Manufacturing process

Manufacturing is process of converting raw materials into finished goods to meet

customer requirements
Manufacturing
process

Surface
Machining
Shaping process Joining Process Finishing
process
Process

Casting Turning Welding Grinding

Forming Drilling etc. Riveting Polishing etc.

The manufacturing method selected is based on :

Type of material to be used for making the part

Dimensional accuracy required
Complex and intricate nature of the part
Economy
 casting
It is a process in which molten metal is poured into the cavity whose
shape is same as that of the type of the casting to be produced, allowed
it to solidify and after solidification casting can be taken out.

Advantages of Casting :
* Production of heavy and bulky parts
* Greater vibration damping capacity for parts
* Large product can be made as a single piece there by eliminating the
need for joining process
* Machinable parts are formed using casting
* Mass production can be employed by automation

Disadvantages of casting:
• Surface finish, dimensional accuracy are poor
• Inherent weakness due to shrinkage, porosity
• High energy consuming process and labour intensive
Applications:
Machine tool structures, base of planning machine lathe etc…
Turbine vanes, railway crossings, engine block, Valves, pipes, statues,
frames, cylinder head, railroad wheels, turbine disk.

Steps in Casting
Pattern making: replica of casting to be produced with tolerance
Mold and core making: Making mold cavity and gating systems
Pouring and solidification: Filling the cavity with molten metal
and allowing it to cool and solidify

Fettling: Removing the cast from the mold.

Inspection: Checking for defects
 Types of casting
Expendable mould casting
SAND CASTING, plastic, shell, plaster and investment mold casting
They use temporary, non re-usable molds.
Used for complex parts
Limited productivity

Permanent Mould casting

Made of metals which can withstand very high temperature
Comparatively good dimensional accuracy
Used for batch production

Some other types of casting are:

continuous casting, gravity die casting, pressure die casting
 forging
Forging is a process in which material is shaped by the application of
localized compressive forces ( exerted manually or with power
hammers, presses or special forging machines)

Advantages :
* Product comes with good finish.
* Improved mechanical properties
* Easy to shape to required dimension

Disadvantages:
• Initial cost and maintenance cost are high hence products are costly
• Intricate shapes, hollow geometry in between etc cannot be made
• Size and shape is limited

Application:
rivets, bolts, crane hooks, connecting rods, gears, turbine shafts, hand
tools
 Classification of die forging
Open die Forging

Compressed between to flat dies.

May be rotated in between blows

( machine forging)

Impression Die Forging

Die has cavities corresponding to the required shape.
When performed the work piece takes the shape of the die cavity

Drop forging
Press forging
 Different forging operations
Upsetting: Fullering: Edging:

Swaging: Forge welding :

 rolling
Process of forming metals (deforming) into required shapes by passing
the metal between rollers.
* Rollers squeeze the metal to reduce the cross section & increase
length
• Arrangement of rollers for the operation constitutes rolling mill

Advantages :
• Brings homogeneity to rolled components
• Grain refinement
• Less time for completed
Disadvantages:
• Expensive process
• Scale formation
• Oxidation
Application:
Bars, plates, sheets, rails and similar structural members are made by
rolling
 Two types of Rolling
Hot rolling Cold rolling

1: Metal is fed to the rolls after being heated above the 1: Metal is fed to the rolls when it is below the
recrystallization temperature. recrystallization temperature.

3: Co-efficient of friction between two rolls and the stock is

3: Co-efficient of friction between two rolls and the stock is
higher, it may even caused shearing of the metal in contact
comparatively lower.
with rolls.

4: Heavy reduction in area of the work piece can be obtained. 4: Heavy reduction is not possible.

5: Mechanical properties are improved by breaking cast

structure are refining grain sizes below holes and others, 5: Cold rolling increased the tensile strength and yield
similar deformation in ingot (get welded) and or removed the strength of the steel.
strength and the toughness of the job should increases.

6:Rolls radius is generally larger in size 6: Rolls radius is smaller.

7: Very thin sections are not obtained. 7:Thin sections are obtained.
 rolling
a) Two high Mill, b) Three high mill, c) Four High Mill, d) Cluster mill, e) Tandem mill
( larger rollers used to support smaller ones from getting deflected,)
 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.

