sheet
metal working is carried with the help of PRESS , so it is called as Press working.
Commonly used sheet metal processes are : Bending, Drawing, Blanking, Punching, embossing.

• Metal Joining Processes : It is the process of joining the two machine components of same
or different material with each other.
The different joining processes are : Welding, Brazing, soldering, riveting, Fastening Nut & bolt,
Pressing.

• Surface Treatments : These processes are used to improve or enhance the certain properties of
different material so as to make them suitable for particular applications. Some of the surface treatments
are : Heat Treatments, Hot & cold working, Shot peening
 Casting Processes
• Casting processes in which the required shape of the product is obtained by pouring the
molten metal into a mould cavity & allowing it to solidify, the cavity having the same shape
as the final product.
Mould :- The mould is made by using
pattern & core prepared. The mould is
prepared by packing the sand around the
pattern . It creates the hollow shape
(cavity) having the same shape as final
product.
Mould box : The upper half & lower
half forms the mould box.
Cope : The upper part of mould box is
known as cope.
Drag : The lower part of mould box is
known as drag.
Casting : The final product obtained
from process is known as casting.
Foundry : The complete plant where
casting is produced is known as foundry
or foundry shop.
Types of casting processes :

Casting Processes

Sand Casting Process Special Casting Process

1) Ceramic mould Casting

2) Permanent mould casting
3) Die casting
4) Shell mould casting
5) Centrifugal casting
6) Continuous casting
• Sand casting : The process in which the castings are made using sand mould is
known as Sand casting process.
• Steps in sand casting process are :
1) Pattern making 2) Mould making 3) core making 4) melting & pouring of
metal 5) Cooling & solidification of casting 6) cleaning & inspection of casting

• Pattern making : Pattern is defined as the model or replica of a casting,

used for making a cavity or mould. The commonly used material for
making pattern are : wood, metals like CI or aluminium , plastic ,
polystyrene. But commonly used material for pattern is wood.
• Mould making : Mould making is the process of making a cavity which is
having same shape as final product.

In mould making, pattern is kept in a split type flask , upper half is called as COPE &
lower half is called as DRAG & moulding sand is filled , rammed around the pattern
along with the gating system. Before filling sand around the pattern, oil is sprinkled on
pattern so that sand will not stick on surface of pattern. Gating system consist of
pouring basin, sprue, runner, ingate & riser. The COPE & DRAG have matching
brackets with holes. By placing cope on drag & inserting pins in brackets , one single
flask is formed.
After ramming, both the flask are separated & pattern is taken out of the sand , the
shape of pattern is left in the rammed sand.
• Gating system : It is a system that provides passage to the flow of liquid to cavity
& maintains definite pressure (head) on the liquid until it solidifies.
Pouring Basin (Cup) : It has a conical shape which opens on the top surface of the mould. The
conical basin or cup always full of molten metal to maintain proper pressure on the solidifying
metal in the cavity.
Sprue : It is slightly tapering vertical tube at the bottom opening of the cup & conveys liquid
metal towards runner.
Runner : These are horizontal passage provided to distribute liquid metal coming down the
sprue to the various parts of mould cavity.
Ingate : These are the orifices through which molten metal enters mould cavity.
Riser : These are the vertical passage connected to last portion of mould or connected to end
opposite to gate. It has two functions :
a) Riser acts as a reservoir of molten metal during solidification & compensate for
the liquid shrinkage by maintaining a head of metal.
b) It allows to escape air, gases, steam from the mould cavity as mould is filled with the molten
metal.
• Core making : Core is predetermined shape made from the sand , which is made separately
from mould, & placed in the mould before pouring the molten metal. Core is used to
produce hole or hollow space in casting.

• Melting & pouring of metal :

The molten metal is melted in furnace like,
cupola, open hearth furnace, pit furnace &
molten metal is poured in pouring basin with
the help of crucible. From pouring basin molten
metal is carried in to mould cavity through
runner. The molten metal is poured till it rises
through the riser as it indicates molten metal is
raised above the highest point in the mould
cavity.
Video 1

