Module- 5
Manufacturing
• Manufacturing Processes: Basic processes like
machining, casting, forging etc. welding, brazing and
soldering.
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What is Manufacturing?
✔ The word manufacture is derived from two Latin words manus
(hand) and factus (make); the combination means “made by hand”
✔ “Made by hand” accurately described the fabrication methods that
were used when the English word “manufacture” was first coined
around 1567 A.D.
✔ Most modern manufacturing operations are accomplished by
mechanized and automated equipment that is supervised by
human workers
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What is Manufacturing?
The process of converting raw materials, components, or parts into finished goods that
meet a customer's expectations or specifications. (or)
Transformation of materials and information into goods for the satisfaction of human
needs.
Manufacturing
Technologically Economically
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Manufacturing
Manufacturing
Secondary
Primary
Final shape and size
Basic shape and size to with tighter control
the material on dimension, surface
characteristics etc.
Casting, forming,
powder
metallurgy Material removal
processes
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Technological Importance
Technology - the application of science to provide society and its
members with those things that are needed or desired
• Technology provides the products that help our society and its
members live better
• What do these products have in common?
– They are all manufactured
• Manufacturing is the essential factor that makes technology
possible
Economical Importance
Indian Economy
Sector: %GDP Gross domestic product )
Agriculture and natural resources 17
Construction and public utilities 13
Manufacturing 16
Service industries* 54
100
* includes retail, transportation, banking, communication,
education, and government
Manufacturing - Technological
• Application of physical and chemical processes to alter the
geometry, properties, and/or appearance of a starting material to
make parts or products
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Manufacturing - Economic
• Transformation of materials into items of greater value by one or
more processing and/or assembly operations
✔When iron ore is converted into steel,
value is added.
✔ When sand is transformed into
✔ glass, value is added.
✔ When petroleum is refined into plastic,
value is added.
✔ when plastic is moulded into the
complex geometry of a patio chair
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Manufacturing Process
Manufacturing Processes
Casting: Forming & Machining: Joining: Finishing:
Shaping:
Expendable Turning Welding Lapping
mold Rolling
Milling Brazing Polishing
Permanent Forging
mold Drilling Soldering Deburring
Extrusion
Boring Bonding Surface
Drawing treating
Grinding assembly
Sheet forming coating
Shaping
Broaching
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Manufacturing Processes
1. Welding
2. Casting
Fundamentals of Manufacturing
3. Forging Processes
4. Rolling (ZERO wastage of
5. Metal Forming parent material)
6. Extrusion
7. Machining Machining Processes
(Wastage of parent material)
Casting of Metals
Process in which molten metal flows by gravity or other force
into a mold where it solidifies in the shape of the mold cavity
• The term casting also applies to the part made in the process
• Steps in casting seem simple:
1. Melt the metal
2. Pour it into a mold
3. Let it freeze
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Introduction to casting
1. Cast Product or Final product
2. Pattern
3. Drag Box
4. Moulding Sand
Metallic CUBE
5. Cope Box
6. Pouring basin and runner
7. Riser
8. Mould cavity
9. Foundry Shop
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Introduction to casting
1. Cast Product or Final product
2. Pattern
3. Drag Box
4. Moulding Sand
Metallic CUBE
5. Cope Box
6. Pouring basin and runner
7. Riser
Wooden CUBE 8. Mould cavity
9. Foundry Shop
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Pattern
Mould Box
Mould Box
Flat Surface - Ground
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Pattern
Mould Box
Mould Box
Pattern
Mould Box
Ground
Flat Surface - Ground
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Mould box filled with Moulding SAND
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Rammer
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Again add
Moulding SAND
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Rammer
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Invert the Mould Box with
pattern
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Inverted Mould Box with
pattern
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Another Mould BOX
Inverted Mould Box with
pattern
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Conical Shaped Wooden
pieces
Inverted Mould Box with
pattern
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Inverted Mould Box with
pattern
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Moulding
Sand
Inverted Mould Box with
pattern
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Rammers
Inverted Mould Box with
pattern
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Rammers
Inverted Mould Box with
pattern
Sand
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Sand
Inverted Mould Box with
pattern
Sand
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Inverted Mould Box with
pattern
Sand
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Mould Box – 2 Sand
Mould Box – 1
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Remove (Pull up) the pattern
with care
Sand
Pattern
Cavity
(Mould cavity)
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Align the two mould boxes
Sand
Pattern
Cavity
(Mould cavity)
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Remove the Conical Shaped Wooden
pieces
Sand
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Sand Mould Box – 2
Mould Box – 1
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Sand Mould Box – 2
Mould Box – 1
(Drag BOX)
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Sand Mould Box – 2
(Cope BOX)
Mould Box – 1
(Drag BOX)
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COPE
Sand
DRAG
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COPE
Sand
DRAG
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COPE
Sand
Mould
Cavity
DRAG
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Pouring basin and runner
COPE
Sand
Mould
Cavity
DRAG
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RISER Pouring basin and runner
COPE
Sand
Mould
Cavity
DRAG
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Molten metal is poured through
the Pouring basin and runner
Sand
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Molten metal is poured through
the Pouring basin and runner
Sand
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Molten metal is poured through
the Pouring basin and runner
Sand
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When the mould cavity is
full, excess molten metal Molten metal is poured through
rises through the RISER
the Pouring basin and runner
Sand
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When the mould cavity is
full, excess molten metal Molten metal is poured through
rises through the RISER
the Pouring basin and runner
Sand Allowed to
solidify
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Solidification complete
Break the mould
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Solidified Metal
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Final Product
Solidified Metal
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Remove the unwanted projections by machining
Final Product
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Final Product
Final Product or CASTING
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Cooling Curve for a Pure Metal
Pure metals solidify at a constant temperature. During freezing the
latent heat of solidification is given off. Most metals shrink on
solidification and shrink further as the solid cools to room
temperature.
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Nucleation and Growth
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Solidification of Pure Metals
• Due to chilling action of mold wall, a
thin skin of solid metal is formed at the
interface immediately after pouring
• Skin thickness increases to form a shell
around the molten metal as solidification
progresses
• Rate of freezing depends on heat transfer
into mold, as well as thermal properties
of the metal .
• randomly oriented grains of small size
near the mold wall, and large columnar
grains oriented toward the center of the
casting
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Solidification Patterns
Solidification patterns for gray cast iron in a 180-mm (7-in.) square
casting. Note that after 11 min. of cooling, dendrites reach each other, but
the casting is still mushy throughout. It takes about two hours for this
casting to solidify completely
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Advantages and disadvantages of Casting
• Can create complex part geometries
• Can create both external and internal shapes
• Some casting processes are net shape; others are near net shape
• Can produce very large parts
• Some casting methods are suited to mass production
Different disadvantages for different casting processes:
– Limitations on mechanical properties
– Poor dimensional accuracy and surface finish for some
processes; e.g., sand casting
– Safety hazards to workers due to hot molten metals
– Environmental problems
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Applications
• Big parts
– Engine blocks and heads for automotive vehicles, wood
burning stoves, machine frames, railway wheels, pipes,
church bells, big statues, pump housings
• Small parts
– Dental crowns, jewelry, small statues, frying pans
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