Takoradi Technical University Faculty of Engineering

TAKORADI TECHNICAL UNIVERSITY
FACULTY OF ENGINEERING
MACHINE DESIGN
GROUP WORK
AIDOO MICHAEL KWEKU 0720361081

PATRICK ASSEWAH 0720361075
ABEDENEGO TAWIAH 0720361138
CHRISTIAN ASIEDU 0720361080
EDWARD ANSAH 0720361067
EVANS DONKOR 0720361011
AWUAH JOSHUA 0720361145
MANUFACTURING PROCESSES AND HEAT
TREATMENT PROCESSES
MANUFACTURING PROCESSES
Manufacturing is the processes of turning raw materials or parts into finished goods through the use of
tools, human labor, machinery, and chemical processing. There are four basic manufacturing processes
for producing desired shape of a product. These are;
1. Casting and molding

2. Machining
3. Joining
4. Forming (deformation processes)
CASTING AND MOULDING: Molding is the act of creating a cavity or hole that carries of an original
model. Molds can be made of a rigid material such as plaster or plastic resin or more commonly a
flexible material such as rubber. The material used should be chosen considering the material model.
Casting on the other hand is the act of pouring liquid material into the cavity of a mould, after a period
of time this liquid will solidified through chemical reaction or cooling. The solidified part is also known as
a casting which is ejected or broken out of the mould to complete the process, casting materials are
usually metals or various mixing of two or more components together, example; epoxy, concrete, clay
etc. Casting is done, when a mould is available. Examples of casting materials or products are; engine
block, pump housing, aluminum gear box, spanner, spoon etc.
Some molded materials
Advantages of casting and mounding process over other manufacturing process;

 Casting can produce very complex geometry parts with internal cavities.
 Casting objects have high compressive strength.
 Any intricate/ complex shape can be produced.
Disadvantages of casting and moulding process
 It is not economical for mass production.

 It gives low fatigue strength compare to forging.
 It gives poor surface finish and mostly requires surface finish operation.
MACHINING: it is a prototyping and manufacturing process that create a desire shape by removing
unwanted material from a large piece of material. Also know as subtractive manufacturing.
There are three main kinds of machining, these are; turning, milling, and drilling there are other
processes that also fall into the category of machining but these three covers the most when it comes to
modern machining processes.
TURNING PROCESS: Turning is a form of machining, a material removal process which is used to create
rotational parts by cutting away unwanted material. The turning process requires a turning machine or
lathe, work piece, fixture, and cutting tools. Some types of turning are; tapping, step turning, contour
turning, chamfer turning.
MILLING PROCESS: Milling is a machining process that involves the use of cutting tools, that are rotated
at a set speed and then brought into contact with a work piece. The work piece is typically held by some
sort of clamping device. Milling is use to make flat or stepped surfaces.
DRILLING PROCESS: Drilling is a metal cutting process performed by a rotating cutting tool, to make a
circular hole in solid materials. The cutting tool is named as a twist drill since it has sharp twisted edges
formed around a cylindrical tool provided with a helical groove along its length to allow the cut material
to escape through it during drilling.
JOINING PROCESS: Joining is the process by which two or more materials can be permanently or
temporarily assembled together. joining process include; welding, brazing, soldering, mechanical
fastening and adhesive and riveting. Joining processes are characterized by their ability to fuse or join
two or more component for the purpose of creating a different object.
FORMING PROCESS: forming is a mechanical process used in manufacturing industries; where in

materials (mostly metals) undergo plastic deformation and acquire required shape and sizes by
application of suitable stresses such as compression, shear and tension. Examples are; forging,
extrusion, rolling, sheet metal working, rotary swaging, explosive farming.
HEAT TREATMENT
Heat treatment is the process of heating and cooling a material to achieve a desire set of physical and
mechanical properties, such as hardening or softening of material. Some of the heat treatment
techniques include; Annealing, Case hardening, Tempering, Normalizing, Quenching etc.
ANNEALING: is a type if heat treatment that alters the physical and sometimes chemical properties of a
material to increase its ductility and reduce it hardness making it more workable, mainly to soften a
metal. Its stages are; Recovery stage, Recrystallization stage, Grain growth stage. Some materials used
are; cast iron, aluminum, brass and copper.
CASE HARDENING: Case hardening also referred as Carburizing, is a heat treatment process that
produces a surface which is resistant to wear, while maintaining toughness and strength of the core.
This treatment is applied to low carbon steel parts after machining, as well as high alloy steel bearings,
gears and other components.
TEMPERING: Tempering is a heat treatment that improves the toughness of hard, brittle steels so that
they can hold up during processing. Tempering requires that the metal reaches a temperature below
what’s called the lower critical temperature depending on the alloy.
NORMALIZING: Normalizing is a heat treatment process where a material is heated to a predecided

elevated temperature which is held at that temperature for a certain period of time and then allowed to
cool freely in the air to reach room temperature. This process is done to make the material more ductile
and tough.
QUENCHING: Quenching is the soaking of a metal at a high temperature, above recrystallization phase,
followed by a rapid cooling process to obtain certain desirable material properties. This process is done
to make the material more durable and more tensile strength.
STAGES OF HEAT TREATMENT
1. Heating stage
2. Soaking stage
3. Cooling stage

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TAKORADI TECHNICAL UNIVERSITY

AIDOO MICHAEL KWEKU 0720361081

1. Casting and molding

Some molded materials

Advantages of casting and mounding process over other manufacturing process;

Disadvantages of casting and moulding process

 It is not economical for mass production.

FORMING PROCESS: forming is a mechanical process used in manufacturing industries; where in

NORMALIZING: Normalizing is a heat treatment process where a material is heated to a predecided

STAGES OF HEAT TREATMENT

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