Advantages:
variety of sections possible (hot extrusion)
grain structure and strength enhancement (cold)
close tolerance (cold)
no material wastage
Different materials can be used
Low cost per weight
Disadvantages
Same cross section throughout the length
No intricate shapes can be produced

Application:
Structural members like I section, T section, Channel section, pipes (
parts with same cross section throughout the length)
 Types extrusion
Direct Extrusion

Indirect Extrusion ( lower extrusion force as work billet is not moving relative to container wall)
 Two types of extrusion
Hot Extrusion Cold Extrusion

1: heated above the recrystallization

1: below the recrystallization temperature.
temperature.

2: Less ram force 2: More ram force

3: Increased ram speed 3: Low ram speed

4:Reduce strength and ductility of material 4: Increases strength

5: Comparatively lower surface finish and 5:comparatively high surface finish and
tolerance tolerance
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 Machining process
Turning
• Used to make cylinder parts
• Uses a single point cutting tool
• Done in Lathe

Application:
Brake drums and brake disks, valve parts, nozzles, pipe and tube
fittings including tees and elbows, rollers, pistons, turbine rotors, hubs,
pins and axles, gun barrels and handles.
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 Milling
• Multi point cutting tool is used
• Plain surface, angular surfaces, complex surfaces like gear etc…
• Done in Milling machine

Application:
Gear manufacturing, keyway slotting, guide ways, brackets, ribs, flanges etc…
 Two ways of feed
Up Milling Down milling

1: Also called conventional milling 1: Also called climb milling

2: work piece fed in opposite direction of 2: Work piece fed in same direction as that of
cutter rotation cutter rotation
3: Chip thickness varies from minimum at 3: Chip thickness varies from maximum at
starting to maximum towards end beginning to minimum towards end

4:Load on cutting tool increases gradually 4: Load on cutting tool decreases gradually

5: Since cutter is moving opposite, it tends to 5:Since cutter rotates in same direction it tends
lift the work piece to support the work piece in the vice
6: Rough finish 6: Smooth finish
 Different milling operations
1) Plain milling 2) Face milling 3) Side milling 4) Gear cutting

5) T Slot milling 6) Angular milling 7) End milling

 drilling
• Multi point ( Twisted) cutting tool is used
• Used for creating circular holes and related variants
• Done in Drilling machine

Application:
For making Dies, Oil holes in engine parts, holes for fastening etc…….
Various drilling operations
 Grinding
• Uses abrasive tools
• Abrasive tool is made to rub against the work piece
• Done in grinding machine
• Mainly used for tight tolerance

Application:
Guide wires, spool valves, bar stock, pins, bushings,
engine parts etc.
 Grinding operations

Cylindrical grinding

Surface grinding Foam grinding

 Shaping
• Uses single point cutting tool
• Used for machining flat surfaces, angular surfaces
• Done in Shaping machine
• Forward stroke alone is cutting stroke

Application:
Keyways, racks, machining, flat surfaces, dove tail, chuck
 Planing
• Uses single point cutting tool
• Used for machining flat surfaces, angular surfaces on large, bulky
work pieces
• Done in Planing machine

Application:
Machining of surfaces for lathe bed, slots and grooves, machining dovetails
 Joining processes
For joining similar or dissimilar materials

Mainly three types

1) Brazing 2) Soldering 3) Welding
 1 & 2 Needs only lower temperatures than required for welding.
 Filler metals are first placed in or supplied to the joint, they are then
melted using an external source of heat. And upon solidification
strong joint is obtained.
 Temperatures for soldering is much lower than those for brazing.
 Strength of a soldered joint is much lower.
 Use of flux is essential in order to prevent oxidation and to remove
oxide films from work piece surfaces. Borax, boric acid, borates,
chlorides and fluorides are generally used for making fluxes
 brazing
 It is a joining process in which filler metal is placed in or between
the faying surfaces to be joined and temp. is raised enough to melt
the filler material (spelter: copper - zinc alloy).

 Molten metal fills the cavity by capillary action.

 Cool it and solidify it.

 Filler metal used for brazing melt above 450 degree. And the temp.
employed in brazing are below the melting point of the base metal

 Application:
Water supply, Fuel gas distribution, Medical gas, Air conditioning and
refrigeration, Fire protection
Brazing……
 soldering
 Operating temp. lower compared to brazing

 Solder: Lead-tin alloy.