Final Product Video 2

• Cleaning & Inspection of Casting : After solidification sand mould is broken to take out
the casting from the mould cavity. The casting is then clean & inspected. The cleaning
involves gating system is removed by chipping or sawing & surface is inspected for any
defects.
• Advantages : 1) The components of intricate shape can produce which cannot be
manufactured by any other manufacturing methods.
2) The components weighing from few grams to few tons can be produced by casting processes.
3) Any metal or its alloy can be used in casting process also non metals like plastics can be used.
4) It is economical for small or large productions.
5) Special casting processes give dimensional accuracy & surface finish except the sand casting.
6) Cost of final product is low.
7) Casting components have better damping properties.
• Disadvantages : 1) Components having thickness less than 6mm cannot be manufactured.
2) It is a high energy consumption process.
3) Process requires larger man power compared to other manufacturing processes.
4) It requires large space for manufacturing activity.
5) The environmental pollution is high.
6) The blow holes, gas cavities & nonmetallic inclusions in casting reduces strength of the
casting.
7) The components produced by sand casting have poor dimensional accuracy as well as
poor surface finish.
• Applications : Automobiles ---Engine blocks, cylinder blocks, pistons, piston rings, gear box
housings, gears, bearing housings etc.
• Aircrafts : Jet engine blades,
• Machine Tools : Machine beds, frames, column,
• Turbine wheels, Housing of steam & hydraulic turbines, turbine blades
• Water supply pipes, sewer pipes, sanitary fittings.
 Metal Forming Process
• Metal forming is the process in which the component of desired shape & size are obtained
through the plastic deformation of the metal or alloy under the action of externally applied
force.
The external forces applied on the metal may be tensile , compressive, shear
force, or combination of forces. On application of initial forces first metal deform
elastically. At certain stress level Sy called yield stress, the deformation changes from elastic
to plastic. On increasing stress, more & more plastic deformation is obtained.
At some high stress Sf, the metal fractures.

The metal forming process can be carried out

in hot & cold conditions of metal.

The various metal forming processes are :

Forging, Rolling, Extrusion, Wire drawing,
deep drawing, bending etc.
Black smithy is best example of metal forming process.
• Forging process : Forging is the oldest known method of metal working. In which a piece of metal is
heated & can be given desired shape & size by hammer blows or exerting a pressure on it by press
machine. It is also known as chipless forming process.
• In forging process, the material is heated to a temperature at which its elastic property completely
disappear. This temperature is known as forging temperature. When external force is applied to such a
hot metal, it deforms plastically in the direction of least resistance without fracture.
The forging process consists of a die which is
having same shape of desired product , split
into two halves. The upper half of die is
connected to the ram which is operated by
crank & connecting rod mechanism.
The lower half is fixed to frame. The electric
motor drives the crank shaft through the belt,
flywheel & gears. The rotary motion of crank
shaft is converted into the reciprocating motion
of ram.
. During downward stroke of the ram, the upper
di die exerts large compressive force on billet due
to which billet deforms into the desired shape.
The forging press operates at 30 to 60 strokes
per minute.
• The material used for forging process must be ductile & following materials are used for forging process
: Low & medium carbon steel, alloy steel, stainless steel, copper & aluminium alloys.
• The components manufactured by forging process are, Spanner, Screw driver, Chisel, Crank shaft, Crank,
Connecting rod, gear blank etc.
Advantages :
1) It is a very fast process.
2) As the dies are machined correctly, high dimensional accuracy is obtained.
3) Die forging components have higher strength & toughness.
4) The thin section material can forged without reducing the strength. This gives light weight components.
5) The forging components have better resistance to shock & vibrations.

Disadvantages : 1) The dies are very costly so initial investment is high & also cost of forging part is high.
2) It requires correct alignment of two half dies otherwise it may damage component or die itself.
3) The complex shape parts cannot be manufactured by forging process.
Applications : Crankshafts, connecting rods, rocker arms, gear blanks, automobile & air crafts parts,
spanner, screw driver, chisel.
• Types of Forging processes :

Forging Processes

Hot Forging Process Cold Forging Process

Closed Die Forging

Open Die Forging Process Process

Hand Machine or
Drop Forging Press Forging
Forging Upset Forging
Process Process
Process Process
• Hot Forging Process : In hot forging process the deformation of material into predetermined
shape is carried out at a temperature greater than its recrystallization temperature.
• The temperature at which all strained, distorted grains are completely replaced by new
crystals is called as the Recrystallization temperature. On heating above TRC the small grain
grow in size & stabilizes at some size is called as Grain Growth Region.

• Forging temperature for steel : 11000 C to 12000 C.

• Forging temperature for Aluminuim : 3500 C to 5250 C.

During forging process at this high temperature oxidation of metal may takes place in certain
cases. In this case, hot forging is carried out in controlled atmosphere. Such a hot forging
process is known as ISOTHERMAL FOGING PROCESS.
Advantages :
1) In this process, strain hardening of metal is avoided.
2) Less force is required to deform the material in required shape as heating decreases yield
strength of material.
3) This process increases ductility of material.
4) It improves homogeneity of material.

Video
• Disadvantages :
1) In hot forging, scale formation takes place due to oxidation of material.
2) High dimensional accuracy cannot be maintained.
3) The components may lead to warping during cooling process.
4) In hot forging grain structure of material may vary.
5) Hot material requires special handling & manipulation machines.

