Systems in mechanical engineering

UNIT- V

INTRODUCTION TO MANUFACTURING
ENGINEERING

[Link]

All India Shri Shivaji Memorial Society’s College Of

Engineering, PUNE (M.H)
 Unit V

Course Objective :
To introduce manufacturing processes applying proper method
to produce components.

Course Outcomes :
❖ Discuss several manufacturing processes and identify the suitable
process

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 Unit-V: Introduction to Manufacturing Processes

Conventional Manufacturing Processes:

❑ Casting,

❑ Forging,

❑ Metal forming (Drawing, Extrusion,etc.),

❑ Sheet metal working,

❑ Metal joining, etc.

❑ Metal cutting processes and machining operations- Turning,

Milling and Drilling, etc.

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 Non-Conventional Manufacturing Process

⚫ Micromachining, Additive manufacturing and 3D Printing.

⚫ Reconfigurable manufacturing system and IOT,

⚫ Basic CNC programming: Concept of Computer Numerical

Controlled machines.

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Manufacturing: Processing the available raw material into a useful
finished product
e.g. Converting a M.S sheet into car body.
Converting a steel bar into a transmission shaft
⚫ Manufacturing is broadly classified into four categories-
A) Casting Process
Sand Casting, Plastic molding,etc
B) Metal forming Process-
(metal are deformed either hot or cold into desired shape)
forging, rolling, drawing, extrusion
C) Material removal & cutting process-
(material is removed by means of sharp cutting tool)
turning, milling, drilling, grinding
D) Joining processes
Welding, Soldering, Brazing, Riveting

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 Manufacturing Processes.

Deforming Machining Joining

Primary Surface
Process Process Process
Shaping Finishing
Process Process
Forging Turning Welding

Casting Grinding
Rolling Facing Soldering
Lapping
Powder Sheet Metal
Metallurgy Drilling Brazing
Working
Plating

Processing Milling Screwing

Metal Forming
Of
Coating
Plastics
Shaping Riveting

Honing

6 Reaming Adhesive
Bonding
 CONVENTIONAL
MANUFACTURING
PROCESSES

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 Metal Casting
⚫ Casting: It is a manufacturing process in which part of desired
shape is obtained by pouring molten metal into cavity of required
shape

⚫ It is one of the oldest manufacturing process (around 6000

year old, Egyptians were first to use castings)

Castings
c

Sand Investment Centrifugal

Die Casting
Casting casting casting

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9
 Steps in Sand Casting:

1. Pattern Making

2. Mould Making

3. Core Making

4. Melting & Pouring

5. Solidification

6. Finishing

7. Inspection
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⚫ Steps in Sand Casting:
1. Pattern Making:
⚫ Pattern is replica of the part to be casted.
⚫ Initially pattern has to be made using different manufacturing
process other than casting.
⚫ Draft/Taper is provided on pattern for its easy removal from sand
mould
⚫ Commonly used materials for pattern making are-
⚫ Wood, Plastic and metal

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⚫ Steps in Sand Casting:
2. Mould Making:
⚫ Mould is a container made from green sand and which
has cavity in which molten metal can poured.
⚫ Mould box has two halves, the upper halve is called
cope and lower halve is called drag
⚫ Arrangement for metal pouring has to be made inside
the mould

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⚫ Steps in Sand Casting:
3. Core Making:
⚫ Core is a device used in sand casting to produce hollow
castings
⚫ Generally core is made from same material as that of the
mould i.e. sand
⚫ Supporting elements called chaplets are used to support
core.

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 Core print is an added projection on the pattern and it forms a
seat in the mould on which the sand core rests during pouring of
the mould. The core print must be of adequate size and shape so
that it can support the weight of the core during the casting
operation.

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⚫ Steps in Sand Casting:
4. Metal Melting and Pouring:
⚫ The raw material is melted using furnace. Furnace may be
operated on electricity or fuel.
⚫ The molten metal is poured into mould using ladle
⚫ Pouring basin, sprue, runner, gate are used to guide molten
metal into the cavity.

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⚫ Steps in Sand Casting:
5. Solidification
⚫ Metal is allowed to cool to room temperature
⚫ During solidification the metal shrinks and the extra metal
required compensate this shrinkage is obtained from the
riser

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⚫ Steps in Sand Casting:
5. Finishing
⚫ Undesired part which corresponds to gating system and riser
has to be cut from main casting
⚫ The casted surface generally is rough and some finishing
operation like grinding, machining, polishing are required

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⚫ Steps in Sand Casting:
5. Inspection
⚫ Before dispatching the casted part has to be checked for
desired dimensions. The part which doesn’t meet expected
dimensions has to be scraped
⚫ Castings are also checked for various undesirable defects

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 Terminology in Sand Casting:

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⚫ Terminology in Sand Casting:
1. Mould Box:
⚫ It is metallic or wooden box in which sand mould is
created.
⚫ Upper part of mould box is called cope and lower part is
called drag
⚫ In some special castings third middle mould box is used
called check

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⚫ Terminology in Sand Casting:
2. Pouring Basin/Cup:
It is a shallow part at the entry of gating system through
which metal is poured

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⚫ Terminology in Sand Casting:
3. Sprue:
⚫ A conical vertical portion immediately after pouring cup is called
sprue

⚫ Flow of the free falling molten metal is reduced by using

reducing cross sectional sprue.

