5

HAPTER

Manufacturing Processes

Manufacturing processes are the steps involved in converting rawmaterials into

finished products. There are many different manufacturing processes, each of which
is suited for a specific type of product and material.
Some of the most common manufacturing processes include:

1. Casting: Molten metal is poured into a mold and allowed to solidify. This
process is used to produce a wide variety of products, including engine
blocks, crankshafts, and machine parts.

2. Forging: Metal is heated and then shaped by hammering or pressing. This

process is used to produce strong and durable parts, such as crankshafts,
connecting rods, and gears.

3. Machining: Metal is removed from a work piece using a cutting tool. This
process is used to produce high-precision parts, such as engine pistons and
valves.

4. Forming: Metal is shaped by applying pressure. This process is used to

produce a variety of products, such as car bodies, appliance parts, and cans.
 5. Welding: Two or more pieces of metal are joined together using heat or
pressure. This process is used to produce a wide variety of products, including
bridges, buildings, and ships.

6. Injection molding: Molten plastic is injected into a mold and allowed to solidify.
This process is used to produce a wide variety of plastic products, such as toys,
bottles, and electronic components.

7. Extrusion: Molten plastic is forced through a die to produce a continuous shape.

This process is used to produce products such as pipes, tubing, and film.

Manufacturing processes can be classified into two main types: primary and secondary.

• Primary manufacturing processes convert raw materials into basic materials, such
as steel, aluminum, and plastic.

• Secondary manufacturing processes convert basic materials into finished products.

Manufacturing processes are constantly evolving as new technologies are developed.

For example, additive manufacturing, also known as 3D printing, is a new
manufacturing process that is used to produce complex parts that would be difficult or
impossible to produce using traditional methods.
Manufacturing processes are essential for the production of all goods that we rely
on in our daily lives. From the cars we drive to the homes we live in, manufacturing
processes are used to create the products that we use every day.

5.0.1Examples of Manufacturing Processes

Here are some examples of manufacturing processes used to produce different types of
products:

1. Cars: The bodies of cars are typically made using sheet metal forming processes.
The engine blocks, crankshafts, and other metal parts are made using casting or
forging processes.

2. Electronics: The circuit boards in electronic devices are made using photo
lithography, a process that uses light to create patterns on a silicon wafer. The
 electronic components are then assembled on the circuit boards using surface
mount technology.

3. Food: Food products are manufactured using a variety of processes, including

mixing, baking, canning, and freezing. For example ,bread is made by mixing
flour, yeast, water, and other ingredients together and then baking the dough.

4. Clothing: Clothing is manufactured using a variety of processes, including cutting,

sewing, and finishing. For example, a shirt is made by cutting fabric into the
desired shape and then sewing the pieces together.

Manufacturing processes are an essential part of the modern economy. By

understanding the different types of manufacturing processes and how they are used to
produce different types of products, we can gain a better understanding of the world
around us.

5.1 Principles of Casting

Casting is a manufacturing process in which a liquid material is poured into a mold,
which contains a hollow cavity of the desired shape, and then allowed to solidify. The
mold is typically made of sand, metal ,or ceramic. Once the material has solidified, the
mold is broken open and the casting is removed.
Casting is one of the oldest manufacturing processes, and it is still widely used
today. It is a versatile process that can be used to produce castings of all sizes and
shapes, from simple objects like brackets and gears to complex components like engine
blocks and aircraft parts.

5.1.1Principles of casting

The basic principles of casting are as follows:

1. Melting: The material to be cast is melted in a furnace.

2. Pouring: The molten material is poured into a mold.

3. Solidification: The molten material solidifies in the mold, taking on the shape of
the mold cavity.
 4. Mold removal: The mold is broken open and the casting is removed. Factors
affecting casting quality

The quality of a casting is affected by a number of factors, including:

1. The quality of the molten metal: The molten metal should be free of impurities
and defects.

2. The design of the mold: The mold should be designed to allow the molten metal
to flow freely and to solidify evenly.

3. The casting process: The casting process should be controlled carefully to avoid
defects such as porosity and shrinkage.

Types of casting processes

There are many different types of casting processes, each with its own advantages
and disadvantages. Some of the most common casting processes include:

• Sand casting: This is the oldest and most widely used casting process. It is a
versatile process that can be used to produce castings of all sizes and shapes.

• Die casting: This is a high-volume casting process that is used to produce castings
with high precision and repeatability.

• Investment casting: This is a precision casting process that is used to produce

castings with complex shapes and fine detail.

• Centrifugal casting: This is a casting process that is used to produce castings with
a tubular shape. Applications of casting

Casting is used to produce a wide variety of products, including:

1. Automotive parts: Engine blocks, cylinder heads, crankshafts, camshafts, wheels,

and other automotive parts are commonly cast.

2. Aerospace parts :Aircraft engine components, landing gear, and other aerospace
parts are commonly cast.

3. Machine parts: Gears, bearings, housings, and other machine parts are commonly
cast.
 4. Hand tools: Hammers, wrenches, and other hand tools are commonly cast.

5. Decorative items: Statues, plaques, and other decorative items are commonly cast.

Casting is a versatile and widely used manufacturing process for producing metal
products. It is a complex process that requires careful control of the molten metal and
the casting process. However, when done correctly, casting can produce high-quality
castings with complex shapes and fine detail.

