Manufacturing Process

PMA (2019)

1. Discuss fusion and non-fusion welding process with a sketch.

Fusion Welding – is a process that uses heat to join or fuse two or more materials by heating
them to melting point. The process may or may not require the use a filler material. External
application of pressure is not required for fusion welding processes, except for resistance welding,
where substantial contact pressure is required during welding for sound joining.

Arc welding – In the welding process if the heat required for melting of the parent material
is obtained due to the Electrical arc called as arc welding.

Gas welding – In the welding process if the heat required for melting of the parent material
is obtained due to the burning of gases called as gas welding.

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Non-Fusion welding – The process of welding in which without melting of parent material, if the
joint is produced is called as a Non-Fusion welding process.

Pressure welding – With application of large amounts of pressure, If a joint is produced is called
as pressure welding operation.

Brazing – In this process by using molten metal through capillary action, the filler
metal is drawn through the joint between the parent metal to create metallurgical bond.

Soldering – The welding process below the temperature 450° C in which it is melted to
join metallic surfaces.

Cold Pressure welding – At room temperature itself with the application of large amounts of
pressure, if a joint is produced is called as cold pressed welding.

Cryogenic welding – The welding in which a metal is cooled below the temperature -183° C and
with the application of large amounts of applying pressure, when the joint is produced called as
cryogenic welding.

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PMA (2019)

2. What is die casting? With a sketch, explain cold chamber die casting process.

Die casting is a metal casting process that is characterized by forcing molten metal under high
pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have
been machined into shape and work similarly to an injection mold during the process. Most die
castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead,
pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber
machine is used.

Cold chamber die casting process.

Cold chamber die casting is a permanent mold metal casting process. A reusable mold, gating system
and all, is employed. It is most likely machined precisely from two steel blocks. Large robust machines
are used to exert the great clamping force necessary to hold the two halves of the mold together
against the tremendous pressures exerted during the manufacturing process.

During cold-chamber die casting, the molten charge, which consists of more material than is required
to fill the casting, is ladled from the crucible into a shot sleeve where a hydraulically operated plunger
pushes the metal into the die. The extra material is used to force additional metal into the die cavity to
compensate for shrinkage, which takes place during solidification.

The main components of a cold-chamber die casting machine are shown below. Injection pressure of
over 10,000psi or 70,000KPa can be obtained from this type of machine.

Operating sequence of the cold-chamber die casting process

i. The die is closed and the molten metal is ladled into the cold-chamber shot sleeve

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ii. The plunger pushes the molten metal into the die cavity where it is held under pressure until it
solidifies.

iii. The die opens and the plunger advances, to ensure the casting remains in the ejector die.
Cores, if any, retract.

iv. Ejector pins push the casting out of the ejector half of the die and the plunger returns to its
original position.

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PMA (2019)

3. Which of the casting processes is the most widely used in the current manufacturing industries,
provide examples to support your argument.

Sand casting, the most widely used casting process, utilizes expendable sand molds to form complex
metal parts that can be made of nearly any alloy. Because the sand mold must be destroyed in order
to remove the part, called the casting, sand casting typically has a low production rate. The sand
casting process involves the use of a furnace, metal, pattern, and sand mold. The metal is melted in
the furnace and then ladled and poured into the cavity of the sand mold, which is formed by the
pattern. The sand mold separates along a parting line and the solidified casting can be removed. The
steps in this process are described in greater detail in the next section.

Sand casting is used to produce a wide variety of metal components with complex geometries. These
parts can vary greatly in size and weight, ranging from a couple ounces to several tons. Some smaller
sand cast parts include components as gears, pulleys, crankshafts, connecting rods, and propellers.
Larger applications include housings for large equipment and heavy machine bases. Sand casting is
also common in producing automobile components, such as engine blocks, engine manifolds, cylinder
heads, and transmission cases.

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PMA (2019)

4. Briefly explain with a sketch the difference between single point cutting tools

i. Back rake angle

Back rake angle is the angle between the face of the single point cutting tool and a line parallel
with base of the tool measured in a perpendicular plane through the side cutting edge. If the
slope face is downward toward the nose, it is negative back rake angle and if it is upward
toward nose, it is positive back rake angle. Back rake angle helps in removing the chips away
from the workpiece.

ii. End clearance angle (End Relief Angle)

End relief angle is defined as the angle between the portion of the end flank immediately
below the cutting edge and a line perpendicular to the base of the tool, measured at right
angles to the flank. End relief angle allows the tool to cut without rubbing on the workpiece.

iii. Side rake angle

Side rake angle is the angle by which the face of tool is inclined sideways. Side rake angle is the
angle between the surface the flank immediately below the point and the line down from the
point perpendicular to the base. Side rake angle of cutting tool determines the thickness of the
tool behind the cutting edge. It is provided on tool to provide clearance between workpiece
and tool so as to prevent the rubbing of workpiece with end flake of tool.

iv. Side relief angle

Side rake angle is the angle between the portion of the side flank immediately below the side
edge and a line perpendicular to the base of the tool measured at right angles to the side. Side
relief angle is the angle that prevents the interference as the tool enters the material. It is
incorporated on the tool to provide relief between its flank and the workpiece surface.

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5. Explain the process application with sketch of the

i. Reaming

Reaming – A reamer enters the workpiece axially and enlarges an existing hole to the
diameter of the tool. A reamer is a multi-point tool that has many flutes, which may be
straight or in a helix. Reaming removes a minimal amount of material and is often performed
after drilling to obtain both a more accurate diameter and a smoother internal finish.

ii. Boring

Boring – A boring tool enters the workpiece axially and cuts along the internal surface
of an existing hole to enlarge the diameter or obtain more precise dimensions. The boring tool
is a single-point cutting tool, which can be set to cut the desired diameter by using an
adjustable boring head.

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