⚫ If straight sprue is used, a vacuum will be created in between

sprue wall and the metal stream.

⚫ This vacuum will be responsible for suction of atmospheric

gases which will create voids in casting

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⚫ Terminology in Sand Casting:
4. Runner:
⚫ The horizontal portion immediately after the sprue
5. Gate:
⚫ A narrow entry through which metal enters mould cavity
is called gate

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⚫ Terminology in Sand Casting:
4. Skim Bob:
⚫ A small hollow spherical bulge above the top runner surface
which is used to separate light floating impurities is called
skim bob

5. Well:
⚫ A deep portion immediately below the sprue which acts as
cushion to molten metal so that the sand is not washed off
into the casting is called well

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⚫ Terminology in Sand Casting:
6. Riser:
⚫ It is a cavity cut into the sand
mould which permits the molten
metal to rise above the casting
cavity
⚫ Main function of riser is to supply
molten metal during the shrinkage
which happens during the
solidification
⚫ The riser shape has to be designed
in such a way that its solidification
time is more than that of the
casting
⚫ Riser can be through or blind.
Through riser also serves as an exit
to the entrapped gases in mould
cavity

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⚫ Terminology in Sand Casting:
7. Chills:
⚫ Chills are the metallic element which are used enhance
solidification rate
⚫ As metals have higher thermal conductivity than sand, heat
transfer rate will be higher in the vicinity of chills hence
the molten metal solidifies faster there
⚫ Using chill we can control solidification direction as well as
grain size ( Faster cooling rate will result in finer grain size)
⚫ Chills can be internal as well s external. Internal chills have
to be made from same material as that of casting

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⚫ Terminology in Sand Casting:
8. Chaplet:
⚫ It is a supporting element which used to hold core in correct
position
⚫ Chaplet has to be made from same material as that of the
casted part

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⚫ Terminology in Sand Casting:
9. Machining Allowance:
⚫ Casted products require finishing operation because of poor
surface finish. After finishing operation, size of the casted part
reduces, In order to compensate this reduction, size of ‘casting
pattern’ is increased while design .
⚫ “This increase in size of pattern with respect base size is called
machining allowance “

9. Shrinkage Allowance:
⚫ When the casted product cools from its melting point to room
temperature , size of component reduces.
⚫ In order to compensate this reduction pattern of bigger size than
product size are used.
⚫ “The percentage increase in size of casted product at its melting
point with respect its size at room temperature is called
shrinkage allowance”.

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Advantages of Sand Casting:
⚫ It is one of the cheapest manufacturing process.

⚫ Operating as well as initial cost of equipment is much lower as

compared to other manufacturing processes.

⚫ Can be used to create complicated shapes.

⚫ Casting can be used to manufacture components made from brittle as

well as ductile material (Almost any material can be cast)

⚫ Casting can be used economically to create small as well as large

components.

⚫ Casting is a primary manufacturing process. Raw material supplied to

various other manufacturing process is obtained through the casting.

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 Disadvantages of Sand Casting:
⚫ Casting can not be used to create very thin components
(thickness < 6mm)

⚫ Casting contains various defects such cracks, voids, foreign

particle inclusions which reduces strength of the component.

⚫ Casted components are brittle in nature as compared forged

components.

⚫ Surface finish of sand casted component is poor

⚫ Man power and space requirement is high.

⚫ Pollution during the casting process is high.

⚫ Risk of injury in metal handling is high.

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 Applications of Sand Casting:
⚫ Machine beds for various machines
⚫ (Lathe, Drilling, Shaping, Milling)

⚫ Automobile parts
⚫ (Pistons, cylinder block, clutch and brake plates, Gearbox casing)

⚫ Aircraft parts
⚫ (Gas Turbine and compressor blades, Engine casing)

⚫ Casings used in various machines

⚫ (Turbine, Generator, Compressors, Motors, Gear box, Pumps)

⚫ Flywheel, Pulleys, Railway wagon wheels, Valves

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 Key-Terms
⚫ Foundry: The shop where Casting is done

⚫ Usually Casting is followed by various manufacturing processes

⚫ Forging

⚫ Machining=Lathe-(turning, facing), Drilling, Shaping, Milling

⚫ Finishing=Grinding

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 Basic Concept:

Cold Working vs. Hot Working

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 Cold Working vs Hot Working
⚫ Hot Working: Metal forming operations which are carried out
above recrystallization temperature RCT but below melting
point of the metal.
e.g. Forging, hot rolling.

⚫ Advantages:
⚫ Metal is soft above RCT hence larger deformations are
possible with less load & effort.
⚫ Current grain structure breaks and new refined smaller
grains are formed. This Fine grain structure results in
better mechanical properties.
⚫ Voids and porosity defects are minimized considerably
⚫ Residual stresses are relieved if they are present before
hot working.

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 Cold Working vs Hot Working
⚫ Disadvantages:
⚫ Oxidation rate is high at high temperature which leads to
poor surface finish.

