Professional Documents
Culture Documents
Course objective: To develop in‐depth understanding on manufacturing processes namely joining,
casting, metal forming, machining and non‐traditional machining processes. Further to introduce few
non‐destructive examination methods.
IIT TIRUPATI
1
Course syllabus
2. Casting: Sand casting process –Steps, mould sand composition and properties, 12
Sand testing, pattern types, allowances, cores, gating system, melting furnaces,
solidification phenomena; special casting methods‐centrifugal casting, permanent
mold casting, hot chamber and cold chamber die casting, investment casting, shell
mold casting, plaster mold casting, CO2 mold casting, casting defects and
remedies.
IIT TIRUPATI
2
Course syllabus
4. Metal forming: Introduction, Forging, rolling, extrusion, wire drawing and tube 10
drawing, forging defects and remedies, sheet metal working.
Total 51
Evaluation pattern: Assignments 10; Quiz I 15; Surprise tests 10; Quiz II – 15; Seminar – 10;
End semester ‐ 40
IIT TIRUPATI
3
Suggested references
1. GrooverMikell P., Fundamentals of modern manufacturing, John Wiley and Sons Inc.
7. R. L. O’Brien, Welding processes, volume 2, eighth edition, Welding hand book (American
Welding Society).
IIT TIRUPATI
4
What is manufacturing?
The word manufacture is derived from two Latin words manu and factus
The combination of
these words means
Made by hand
Solidification processes
Material removal
Processing Property
Heat treatment
operations enhancing processes
Cleaning and
Surface processing surface treatments
Manufacturing operations
Coating and
processes deposition processes
Welding
Permanent joining
Brazing and soldering
processes
Assembly Adhesive bonding
operations
Mechanical Threaded fasteners
Joining two or more
components to create a new fastening Permanent fastening methods
entity, called as assembly.
IIT TIRUPATI
6
An overview of the selected Manufacturing processes
IIT TIRUPATI
7
Manufacturing processes
Solidification processes
Particulate processing
Shaping processes
Deformation processes
Material removal
Processing Property
Heat treatment
operations enhancing processes
Cleaning and
Surface processing surface treatments
Manufacturing operations
Coating and
processes deposition processes
Welding
Permanent joining
Brazing and soldering
processes
Assembly Adhesive bonding
operations
Mechanical Threaded fasteners
fastening Permanent fastening methods
IIT TIRUPATI
8
Shaping processes – solidification processes
• The starting material is heated sufficiently to transform it into a liquid or highly plastic (semifluid) state.
• The material in liquid or semifluid form can be poured or otherwise forced to flow into a mold cavity.
• After solidification, the material take the solid shape that is same as the cavity.
• Examples are the casting and molding processes
Pouring ladle
Sprue and
Molten metal runner to be
trimmed
Downsprue Parting Solid casting
line
Mold
(sand)
(a) (b) Alloy wheel of a Nissan made SUV
Casting process
• The starting material is shaped by the application of forces that exceed the yield strength of the material.
• The material should be ductile to avoid fracture during deformation.
• The material is often heated before forming to a temperature below the melting point to increase the ductility.
• Examples are the forging and extrusion processes
Extruded
Chamber cross section
v, F
Forging Ram
Aero blade load bar
Die
Flash (to
be trimmed) v, F
Die
Die
Starting billet
(a) Forging (b) Extrusion Side intrusion beam
Ford frame with 32 Al extrusions
Multi port extruded tubes in
car heat exchanger
Spanners
Nuts and bolts Connecting rods
Pistons Wheels
Electrode
Filler metal
Arc Welded joint
Shielding gas Molten pool
Base metal Penetration
Welding arc
Two parts to be welded
(base metal)
both heat and
pressure are
RSW sources
heat is the SMAW
source
EW
pressure is
the source
Welding: It is a material joining process in which two are more parts are joined
together at their contacting surfaces by a suitable application of heat alone or
pressure alone or both simultaneously.
IIT TIRUPATI
12
Welding – examples
Train tracks
Pipe welding Ship building
Train compartments
IIT TIRUPATI
13
Shaping processes – material removal
• Removes excess material from the starting workpiece so that the resulting shape is the desired geometry.
• Material removal processes tends to be wasteful of material, simply by the way they work. The material
removed from the starting shape is waste.
• Few material removal processes are
Machining
Grinding
Non‐traditional processes
• The machining process is the most important and the common material removal process. It is categorized as
Turning
Drilling
Milling
Rotation
Starting Diameter
Feed Milling Rotation
work diameter Chip after turning
piece Drill bit cutter Material
removed
Rotation work
(work) piece work
piece
Hole
Feed tool Single point
cutting tool Feed
(a) Turning (b) Drilling (c) Milling
IIT TIRUPATI
14
Shaping processes – material removal
Rotation
Starting Diameter
Feed Milling Rotation
work diameter Chip after turning
piece Drill bit cutter Material
removed
Rotation work
(work) piece work
piece
Hole
Feed tool Single point
cutting tool Feed
(a) Turning (b) Drilling (c) Milling
A single‐point cutting tool removes A work piece is fed past a rotating
metal from a rotating work piece cutter with multiple edges
to reduce diameter A rotating drill bit is fed into the
work to create a round hole
IIT TIRUPATI
15
Non‐destructive testing (NDT)
Welding defects
Surface defects
Sub‐surface defects
IIT TIRUPATI
16
Non‐destructive testing (NDT)
“Non‐destructive testing in the welding / foundry is the method of detecting defects or flaws in welds /
casting products without impairing the usefulness of the component or structure under test.”
• NDT methods
Visual inspection
Liquid penetrant testing / dye penetrant testing
Magnetic particle testing
Ultrasonic testing
Eddy current testing
Magneto graphic testing
Radiographic testing
Acoustic emission testing
IIT TIRUPATI
17
18