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MEE1007 MANUFACTURING PROCESS

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Dr. CHINMAYA P. MOHANTY


Assistant Professor (Senior)
School of Mechanical Engineering,
VIT Vellore, Vellore, TN, India – 632 014.
MEE1007 MANUFACTURING PROCESS

Manufacturing - The Role of Manufacturing Development in the growth of a country –


Classification of manufacturing processes
Module – 1 Casting processes Casting: Fundamentals of metal casting –Pattern and mould making-
Different casting techniques-Melting practice and furnaces - Defects in casting – Testing and
inspection of casting.

Module – 2 Joining Processes Fusion welding processes-Solid state welding processes-Advanced


welding techniques-Weld quality – Testing welded joints.

Metal forming Processes Cold and Hot working-Bulk metal forming -Sheet metal forming –
Module – 3 High Energy Rate Forming Processes: Explosive Forming – Electro Hydraulic Forming – Electro
Magnetic Forming.

Processing of Powder Metals, Ceramics, Glass and Plastics Powder metallurgy- Shaping
of ceramics-Glass-Processing of plastics: Injection molding – Blow molding – Compression
Module – 4 molding – Transfer molding – Thermoforming

Contd. …..

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MEE1007 MANUFACTURING PROCESS

Process selection Systematic process selection-Process selection charts-Ranking process cost-


Module – 5 Cost modelling

 Aluminium Connecting Rod,


 Fan leaf with nylon material,
 Airbag canisters,
Case  Joining a Steel Radiator,
Studies  Car bonnet,
 Spark Plug Insulators,
 Ceramic knife,
 Devices to open corked bottle,
 Aircraft wing spar,
 Forks for a racing bicycle,
 Spark plug insulator,
 Insulation for refrigerator etc.

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BOOKS

TEXT BOOKS
1. Manufacturing Technology, P. N Rao, McGraw Hill Education

REFERENCE BOOKS

1. B.S.Nagendra Parashar, R.K.Mittal, Elements of Manufacturing


Processes, PHI, 2010

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MANUFACTURING

 Manufacturing – The process of making a product is called manufacturing.


It is the process of converting raw materials into a finished product.
 Raw material – The material as found in nature is called Raw material
 Product – Any object made by us for any specific purpose is called a
product.

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FOR CARRYING OUT MANUFACTURING ACTIVITY WE REQUIRE 5 M’S

 Material

 Methods

 Machinery

 Men

 Money

Manufacturing Process and its interaction with the 5 M’s

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ROLE OF MANUFACTURING IN NATION GROWTH

 Manufacturing has been the path to development


Rich nations like Germany, Japan , US have excellent
manufacturing sectors for development of national wealth and
power.
 Manufacturing is the foundation of global “Great
Power”
The most powerful nations are those which control the bulk of
the production. The key issue is not to produce in large
quantities but to know to prepare the machineries that prepares
product. The key is to know the means of production.
 Manufacturing is the most important cause of
economic growth
Attractive and flexible product sell themselves not only in
the country but also world wide. As a result the economic
growth of the company increases.
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 Services are dependent on manufactured goods
If manufactured goods are of good quality its will drastically
enhance the economy of country. To sum up: the health of the
economy is critically dependent on the health of the
manufacturing sector of the nation.
 Manufacturing creates jobs
Most jobs, directly or indirectly, depend on manufacturing — and
reviving the sector could provide tens of millions of new jobs,
eradicating the Great Recession.

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CLASSIFICATIONS OF MANUFACTURING PROCESS

Broadly manufacturing process are classified in to five types

 Casting

 Machining

 Forming

 Powder Metallurgy

 Joining

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CASTING PROCESS

 Casting may be defined as a metal object obtained by pouring


molten metal in to a mould and allowing it to solidify.

 Casting process is based on the property of liquids to take up the


shape of the vessel containing it.

 Molten metal when poured in to a cavity of desired shape (called


mould) flows in to every nook and corner of the cavity and fills all
the shape.

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Engine Parts Made of Casting

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MACHINING

The process of manufacturing a component by removing the unwanted


material using a machine is known as Machining and when used with
metals it is referred to as metal machining or metal cutting.

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METAL FORMING

Shaping of a component by the application of external forces is known


as the metal forming.
Metal forming can be described as a process in which the desired size
and shape are obtained through the deformation of metals plastically
under the action of externally applied forces.

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POWDER METTAULRGY

Fine powdered materials are blended, pressed into a desired shape in


a die and then heated in a controlled atmosphere to bond the
contacting surfaces of the particles and get the desired properties.

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Where Powder metallurgy gains importance?

1. When Melting temperature of metal becomes very high


2. Materials where machining is difficult due to very hardness
3. Some metals react drastically during melting in furnace
due to chemical reaction.
4. Where more number of components have to be
manufactured.
5. When manufacture requires his own property in a
particular material.

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JOINING

Two or more pieces are joined together to produce the required shape and/or
size of the product.
All joining processes can be categorized based on the type of joint produced
under two categories:
1. Permanent Joint
2. Temporary joint
Permanent Joint: the joint is made such that it has the properties similar to
the base metal of the two parts.
Permanently joined parts cannot be separated in to their original shape, size
and surface finish.
A temporary joint can be easily dismantled separating the original parts
without any damage to them.

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