⚫ Close tolerances are difficult to maintain as part shrinks

when it cools from RCT to room temperature.

⚫ Oxidation causes loss of carbon at surface hence strength

of the steel at surface is weakened. Weakened surfaces are
vulnerable to fatigue.

Note: RCT of lead(-350C) and tin (300C) is below room temperature

hence their forming process carried out at room temperature can be
classified as hot working.

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 Cold Working vs Hot Working
⚫ Cold Working: The term cold working is referred to metal
forming operations which are carried out below recrystallization
temperature.
e.g. Sheet metal forming operations, cold rolling.

⚫ Advantages:
⚫ Better surface finish is achieved because no oxidation takes
place.
⚫ Strength and hardness of component is improved because of
plastic deformation.
⚫ Better dimensional control is achieved.

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 Cold Working vs Hot Working
⚫ Disadvantages:
⚫ Deformation forces required are high which increases die
cost and size.
⚫ Over cold working results in cracking of material.
⚫ Grain structure become distorted which results in poor
mechanical properties.
⚫ Cold working results in residual stresses. Tensile residual
stresses lower the fatigue life of the component.

Note: Cold working only improves strength and

hardness other mechanical properties are
deteriorated because of distorted grain structure

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 Metal Forming Processes:

Forging

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⚫ Forging:
It is a manufacturing process in which the metal is plastically
deformed with or without the help of heat, to the desired shape by the
application of compressive force using a hand hammer, power hammer or
press.

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⚫ Steps in Forging:
i. Take a raw material of approximate
shape, mostly obtained from castings

ii. Heat the part until it become

red/yellow hot

iii. Deform the part by applying

compressive force by a hammer or a
press until desired shape obtained

iv. Sometimes forging operations is

done without the application of heat
known as cold forging. Cold forging is
very popular now-a-days.

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Classification of Forging Processes: Open Die Forging
a)According to the arrangement of die
⚫ Open Die Forging:
The compressive force is applied by means of flat
surfaces.

⚫ Closed Die Forging:

The compressive force is applied by means dies which
have impression of final shape on them

Closed Die Forging

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 b)According to the temperature

Hot Forging: Workpiece is heated above the

recrystallization temperature (RCT) and force is
applied.

Cold Forging: Workpiece is worked at room temp or

at warm condition i.e. below the recrystallization
temperature (RCT) temperature and force is applied.

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C) According to Different Forging Method:
⚫ Hand Forging: The compressive force is applied
manually by hammering.

⚫ Drop Forging: The compressive force is applied by

dropping the die suddenly i.e. the applied load is impact
load.

⚫ Press Forging: The material is squeezed into desired

shape by the gradual compressive force.

⚫ Upset Forging: It is a subtype of press forging. When a

press forging is used to increase the diameter of
cylindrical bar at the expense of reduction in length it
called upset forging.
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49
 Advantages of Forging:
1. Forging gives tougher product than casting.

2. Forging eliminates voids in the materials which are formed

during the casting.

3. Forging reduces the grain size.

4. Fine grain components have better mechanical properties than

coarse grain. Grain flow direction can be controlled in forging
which helps in achieving better properties in particular
direction

5. Forging (especially cold forgings) have better surface finish

than castings.

6. Thin products can be manufactured using forging.

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 Disadvantages of Forging:
1. Forging is costly as compared to casting. Initial investment is
high.

2. Size of products to be forged to the size of press.

3. Complex shapes cannot be produced easily.

4. Brittle materials likes cast iron cannot be forged.

Applications of Forging:
⚫ Pistons ,Connecting rods, Crankshafts, Camshaft, Nut-Bolts.

⚫ Hammers, Wrenches, spanners.

⚫ Crane Hooks and Various component which require high strength

and durability.
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 Sheet Metal Operations
(Press Working)

Size: 0.1mm to 6 mm (8 mm)

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 Sheet Metal Operations: Classification

Sheet Metal
Operations

Cutting Operations
• Piercing , Forming
• Punching Operations
• Blanking • Drawing
• Perforating • Bending
• Lancing • Embossing
• Notching • Coining
• Slitting
• Shaving

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 Sheet Metal Cutting Operations

Punching
Blanking
Sliting
Notching
Nibbling
Shaving
Lancing

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 Sheet Metal Operations: Punching
⚫ Punching: It is a sheet metal operation in which a circular shaped
hole is produced in a sheet by the cutting or shearing operation with
the help of punch and die.
⚫ In this the punch size is equal to the punch size and shear is provided
on the punch.

Note: Punching and piercing are

interchangeable terms however
some authors reserve term
piercing for ‘non circular’ holes

⚫ Application: Electronics Boards, Printed circuit board, etc.

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 Sheet Metal Operations: Blanking
⚫ Blanking: Blanking is similar to punching except the blank
is desired product and the remaining portion of sheet is
scrap.
⚫ In this the die size is equal to blank size. Shear is also
provided on die

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Sheet Metal Operations: Punching Mechanism
⚫ Punching/Blanking Mechanism:
⚫ Mechanism of punching is shearing
⚫ Punching operation takes place when clearance is very small
⚫ Crack start at the edge of die and punch simultaneously

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 Concept of Shear
⚫ Shear:
⚫ If the penetrating face of punch is inclined instead of parallel to the die
surface then the punch is called sheared punch.
⚫ Shear is used to reduce cutting force required to punch
⚫ depending upon shear is provided on what i.e. die or punch, deformation of
sheet or blank varies accordingly.
⚫ “In punching operation shear is provided on punch in blanking operation
shear is provided on die”.

