BAEEE101 – BASIC

ENGINEERING

Module – IV – Manufacturing Processes,

Energy conversions and Mechanical
Automation

Lecture – 1 – Metal Casting & Forming

Course Faculty:
Dr. Saravanakumar D, SMEC
VIT Chennai.
 Introduction to Manufacturing

What is manufacturing?

Raw material
(steel ingots)

Conversion of raw material into a useful product

 Introduction to Manufacturing

Methods of manufacturing

Manufacturing

Metal Metal Joining Powder

Machining
casting forming processes metallurgy
 Casting
❖ Casting is a manufacturing process that
involves pouring a liquid material into a
mold and allowing it to solidify.

❖ The solidified object is taken out from

the mold either by breaking or taking
the mold apart.

❖ The solidified object is called casting

and the process followed is known as
casting process.

❖ Steps in casting:
▪ Melt the metal
▪ Pour it into a mold
▪ Let it freeze
Dr. Atul Kumar Sharma
 Capabilities and Advantage of Casting

• Casting can be applied to shape any metal that can melt

• Product can be cast as one piece.

• Complex shapes can be manufactured

• Some casting processes are net shape; others are near

net shape

• Can produce very large parts (with weight more than 100 tons), like
m/c bed

• Metals difficult to be shaped by other manufacturing processes may be

cast (eg: Cast Iron)

Dr. Atul Kumar Sharma

 Disadvantage of Casting

Different disadvantages for different casting processes:

• Casting process is a labour intensive process

• Safety hazards to workers due to hot molten metals

• Limitations on mechanical properties

• Poor dimensional accuracy and surface finish for some processes; e.g.,
sand casting

Dr. Atul Kumar Sharma

 Casting examples
Big parts
• Engine blocks, machine frames, railway wheels, pipes etc.

Small parts
• Dental crowns, jewelry, small statues, Etc.

Dr. Atul Kumar Sharma

 Sand Casting [Expendable mold casting]
❑ Use of temporary, non-reusable molds (mold is broken to take out the
solidified cast). No limit to size, shape or weight.

❑ Suitable for materials with high melting point temperature.

❑ Coarser surface finish and wide tolerance.

Section View of Sand Casting

Selection of parting line

along flat plane rather
than contoured is better
for economical casting.
 Parting Molding
Flask Pattern Core
line sand
A metal or
wood frame. The mold Mixture of Part of the
Dividing
cavity is silica sand, mold,
[Drag – lower line
made with clay, and generally
flask, Cope – between the
the help of moisture baked, used
upper flask, flasks that
wood or without to create
Cheek – makes up
metal losing its various
intermediate the mold
pattern permeability cavities
flask]

Elements of Sand Casting

Pouring
Sprue Runner Chaplets Riser
basin
The channel A column of
Funnel The passage
through the Used to molten
shaped through
molten support the metal
cavity in which the
metal is cores to placed in
which the molten
carried take care of the mold to
molten metal
from the its own feed the
metal is reaches the
sprue to the weight castings as
poured mold cavity
gate it shrinks
 Steps Involved in Sand Casting

Casting
Step1: Place a pattern (Shape of the part to
be cast.

Step2: Incorporate the gating system.

Step3: Remove the pattern and fill the mold

cavity with molten metal.

Step4: Allow the molten metal to cool until

Source: Materials Selection in Mechanical it solidifies.
Design Fourth Edition Michael F. Ashby
Step5: Break the sand mold and remove the
cast component.
 Steps Involved in Sand Casting

Source: [Link]
instruction
 Casting Defects

Shift or Mismatch Metal Penetration

Improper alignment of mold Blowholes Improper mold strength,
cavities on cope and drag Insufficient Venting high pouring temperature

Shrinkage Cavity Cold Shut Hot Tears or Hot Cracks

Poor design or feeding Low pouring temperature, Improper composition
system Lack of fluidity
 How to avoid Shrinkage Cavity?
Solidification of intersecting sections results in hot spots and shrinkage cavities.

Hot spots retard solidification and usually cause porosity and shrinkage cavities.

Liquid-to-solid shrinkage can leave a void

at the last point to solidify.
 Importance of Riser Placement
The riser supplies metal to the casting during solidification and contains
the final void. The riser is removed later, leaving a solid casting.

Risers are attached to the heaviest sections. All surrounding sections

should be thinner. The thinnest sections are farthest from the riser and
solidify first. Solidification progresses toward the heaviest section and
then the riser.

The designer should visualize the direction of solidification and taper

sections as necessary to ensure that solidification proceeds toward the
direction of risers, thus minimizing the chance for voids to occur.
 Pattern/Casting/Component
The construction of pattern must take account of:

❑ The mould parting line

❑ Machined surfaces

❑ Shrinkage of material

❑ Draft to facilitate the extraction from the

mould Cast Iron Pulley –
Machined All Over

Ref: Designing for Manufacture by Harry Peck

 Types of Patterns
Single Piece Pattern
or Solid pattern Split pattern Match plate pattern

A pattern made as a single, Constructed in two or more Cope and drag halves of the
complete unit without any parts, typically separated at pattern are mounted on
joints or loose pieces the parting line. opposite sides of a plate.

