Introduction to Manufacturing Process

• Casting Process: Introduction : Concept of Manufacturing process,

its importance.

• Classification of Manufacturing processes. Introduction to Casting

process & steps involved.

• Varieties of components produced by casting process. Advantages &

Limitations of casting process.

• Patterns: Definition, functions, Materials used for pattern, various

pattern allowances and their importance. Classification of patterns.

• Binder: Definition, Types of binder used in moulding sand.

• Additives: Need, Types of additives used.

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Classification of Manufacturing Process

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Classification of Manufacturing Process

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 Types of Production Systems

• Mass production / continuous flow process

• Batch production

• Job shop production

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Sand Casting

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Sand Casting

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Sand Casting

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 Rolling

Hot-rolling

Cold-rolling

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Extrusion: Schematic, Dies

chamber die

extruded shape
hydraulic
stock
piston

chamber

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 Shearing
A large scissors action, cutting the sheet along a straight line

Main use: to cut large sheet into smaller sizes for making parts.
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 Punching
Cutting tool is a round/rectangular punch, that goes through a hole,
or die of same shape.

F  t X edge-length of punch X shear strength

crack piece cut away, or slug

(failure in shear) Punch

t sheet

die die

clearance
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 Lathe

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Lathe operation ( Turning)

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Drilling Operation ( Drilling)

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Milling Operation ( Drilling)

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Grinding Operation

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Water Jet Machining

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Electric Discharge Machining

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Electro Chemical Machining

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Plasma Arc Machining

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Welding Operation

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Riveting Operation

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Soldering Operation

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 Factors to be considered for selecting a
production process
a) Shape and size to be produced - For products with simple shape,
machining is best suited. But for complex and intricate shapes,
casting is preferred. The size of the product is also an important
factor. For example, 'long' products such as rails or 'thin' products
such as car-body panels can be best made by forming process
compared to others.
b) Quantity to be produced - Both machining and casting can be used
for producing large quantity products, but are not suitable for small
quantity products, as they are not economical.
c) Type of material - Materials possess various properties like
ductility, hardness, toughness, brittleness etc. Hard materials
cannot be machined easily. Brittle materials cannot be
mechanically worked (Forming process). In such cases, casting is
preferred.
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 Factors to be considered for selecting a
production process
(d) Surface finish and dimensional accuracy - Casting with
expendable moulds does not yield good surface finish. However,"
if casting process is selected, it should be followed by machining
process to obtain the desired surface finish and dimensional
tolerance.
(e) Quality and property requirements - A defect-free product with
specific properties serve its purpose for long life. Properties of
cast material are generally less when compared to that of
mechanically worked materials. Also, casting gives a lot of defects.
Hence, a process that gives better properties and quality should
be selected.
(f) Cost of the product - Customers often demand for products with
more features and performance at reduced prices. Hence, a low
cost production process should be selected, but at the same
time, see that no compromise
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CASTING PROCESS

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Terms involved in casting

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 Terms involved in casting process
• Mould Box (flask) : It is usually a metallic frame used for making
and holding a sand mould. The mould box has two parts: the upper
part called 'cope', and the lower part called 'drag'.
• Parting Line/Parting Surface: It is the zone of separation between
cope and drag portions of the mould in sand casting.
• Sprue: It is vertical passage
through which the molten
metal will enter the gate.
• Pouring Basin: The enlarged
portion of the sprue at its top
into which the molten metal
is poured.

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 Terms involved in casting process
• Gate/Ingate: It is a short passage way which carries the molten
metal from the runner/ sprue into the mould cavity.
• Riser: A riser or feed-head is a vertical passage that stores the
molten metal and supplies (feed) the same to the casting as it
solidifies.
• Mould Cavity: The space in a mould that is filled with molten metal
to form the casting upon solidification.
• Core: A core is a pre-formed
(shaped) mass of sand placed in
the mould cavity to form hollow
cavities in castings.
• Core Print: It is a projection
attached to the pattern to help
for support and correct location
of core in the mould cavity.
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 Steps Involved In Making A Casting
The basic steps in making a casting are:
(a) Pattern making

(b) Mould preparation (including gating and risering)

(c) Core making

(d) Melting and Pouring

(e) Cleaning and Inspection

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 a) Pattern making
• A pattern is a replica of the object to be cast.