Single Shear on Punch Double Shear on Punch Double Shear on die

Note: Shear only reduces cutting force but energy required punch the
58 hole will remain same
 Sheet Metal Operations: Progressive Die
⚫ Progressive Die: If two or more sheet metal operations
are performed on a single die then the die is known as
progressive die
⚫ In following progressive die punching and blanking operations
are performed at single workstation

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 Sheet Metal Operations: Perforating
⚫ Perforating: If an array of holes are produced in
punching operation then the operation is known as
perforating

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 Sheet Metal Operations: Slitting
⚫ Slitting: The cutting operation performed on a sheet
metal to produce a slit is called slitting

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 Sheet Metal Operations: Notching
⚫ Notching: If a hole is produced on edge of the sheet
during the punching operation the operation is known as
notching

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Prof. [Link], AISSMS COE Pune. email-sskhasbage@[Link] [Link]
 Sheet Metal Operations: Nibbling
⚫ Nibbling: It is a sheet metal operation in which a definite
profile is cut in sheet metal by using the punching
operation repeatedly
⚫ Nibbling eliminates need of specialized tool to cut the profile
in sheet
⚫ However, an additional finishing operation is required after
nibbling to get smooth contour

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 Sheet Metal Operations: Shaving
⚫ Shaving: It is a cutting operation performed on a sheet
metal to remove small portion of sheet near its edge for
smoothening purpose

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 Sheet Metal Operations: Lancing
⚫ Lancing: Lancing is a sheet metal operation in which a
portion of the sheet is cut and bent in single step.

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 Sheet Metal Forming Operations

Bending
Drawing
Embossing
Coining

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 Sheet Metal Operations: Bending
⚫ Bending: Bending is a sheet metal operation in which the
sheet is bent at some definite angle
⚫
⚫ Spring Back Effect:
⚫ If the sheet is released after bending it will retrace towards
original position by some angle. This phenomenon is called
spring back effect.
⚫ Spring back effect happens because of elastic part of
deformation

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 Sheet Metal Operations: Embossing
⚫ Embossing: It is a sheet metal forming process of
producing depressed impression on sheet metal in the
form letter, figure or design.

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 Sheet Metal Operations: Coining
⚫ Coining: It is a sheet metal forming process in which
impressions on sheet are produced by plastic flow of
material into die cavity
⚫ Mechanism of coining is similar to forging where as
mechanism of embossing is similar bending or drawing
⚫ Sheet thickness in case of embossing is constant everywhere
but in case coining sheet thickness varies wherever
impressions are present

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 Sheet Metal Operations
⚫ Advantages:
⚫ Component made from sheet metal are light & cheap
⚫ High dimensional accuracy can be obtained with High
surface finish
⚫ Processes can be automated hence production rate is
high
⚫ It doesn’t require skilled labour
Disadvantages:
⚫ Components are weak (low strength)
⚫ There is limitation on thickness of the sheet to be
processed

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 Sheet Metal Operations
⚫ Applications:
⚫ Automobile, aircraft body parts
⚫ Kitchen utensils
⚫ Steel furniture
⚫ Furniture
⚫ Cans, jars
⚫ Coins

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 Kitchen Tools

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 Machine Parts
Industrial Components

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 Automobile bodies

Aircraft bodies

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 Metal Forming
⚫ It is a process in which the forces are applied on the material such
that the stresses induced in the material are greater than the
yield stress and less than ultimate stress, so that the plastic
deformation produced in the material will be used for changing the
shape of the component, is called as metal forming process.
⚫ eg. Extrusion & Drawing

⚫ Advantages of metal forming process :

1. Wastage of material will be minimum or sometimes zero.
2. The grain orientation is possible.
3. The production rate is high.
4. In some forming process, increase in strength and hardness of
the materials takes place

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 Drawing
⚫ Drawing: It is a sheet metal forming process in which a
flat metal sheet is converted into a cup like hollow object
by application force with help of punch and die
combination

Note: If the height of hollow object

produced is more than its diameter
then the process is popularly known
as deep drawing

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 Drawing
⚫ Drawing Mechanism:
⚫ “The equipment used for drawing is similar to punching but
mechanism is similar to bending”
⚫ Higher clearances are used in drawing operation than punching
⚫ As the clearance is increased the tendency sheet to get
drawn into die cavity increases

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 EXTRUSION

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 Metal Joining Processes: Welding
Welding:
⚫ Welding is a metal joining process in which the two metallic
parts are heated above their melting point to form a joint,
with or without application of external force, with or
without use of filler metal
Not Compulsory

Filler

Welding

Pressur
Compulsory Heat Not Compulsory
e

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 Metal Joining Processes: Classification