Sweep pattern Gated pattern Skeleton pattern

To create mold cavities, To create multiple identical To create molds for simple,
particularly for symmetrical castings within a single large castings
castings mold
 Extrusion
Extrusion - To produce long parts of uniform cross sections
❑ Initial shape is squeezed
through a die to get the
deformed part in the shape of
die opening.

❑ It is used to produce cylindrical

bars and hollow tubes.

❑ Most of the parts are produced

Hot Extrusion
by hot extrusion, because
required flow stress for metal is
Extrusion process sequence:
less at high temperature.

Heating of billet of metal → Insertion into a container → Forcing through a

die hole → Desired cross-section.

✓ Extrudability is in reverse order of strength. Al, Cu, Mg, Zn alloys > Steels
 Types of Extrusion

Force needed for the

extrusion of billet is
more.

Frictional forces are

easily eliminated due to
simultaneous movement
of billet and container.

Source: Materials Selection in Mechanical Thin walled extrusions are more difficult to
Design Fourth Edition Michael F. Ashby produce due to difficult flow of metal in narrow
path.
 Types of Extrusion
Hot Extrusion → Above the recrystallization temperature, to ensure easy
flow and to avoid work hardening,

Cold Extrusion → Done at room temperature or at warm condition, lack of

oxidation, higher strength due to cold working, closer tolerances, better
surface finish.
Impact Extrusion → Billet is pressed at a high velocity with extreme force into
a die by a punch.

Hydro-static Extrusion → Billet is completely surrounded by a pressurized liquid

(Less friction, ductility increases at high pressures, even flow, No residue on walls).
 Forging

Forging

Forging complexity is increased by

several features.

❖ The presence of thin sections in

Source: Materials Selection in Mechanical
the part
Design Fourth Edition Michael F. Ashby
❖ Large changes in cross-sectional
Forging provides increased area of the part
mechanical strength and superior
structural integrity and eliminates ❖ Part shapes that require the die
cavities, voids and pores. parting line to be cranked
 Closed Die Forging

Conventional impression-die forging sequence

Ref: Design for Manufacturability - Handbook, James Bralla, Mc Graw Hill
More complex
and highly
Refined and deformed shape
controlled grain
Controlled plastic structure
deformation @
elevated
temperature

Ref: [Link]
 Forging Nomenclature
Rib, and boss → Any wall filled by flow parallel to die motion.

Web → The wall filled by horizontal flow, perpendicular to die motion and parallel to
the parting plane.

Recess → Small web area surrounded by thicker metal.

Features of a part to the direction of die motion

Parting line location is a critical step in forging design. It determines the die cost, draft
requirements, grain flow, and trimming procedures.

Ref: Design for Manufacturability - Handbook, James Bralla, Mc Graw Hill

 Benefits of Forging
❑ Grain flow is the directional pattern that metal
crystals assume during plastic deformation.

❑ Unbroken grain flow following the contour of the

part.

❑ Alignment of grain flow with directions of the

principal stresses.

❑ Enhanced mechanical properties along the grain flow

direction than in the randomly oriented crystals of
cast metal or weld metal.

Ref: Design for Manufacturability - Handbook, James Bralla, Mc Graw Hill

 Rolling Flat Rolling, and Shape Rolling

Extrusion

Source: Materials Selection in

Mechanical Design Fourth Edition ❑ The metal is plastically deformed between
Michael F. Ashby rotating rolls and causes reduction in
thickness and change of shape [cross-section].

❑ The volume remains same due to reduction in

thickness and increase in length and width.

❑ Hot rolled steel is ideal for products where

tight tolerances are not required.
 Types of Rolling
Characteristics of Cold
Rolling

✓ Better, more finished surfaces

with closer tolerances.

✓ Smooth surfaces that are often

oily to the touch.

✓ Bars are true and square, and

often have well-defined edges
and corners.

✓ Tubes have better concentric

uniformity and straightness.

[Link]
 Important Terms of Rolling
Roll gap
Roll Force

Roll Force

Draft → Initial Thickness – Final Thickness

Source: [Link]
material-grain-size-matters-in-sheet-metal-bending
 Back-up Rolls
Large rolls are used to support smaller work rolls in high load
applications

Source: [Link]
 Shape Rolling

Source: [Link]
 Hot Rolling, Hot forging, Hot Cold Rolling, Cold forging, Cold
Extrusion Extrusion

❑ Above recrystallization ❑ Below recrystallization

temperature temperature
❑ More ductility of metals at ❑ Less ductility at room
high temperature temperature
❑ Less force is required ❑ More tonnage is required
❑ Rough surface finish due to ❑ Better finish and dimensional
oxidation and scale formation accuracy
❑ No residual stress formation ❑ Residual stress is induced to
plastic deformation
❑ More tool life ❑ Tool life is less due to wear
❑ More energy consumption due ❑ Less consumption of heat
to the requirement of heating energy but more force is
required
 How It’s Made?
Identify the given parts and name the manufacturing process used.
Justify the reason behind choosing that manufacturing process.