• It is used to prepare a cavity into which the molten metal is

poured.

• A skilled pattern maker prepares the pattern using wood, metal,

plastic or other materials with the help of machines and special
tools.

• Many factors viz., durability, allowance for shrinkage and

machining etc., are considered while making a pattern.

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 b) Mould preparation
• Mould preparation involves forming a cavity by packing sand
around a pattern enclosed in a supporting metallic frame called
'flask' (mould box).
• When the pattern is removed from the mould, an exact shaped
cavity remains into which the molten metal is poured.
• Gating and risering are provided at suitable locations in the
mould.
– Gating - Passage through which molten metal flows and
enter the mould cavity.
– Risering - A reservoir of molten metal connected to the
mould cavity to supply additional metal so as to compensate
for losses due to shrinkage, as the metal solidifies.

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 c) Core making
• In some cases, a hole or cavity is required in the casting.

• This is obtained by placing a core in the mould cavity.

• The shape of the core corresponds to the shape of the hole

required.

d) Melting and Pouring

• Metals or alloys of the required composition are melted in a
furnace and poured into the mould cavity.

• Many factors viz., temperature of molten metal, pouring time,

turbulence etc., should be considered while melting and pouring.
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 e) Cleaning & Inspection
• After the molten metal has solidified and cooled, the rough
casting is removed from the mould, cleaned and dressed.

• This involves removing cores, adhered sand particles, gating and

risering systems, fins, blisters etc., from the casting surface.

• then sent for inspection to check for dimensions or any defects

like blow holes, cracks etc.

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Procedure for making the casting

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 Components Produced by Casting Process
• Casting is the first step and the primary process for shaping any
material.

• All materials have to be cast before it is put to use.

• The ingots produced by casting process are used as raw material

for secondary processes like machining, forging, rolling etc.

• More than 90 % of all manufactured goods and capital equipment

use castings for their manufacture.

• To list the components produced by casting is an endless process. A

few major components produced by casting are given below.

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 Components Produced by Casting Process
• Automotive sector - Nearly 90 % of the parts in automobiles are-
manufactured by castings. A few parts include brake drum,
cylinder, cylinder linings, pistons, engine blocks, universal joints,
rocker arm, brackets etc.,
• Aircraft - Turbine blades, casing etc.
• Marine propeller blades.
• Machining - Cutting tools, machine beds, wheels and pulleys,
blocks and table for supports etc.
• Agriculture and rail road equipments.
• Pumps and compressors frame, bushings, rings, pinion etc.
• Valves, pipes and fittings for construction work.
• Camera frames, parts in washing machine, refrigerators and air-
conditioners.
• Steel utensils and a wide variety of products.
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 Advantages of Casting process
• Large hollow and intricate shapes can be easily cast.
• Quick process, and hence suitable for mass production.
• No limit to size and shape. Parts ranging from few millimeters to
meters and few grams to tons can be cast efficiently and
economically.
• Better dimensional tolerances and surface finish can be obtained
by good casting practice.
• Castings exhibit uniform properties in all the directions -
longitudinal, lateral and diagonal.
• The casting process is usually the cheapest process.
• Unrelieved internal stresses are absent in cast components.
• Certain metals and alloys can be manufactured by means of
casting only, e.g., Phosphor-Bronze.
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 Limitations of Casting process
• Presence of defects in cast parts is a major disadvantage.

• Casting process is not economical for small number of parts.

• Properties of cast materials are generally inferior when

compared to those made by machining or forging process.

• Casting process mostly deals with elevated temperatures.

• There are limitations regarding thin sections.

• Casting process is not suitable for very small number of

components.

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