SMAW: Shielded Metal arc welding

MIG: Metal Inert Gas /Gas metal arc welding (GMAW)
83 TIG: Tungsten metal Inert Gas
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 Welding: Electric Arc Welding
Electric Arc Welding:
⚫ Electric Arc Welding is non pressure welding process in which
heat is produced because of electric arc in between electrode
and work piece and the electrode itself acts as filler material

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 Welding: Electric Arc Welding
Equipment:
⚫ Power Supply:
⚫ Low voltage (20 to 40 V), high current (150 to 1000A) DC or AC
power supply is used
⚫ Negative terminal of power supply is connected to the electrode
and positive terminal to work piece
⚫ This is because arc will flow from negative to positive terminal
⚫ Electrode:
⚫ Electrode is consumable & coated with flux
⚫ Flux will form a protective shield of inert gases which will prevent
reaction of molten metal with atmospheric oxygen and nitrogen
⚫ Contact of oxygen and nitrogen with metal is avoided, because
when they come into contact metal oxides and nitrides are
formed, which reduces the strength of welded joint

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 Welding: Electric Arc Welding
Procedure:
1. The joining surfaces of the two metal are cleaned
2. Negative terminal of power supply is connected to the
electrode and positive terminal to work piece
3. An arc is initiated by slightly touching electrode with
work piece. High current generates large heat which
melts electrode as well as base metal. (Max temp
20000C to 40000C)
4. Once arc is started electrode is slightly moved away
from work piece (3 to 6 mm) .( Contact of electrode
with work piece during welding causes spatter of molten
metal. )
5. Electrode is slowly moved along joint in such a way that
90 it makes acute angle with direction of motion
Prof. [Link], AISSMS COE Pune. email-sskhasbage@[Link] [Link]
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Prof. [Link], AISSMS COE Pune. email-sskhasbage@[Link] [Link]
 Welding: Electric Arc Welding
Advantages:
1. It does not require external pressure
2. Arc welding is the most versatile welding process which can
be used to join thick as well thin section. It can be used to
join complicated shapes
3. It is one of the least expensive welding process
4. The set up is portable
Disadvantages:
1. Process is slow because of frequent change of electrode
2. Operator skill required is high
3. It is subjected to defects such as slag inclusion, cracking

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Prof. [Link], AISSMS COE Pune. email-sskhasbage@[Link] [Link]
Electrodes:
Consumable -same base material
Non-consumable-Tungsten, Carbon or Graphite

consumable electrode can be coated / uncoated (bare

electrode)

Coatings serve a no. of purposes-

• establishment and maintenance of arc
• produce shield gas around arc & weld pool
• provide formation of slag to reduce rapid cooling.
• introduce alloying elements not contained in core wire.

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Prof. [Link], AISSMS COE Pune. email-sskhasbage@[Link] [Link]
1) Shielded Metal Arc Welding: (SMAW)

Metal rod is used as electrode. The temp is about 2400°c

on -ve and 2600°c on +ve electrodes respectively.
This is called SMAW- when stick (coated) electrodes are
used.
This is a manual process & used for general purpose
Welding.

•AC is the current source,

•DC can also be used.
•used for thicknesses above 3mm.
Disadvantages
slow speed, slag inclusion,
moisture pick up by coatings,
wastage of electrode material etc.
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Prof. [Link], AISSMS COE Pune. email-sskhasbage@[Link] [Link]
 Gas Welding

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Prof. [Link], AISSMS COE Pune. email-sskhasbage@[Link] [Link]
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Prof. [Link], AISSMS COE Pune. email-sskhasbage@[Link] [Link]
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Prof. [Link], AISSMS COE Pune. email-sskhasbage@[Link] [Link]
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 Comparison: Welding, Brazing, Soldering
Parameters Welding Brazing Soldering

Mechanism Fusion Wetting and Wetting and

adhesion adhesion
Condition of Joining surfaces Joining surfaces Joining surfaces
Joining surfaces melt and merge with do not melt do not melt
each other
Operating Highest (2000 to Intermediate Lowest (150
Temperature 40000C) (450 to 12000C) to 4500C)

Filler material Iron Brass (63-37) Sn-Pb

alloy
Strength of Joint Highest (comparable Intermediate Lowest
to base metals)

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 Machine Tools

Machine Tools

Cutting Machine Finishing Machine

Tools Tools

c Milling Drilling
Lathe c
Machine
Shaper c
machine
Grinding Honing Lapping
Machine Tools: Lathe
 Introduction
• Most versatile and widely used machine tools
• Main function: to remove metal from a job to give it the required
shape and size.
• The job is securely and rigidly held in the chuck or in between
centers on the lathe machine and then turn it against a single point
cutting tool which will remove metal from the job in the form of chips.

• Besides the simple turning operation as described above, lathe can be

used to carry out other operations also, such as drilling, reaming,
boring, taper turning, knurling, screw/thread cutting, grinding etc.