• Cold forging process : In cold forging process, the deformation of material into
predetermined shape is carried out at a temperature below recrystallization temperature,
usually at room temperature.
• This process is preferred when material is soft like aluminium.

Advantages : 1) High dimensional accuracy is maintained.

2) No oxidation of components takes place.
3) No warping of metal components.

Disadvantages : 1) The amount of deformation is limited due to work hardening.

2) The force required to deform the material is large due to work hardening.
3) High internal stresses developed during process may lead to failure of product.
4) The product obtained is hard due to high internal stresses. Video
• Classification of Forging Process on basis of types of dies.
1) Open Die Forging Process 2) Closed Die Forging Process

In open die forging, the material or workpiece In closed die forging, the material or workpiece
is deformed between two flat dies or dies is deformed between two dies have the same
having simple shape. shape as the desired shape.

Video
• Forging is again classified on the basis of application of force :
1) Hand Forging 2) Drop Forging 3) Press Forging 4) Upset or Machine forging

Hand Forging : It is a process of deforming the material or workpiece into desired or required
shape by application of repeated hammer blows. In this Blacksmith operator adjust the position of
die to get the desired shape to the material. In this process operator has to apply past experience
to deform the material into desired shape.
• Drop Forging Process : It is the process of deforming the hot material into the desired
shape by using the arrangement of pneumatic cylinder & allowing it fall under gravity to
impart the blows on the hot material.

In this, lower die is fixed to frame & upper die is fixed to

the RAM which moves up & down in the guide ways.
Other end of RAM is connected to piston through piston
rod which is operated pneumatically.
During upward motion of piston compressed air is
supplied to cylinder through port A & piston moves from
BDC to TDC.
As piston reaches TDC, compressed air supply to the port
A is cut-off. Due to this, the RAM along with die falls
down to impart impact load or blow to the hot material.
The impact load on the material can be increased by
supplying air through port B to the upper part of piston.
It is also known as drop hammer process as die & ram acts
as a mechanized hammer.

Video
• Press Forging Process : It is the process of deforming the hot metal in to the desired shape
by slow squeezing action.

Video
• Upset or Machine forging Process : In this process cross section of hot material is increased
locally by corresponding reduction in the length of material.
The process is as same as press forging process only difference is that in case of press forging
, the operation is in vertical direction but in case of upset forging operation is in horizontal
direction.
HUF is mainly used for manufacturing of bolts, rivets, screws, making nails, automobile
fittings.
Example : Forming head of bolt.
 Sheet Metal Working

It is the process of manufacturing the

components from flat sheet of thickness .1
to 6 to about 6mm to 8mm.
The machine on which operation carried out
are press machine so it is also known as
press working.

Advantages : 1) Light weight components.

2) The cost of components are cheap.
3) The rate of production is high
4) It give high dimensional accuracy.
5) Surface finish obtained is also high
6) It does not require skilled labour.
Disadvantages :
1) Limitations on thickness of sheet used.
2) Components have relatively low
strength.

Applications : Automobile & air craft bodies, Utensils, steel furnitures

 Sheet Metal
Working

Sheet Metal Sheet Metal

Shearing or forming
Cutting

Drawing & Forming Coining Embossing

Bending
Deep Drawing

Piercing Punching Blanking Perforating Slitting Lancing Notching

 Punching

Piercing

Piercing
 Blanking

Perforating
 Slitting

Lancing

Notching
Sheet Metal Forming Process
Drawing
 V- Bending Bending
U- Bending

Edge- Bending
Angle- Bending

Curling- Bending
Forming
Coining (Squeezing)
Embossing
Wire Drawing

VIDEO
 Metal joining Processes
• Welding
• Brazing
• Soldering
Welding
 Electric Arc Welding

• Electric arc is initiate by striking the tip of electrode against the workpiece
& then withdrawing it quickly to maintain the arc. ( The gap is 3-6 mm)
• Due to gap and voltage, large currnt jumps between workpiece and
electrode, producing immense heat (24000c-40000c)
• The metal along the seam melts and subsequently solidify, forming the
welded joints.
VIDEO
 Advantages
• Versatile process that can be used for thin & thick sections
• Used for welding any complicated shapes.
• Good quality weld of high strength.
• Setup is least expensive.
• Does not required external pressure.
Disadvantages
• Process requires filler material
• An electrode isconsumed, causing downtime.
• Quality depend on skill of operator.
Types of Electric Arc Welding
• Sheilded Metal Arc Welding (SMAW)
• Tungsten Inert Gas Welding (TIG)
• Metal Inert Gas Welding (MIG)
• Carbon Arc Welding
Soldering

Video
Brazing

Video