 Process takes place at a temp. less than 450 degree and also less
than the melting point of the base metal.

 Solder fills the gap by capillary action

 Should have good wetting characteristics.

 It is mainly used in electronics industry.

 Soldered joint has limited use at elevated temp.

 Copper, silver and gold are easy to solder

 Electronics manufacture, implantable devices, medical devices, connectors etc
 Soldering Brazing

1: Filler material: solder 1: Filler material : spelter

2: Comparatively weak joints 2: stronger joints

3: No resistance to corrosion 3: Good resistance to corrosion

4:suitable for thin sheet metals 4: suitable for thin as well as thick sheets

5: Comparatively lower operating temp 5:comparatively higher operating temperature (

(<450degree Celsius) > 450 degree Celsius)
 welding
It is a process of joining two or more similar or dissimilar metals,
 With or without the application of heat

 With or without the application of filler metal

 With or without the application of pressure

Classification of welding
 Gas welding: Oxy acetylene , Air acetylene, Oxy hydrogen

 Arc welding: TIG, MIG, SMAW, FCAW

 Resistance welding: Seam, spot, projection etc

 Chemical welding: Thermit welding

Applciation
Pressure vessels, bridges, ship building, automobile industry (chassis,
body, structure, doors), railways (tracks, coaches/wagons).
 Advantages of Welding:
1) Cost of welding arrangement is low
2) Automation is possible (mega factories have robotic arms which performs welding operations)
3) Resistance to corrosion
4) Portability: small size equipments are available
5) Large number of metals can be welded: helps in mass production

Disadvantages of welding:
1) Work piece is deformed during the operation
2) Heat treatment is required to refine the grain structure and improve mechanical properties
3) Produces high frequency radiations harmful for humans
4) Some time produces harmful gases
5) Skilled labour required
Oxy acetylene welding
Type of flames
 Filler rods
 Commonly used filler rods are Low carbon steel, mild carbon steel
and brass etc.
 Properties to be possessed by filler rod: Density, Melting point,
Easiness of mixing
flux
 It is useful for the successful welding of different metals and alloys.
 Deoxidize the melt., to absorb the gases, To form slag layer over weld bead,
Slow down the cooling rate of the weld.
 Helps in adding alloying elements to the weld metal.
 Flux coating is essential in the case of alloys and non ferrous materials.
 Borax can be used as a common flux during gas welding of all other
materials.
 During gas welding of carbon or nickel alloys there is no need of flux.
Arc welding
 Arc welding electrodes
 Consumable and non consumable electrodes.
 Non consumable electrodes consist graphite or carbon (Carbon Arc Welding).
 Should have high electrical conductivity.
 All non consumables are made as bare wire electrodes only.
 Consumables (Metal Inert Gas welding) are again classified into bare electrodes
and coated electrodes.
 Commonly used materials are LC steel, MC steel, brass etc.
 Properties to be possessed are – density, MP, proper mixing.
 Type of coatings on electrodes are...
 Ferro silicon or ferro magnetic coating – to deoxidize the weld bead and to
absorb the gases.
 Rutile coating/TiO2 – for producing slag in the weld bead.
 Potassium compound coating – stabilize the arc.
 Shielded metal arc welding (SMAW)
 The workpiece and the electrode melts forming a pool of molten
metal (weld pool) that cools to form a joint.

 As the weld is laid, the flux coating of the electrode disintegrates,

giving off vapors that serve as a shielding gas and providing a layer
of slag, both of which protect the weld area from atmospheric
contamination.
 Intro to CNC machines
The CNC machines consists of a central computer. By using this central computer all the
machine tool operations are controlled. The main components of CNC machines are CPU
(central processing unit), memory unit, I/O module etc.

Fig. below shows a schematic of a machine tool controlled by a computer. It consists of a

Machine Control Unit (MCU: computer ROM, control loop consisting of PLC & input
output devices) and machine tool itself. MCU, a computer is the brain of a CNC machine
tool. It reads the part programs and controls the machine tools operations. Then it decodes
the part program to provide commands and instructions to the various control loops of the
machine axes of motion. MCU + Machine tool = CNC machine tool

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