Working Principle of lathe

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 Lathe Components: Lathe Bed

Headstock:
⚫ It contains drive mechanism with necessary speed
change arrangement to achieve different speeds.
⚫ Work holding devices such as chuck is mounted on
it.
 Lathe Components: Lathe Bed
❖ Lathe Bed:
Function: Provides platform for entire machineCarriage,
tail stock can slide along the bed by means of guide
ways.
⚫ Made from cast iron using casting process
 Lathe Components: Lathe Bed
❖ Chuck:
⚫ Function: Holds the work piece
⚫ Three Jaw Chuck:
⚫ All the three jaws move simultaneously
⚫ Used in coaxial turning
⚫ Four Jaw Chuck:
⚫ Each jaw can move independently
⚫ Used in eccentric turning
Lathe Components: Carriage
Lathe Components: Carriage
❖ Carriage:
⚫ Function: Used to move tool post in
desired direction.
⚫ It has three independent degrees
of freedom.
⚫ Apron(4) provides motion parallel to lathe
bed,
⚫ Cross slide(3) provides motion
perpendicular to lathe bed,
⚫ Compound rest(2) provides motion
inclined to lathe axis in a horizontal plan
⚫ Three calibrated wheels are used to control
the motion of the tool within fraction of a
millimeter
 Lathe Components: Tail Stock
❖ Tailstock:
⚫ Function: Used to hold drill, centre
mount
⚫ Longitudinal motion of the drill can
be controlled using a calibrated
wheel
⚫ Entire tail stock can be moved along
the lathe bed and this motion can be
synchronized with lead screw
 Lathe Components: Lead Screw
❖ Lead Screw: Lead Screw
⚫ Function: Used to move
carriage, tailstock at
constant speed along lathe
bed (threading operation)
⚫ Rotational speed of lead
screw is synchronized with
chuck speed
⚫ Half nut mechanism is
used to engage/ disengage
lead screw with the
carriage
 Lathe Components: Gearbox
❖ Gear Box:
⚫ Function:
⚫ Provides velocity reduction
between drive motor and
chuck
⚫ Used to change the speed
of chuck
⚫ It is used to synchronize
rotational speed chuck with
lead screw speed
 Lathe Operations: Turning
⚫ Turning: Turning is a lathe operation in which
diameter of work piece is reduced by keeping
length constant
⚫ Depth of cut is given in radial direction
⚫ Feed is given in axial direction
⚫ Work piece rotates towards operator
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Machine Tools: Drilling Machine
 Drilling Machine: Hand Drilling Machine
⚫ Hand Drilling Machine:
⚫ It is also known as portable drilling machine
⚫ Accuracy of drilled hole depends on operator skill
 Drilling Machine: Radial Drilling Machine
⚫ Radial Drilling Machine:
⚫ It is very similar to column drilling machine except that it
has an additional degree of freedom
⚫ The spindle can move along radial direction with respect to
column
⚫ It is more versatile than column drilling machine
Drill Bit Nomenclature
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 Operations on Drilling Machine: Drilling
⚫ Drilling:
⚫ It is a process of producing circular hole inside a work
piece

Drill Bit
 Operations on Drilling Machine: Reaming
⚫ Reaming:
⚫ It is a process accurately sizing or smoothening already
existing hole
⚫ Radial increment is very small. Reaming is often performed
as finishing operation which follows after drilling
operation
Reamer
 Operations on Drilling Machine: Boring
⚫ Boring:
⚫ It is a process of enlarging already existing hole to meet
desired size
⚫ Radial increment is large as compared to reaming operation

Boring Cutter
Operations on Drilling Machine: Counter Boring
⚫ Counter Boring:
⚫ It is a process of enlarging the opening of already existing hole
by making a cylindrical step within the hole
⚫ The cylindrical step is produced so that it can accommodate
bolt head within it Counter Boring Tool
 Operations on Drilling Machine: Spot Facing
⚫ Spot Facing:
⚫ Spot facing is similar to counter boring except the depth of
step produced is very shallow
⚫ The shallow step is produced so that it can accommodate
washer Counter Boring Tool
can be used perform
Spot Facing
Operations on Drilling Machine: Counter Sinking
⚫ Counter Sinking:
⚫ It is a process of chamfering edge of circular hole to produce
conical opening is called counter sinking
⚫ The conical opening is produced so that it can accommodate a
screw head within it Countersinking Tool
 Operations on Drilling Machine: Tapping
⚫ Tapping:
⚫ It is a process of producing internal threads within already
existing hole

Tapping Tool
 Operations on Drilling Machine: Trepanning
⚫ Trepanning:
⚫ It is process of producing a large circular hole inside a
work piece by removing material along the circumference
of the hole to be produced
⚫ There are two types of trepanning tools viz.
⚫ Multipoint hollow Trepanning tool
⚫ Single point trepanning tool
⚫ Working of single point trepanning tool is similar to that of
a drafting compass
Multipoint
Trepanning Tool
 Operations on Drilling Machine: Trepanning
⚫ Trepanning:

Single Point
Trepanning Tool
 Milling Machine Tool
Milling is a machining process that uses a rotating cutting tool to remove material from a
workpiece. The cutting tool, called a milling cutter, has multiple cutting edges and rotates
at high speed to create various shapes, features, and surfaces on the workpiece. Milling
is used to produce a wide range of parts, from simple flat surfaces to complex
three-dimensional shapes.

most common types of milling are: [Link]

1. Face milling: In face milling, the milling cutter is mounted perpendicular to the workpiece
surface and removes material in a flat plane to create a flat surface.
2. End milling: In end milling, the milling cutter has cutting edges on the end and along the
sides, and is used to create slots, holes, and other features.
3. Chamfer milling: In chamfer milling, the milling cutter is used to create beveled edges or
angles on the workpiece.
4. Thread milling: In thread milling, the milling cutter is used to create threads on the
workpiece.
5. Gear milling: In gear milling, the milling cutter is used to create gears or gear-like shapes
on the workpiece.
6. Horizontal milling: In horizontal milling, the milling cutter is mounted horizontally and is
used to create horizontal grooves, slots, and other features.
7.
149 Vertical milling: In vertical milling, the milling cutter is mounted vertically and is used to
create vertical grooves, slots, and other features.
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 Advantages:

1. Versatility: Milling can be used to produce a wide range of parts, from simple flat surfaces
to complex three-dimensional shapes.
2. High precision: Milling can produce parts with high accuracy and surface finish, making it
suitable for applications that require tight tolerances.
3. Efficiency: Milling can remove material quickly and efficiently, making it a cost-effective
machining process for high-volume production runs.
4. Automation: CNC milling can be automated using computer software to control the milling
machine and ensure consistent and accurate results.
5. Customization: Milling can be customized to suit specific requirements by selecting the
appropriate cutter, cutting parameters, and milling technique.

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 Limitations:
Tool wear: Milling cutters can wear out quickly, particularly when used on hard or
abrasive materials, requiring frequent replacement and increasing costs.

1. Complexity: Milling requires skilled operators who are knowledgeable about the
different types of cutters, cutting parameters, and milling techniques, making it
a complex and challenging machining process.
2. Material limitations: Milling may not be suitable for all types of materials,
particularly those that are difficult to machine or have poor machinability.
3. Surface damage: Milling can sometimes cause surface damage or
imperfections due to the force of the cutter on the workpiece.
4. Cost: The cost of milling equipment and tooling can be high, making it less
suitable for small-scale production runs or prototyping.

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 ADVANCED
MANUFACTURING
PROCESSES

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 Introduction to Advanced Manufacturing
Advanced manufacturing processes are modern and innovative manufacturing
techniques that involve the use of advanced technology, equipment, and techniques to
create high-quality products. These processes typically involve the use of
computer-controlled systems, robotics, artificial intelligence, and other technologies to
automate and streamline production processes, reduce waste, and improve product
quality.

Some examples of advanced manufacturing processes include:

1. Additive Manufacturing: Also known as 3D printing, this process involves creating

a three-dimensional object by depositing successive layers of material.
2. Laser Cutting: This process uses a high-powered laser to cut, engrave or mark
materials such as metal, plastic, and wood.
3. Electron Beam Machining: This process involves using a high-speed beam of
electrons to cut or drill materials.
4. Waterjet Cutting: This process uses a high-pressure jet of water mixed with abrasive
particles to cut materials such as metal, stone, and glass.

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 Advantages of advanced manufacturing processes include increased production speed,
improved product quality, reduced material waste, increased efficiency, and the ability to
produce complex parts and components that would be difficult or impossible to produce
with traditional manufacturing methods.

Limitations of advanced manufacturing processes include the high cost of equipment, the
need for specialized training, and the complexity of some of the processes.

Applications of advanced manufacturing processes can be found in a wide range of

industries, including aerospace, automotive, electronics, medical devices, and consumer
products. These processes are used to create everything from airplane parts and medical
implants to custom jewelry and toys.

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 Additive Manufacturing and 3D Printing
Additive manufacturing and 3D printing are advanced manufacturing processes that

have revolutionized the manufacturing industry. Both processes involve the creation

of three-dimensional objects from digital models, using additive processes that build

up the objects layer by layer.

Additive manufacturing is a techniques for creating objects by adding material layer

by layer. 3D printing is a specific type of additive manufacturing that uses a printer to

create a physical object from a digital model. The printer reads the model file and

deposits material layer by layer until the object is complete. The material can be

plastic, metal, ceramic, or even food, and the printer can create complex shapes and

designs that would be difficult or impossible to create using traditional

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manufacturing processes.
 Both additive manufacturing and 3D printing offer several advantages over traditional

manufacturing processes.

Advantages :They can create complex geometries and internal structures that would be

difficult to achieve with traditional methods. They also have the potential for faster

production times and reduced waste, as they only use the exact amount of material needed

for each object.

Limitations:They can be expensive to set up and may require specialized knowledge and

skills to operate. The quality and strength of the finished products may also be inferior to

those produced using traditional methods, particularly in industries such as aerospace or

medical devices where strict standards are required.

Additive manufacturing and 3D printing have many applications in a variety of industries,

including aerospace, automotive, medical devices, and consumer products. They are
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particularly useful for creating prototypes, custom parts, and small production runs.
 Micro-machining
■ Micromachining is a manufacturing process that involves the fabrication of
miniature components with dimensions in the range of micrometers.
■ It is a highly precise and accurate machining process used to produce intricate and
delicate parts that cannot be manufactured using conventional machining
methods.
■ Micromachining involves the removal of material using a variety of techniques,
including cutting, grinding, and etching, to create parts with features in the range of
micrometers.

Examples of Micromachining

1. Laser Cutting: This process uses a high-powered laser to cut, engrave or mark
materials such as metal, plastic, and wood.
2. Electron Beam Machining: This process involves using a high-speed beam of
electrons to cut or drill materials.
3. Waterjet Cutting: This process uses a high-pressure jet of water mixed with
abrasive particles to cut materials such as metal, stone, and glass.
4. Electrochemical Machining: This process uses an electrolyte solution and an
electric current to remove material from a workpiece.
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 The use of micromachining has grown significantly in recent years due to the increasing
demand for smaller and more precise components in various fields, including electronics,
biomedical engineering, and microfluidics.

Advantages of Micromachining

high precision, accuracy, and repeatability, as well as the ability to produce complex and
intricate geometries with high aspect ratios.

Limitations of Micromachining

the limited material removal rates, high cost of equipment, and the need for specialized
expertise in programming and machining operations.

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 Reconfigurable manufacturing System
Reconfigurable Manufacturing System (RMS) is a type of flexible manufacturing system
(FMS) that can quickly adapt to changes in production requirements. RMS uses a modular
design approach and can be reconfigured to produce different products with minimal
downtime. The system comprises different types of machine tools, material handling systems,
and control systems that can be reconfigured for different production requirements.

Internet of Things (IoT) refers to the network of physical devices, vehicles, buildings, and other
objects that are embedded with sensors, software, and network connectivity to collect and
exchange data. In manufacturing, IoT enables the integration of physical systems with digital
systems to provide real-time monitoring and control of machines and processes. It enables
predictive maintenance, production optimization, and quality control.

The integration of RMS and IoT enables the creation of a smart factory, where machines and
processes are interconnected and communicate with each other to optimize production. RMS
allows for quick reconfiguration of the production line to adapt to changing demands, while IoT
provides real-time monitoring of the machines and processes to optimize performance. The
combination of these technologies can improve productivity, reduce downtime, and improve
product quality.
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 Computer Numerical Control (CNC)
Computer Numerical Control (CNC) machines are used in modern manufacturing

processes to perform a variety of tasks, such as drilling, milling, cutting, and shaping

materials. These machines are controlled by a computer program that provides precise

instructions on how to perform the required operation. CNC programming which includes

G-Code and M-Codes is the process of writing a program that controls a CNC machine.

The basic concept of CNC programming involves using software to create a set of
instructions that are then fed into the machine. These instructions are in the form of a
code that tells the machine what operations to perform, how to move the cutting tool, and
how fast to perform the operation. The code is written using a programming language
specific to the CNC machine.

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 Computer Numerical Control (CNC)

Applications:

In addition, CNC programming can be used in a variety of industries, including

aerospace, automotive, and electronics manufacturing. The use of CNC machines has
revolutionized the manufacturing industry by providing a cost-effective way to produce
high-quality parts and products.

Advantages: CNC programming has numerous advantages over traditional manual

machining. It is more accurate, faster, and can be used to create complex shapes and
designs.

CNC machines are also capable of running for long periods without human intervention,
making them ideal for mass production.

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 Computer Numerical Control (CNC)
There are several advantages of CNC (Computer Numerical Control) machines,
including:

1. Increased precision and accuracy: CNC machines are capable of producing highly
accurate and precise parts due to the use of computer software to control the
movement of the machine. This eliminates the possibility of human error and
ensures that each part is identical.
2. Increased production speed: CNC machines are capable of producing parts at a
much faster rate than traditional manual machines. This allows for increased
productivity and shorter lead times.
3. Improved flexibility: CNC machines can be programmed to produce a wide variety
of parts, making them highly flexible and adaptable to changing production needs.
4. Reduced labor costs: CNC machines require less labor than traditional manual
machines, as they can be operated by a single operator who is responsible for
programming the machine and overseeing its operation.
5. Improved safety: CNC machines are designed with safety features that help
prevent accidents and injuries. For example, they may have automatic shut-off
systems that are triggered if a tool breaks or if the machine detects a fault.
6. Greater consistency and repeatability: CNC machines can produce parts with a
high degree of consistency and repeatability, which is important for industries that
require identical parts for large-scale production.
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 Computer Numerical Control (CNC)

Limitations of CNC machines:

1. Cost: CNC machines are typically more expensive than conventional

machines due to their advanced technology and components.
2. Complexity: The programming and operation of CNC machines require
skilled operators and programmers who have a thorough understanding of
the technology and software.
3. Maintenance: CNC machines require regular maintenance to ensure
proper functioning, which can be time-consuming and expensive.
4. Size limitations: The size of the workpiece that can be machined is limited
by the size of the machine bed and the range of motion of the cutting tool.
5. Material limitations: Some materials, such as composites and certain
metals, can be difficult to machine with CNC due to their physical properties.
6. Production limitations: CNC machines are not suitable for low-volume
production runs or prototyping, as the setup time and programming costs
can be significant.
7. Power failure: Power failure during the machining process can cause
damage to the machine and workpiece, resulting in significant downtime and
repair costs.

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