5.2 Principles of Metal Forming

Metal forming is a manufacturing process in which a metal work piece is deformed
plastically to take the shape of a die or mold. Plastic deformation is defined as the
permanent deformation of a material beyond its yield strength.
The principles of metal forming are based on the following:
Conservation of mass: The total mass of the work piece must remain the same before
and after deformation.
Conservation of energy: The total energy of the work piece must remain the same
before and after deformation.
Plasticity: The work piece must be able to deform plastically without fracturing. The
mechanics of metal forming can be complex, but the following are some general
principles:

1. Yield strength: The yield strength of a material is the minimum stress required to
cause plastic deformation. The yield strength of a material increases with strain
hardening.

2. Strain hardening: Strain hardening is the phenomenon where by a material

becomes stronger and harder as it is deformed plastically.

3. Flow curve: The flow curve of a material is a graph that shows the relationship
between stress and strain for the material. The flow curve can be used to
determine the forces required to deform a material to a desired shape.

4. Friction: Friction between the work piece and the die or mold can resist
deformation. Friction can be reduced by using lubricants and by designing the die
or mold to minimize contact area.
Metal forming processes can be classified into a number of different categories,
including:

1. Rolling: Rolling is a process in which a work piece is compressed between two

rotating rolls. Rolling can be used to reduce the thickness of a work piece, to
change its width, or to create a desired shape.

2. Forging: Forging is a process in which a work piece is compressed between two

dies .Forging can be used to create a wide variety of shapes, including crankshafts,
connecting rods, and gears.

3. Extrusion: Extrusion is a process in which a work piece is forced through a die to

create a desired shape. Extrusion can be used to create long, thin products, such as
rods, tubes, and wires.

4. Drawing: Drawing is a process in which a work piece is pulled through a die to

reduce its diameter and increase its length. Drawing is often used to create
seamless tubes and wires.

5. Bending: Bending is a process in which a work piece is deformed to change its

angle. Bending is often used to create elbows, tees, and other curved shapes.

6. Metal forming is a versatile and widely used manufacturing process. It is used to

produce a wide variety of products, including automotive parts, aerospace
components, and consumer goods.

Here are some of the advantages of metal forming:

1. Near net shape forming: Metal forming can be used to produce parts that are very
close to their final shape. This reduces the amount of machining that is required,
which can save time and money.

2. High strength and hardness: Metal forming can produce parts with high strength
and hardness. This is because the deformation process causes the grains in the
metal to flow and align, which creates a stronger and more homogeneous
structure.

3. Good surface finish: Metal forming can produce parts with a good surface finish.
This is because the dies and molds are typically made of very smooth materials.
 4. Cost-effectiveness: Metal forming is a cost-effective manufacturing process for
mass production of parts.

Metal forming is a complex and challenging field, but it is also a rewarding one. By
understanding the principles of metal forming, engineers can design and produce high-
quality metal parts at a competitive cost.

5.3 Joining processes

Joining processes are used to connect two or more materials together to form a single
unit. There are many different types of joining processes, but they all work on the same

basic principles:

1. Coalescence: Coalescence is the process of two or more materials merging together

to form a single, continuous phase. This can be done by melting the materials,
applying pressure, or using a combination of heat and pressure.

2. Adhesion: Adhesion is the process of two or more materials sticking together to

form a bond. This can be done using adhesives, or by creating mechanical
interlocks between the materials.

The specific principles that are used in a particular joining process depend on the
materials being joined and the desired properties of the joint. For example, welding is a
coalescence process that uses heat to melt the materials being joined, while soldering is
a coalescence process that uses a filler metal to melt and bond the materials together.
Adhesive bonding is an adhesion process that uses an adhesive to bond the materials
together.
Here are some of the most common joining processes:

1. Welding: Welding is a process that uses heat to melt the materials being joined,
forming a permanent bond. There are many different types of welding processes,
such as arc welding, gas welding, and laser welding.

2. Brazing and soldering: Brazing and soldering are processes that use a filler metal
to melt and bond the materials together. Brazing uses a filler metal with a melting
point that is above 450°C, while soldering uses a filler metal with a melting
point that is below 450 °C.
 3. Adhesive bonding: Adhesive bonding is a process that uses an adhesive to bond
the materials together. Adhesives can be used to bond a wide variety of materials,
including metals, plastics, and ceramics.

4. Mechanical joining: Mechanical joining methods, such as bolting, riveting, and

screwing, use fasteners to connect the materials together. These methods are often
used to create temporary joints that can be disassembled easily.

Joining processes are used in a wide variety of industries, including manufacturing,

construction, and transportation. They are essential for creating strong and durable
products and structures.

Here are some of the factors that should be considered when selecting a joining
process:

1. The materials being joined: The type of materials being joined will determine
which joining processes are feasible. For example, some joining processes, such as
welding, are only suitable for certain types of metals.

2. The desired properties of the joint: The desired properties of the joint, such as
strength, ductility, and corrosion resistance, will also influence the choice of
joining process.

3. The cost and complexity of the process: The cost and complexity of the joining
process must also be considered. Some joining processes, such as welding, can be
expensive and complex, while others, such as adhesive bonding, are relatively
simple and inexpensive.

It is important to select the right joining process for the specific application in order to
ensure that the joint is strong, durable, and meets all of the required requirements.

5.4 Principles of machining processes

Machining is a manufacturing process in which a cutting tool is used to remove

material from a work piece to create the desired shape and size. Machining is one of the
most important manufacturing processes in the world, and it is used to produce a wide
range of products, from simple components to complex structures.

5.4.1 Principles of machining processes

The basic principles of machining processes are the same regardless of the specific type
of machining being performed. These principles include:

1. Relative motion between the cutting tool and the work piece: There must be
relative motion between the cutting tool and the work piece in order for
machining to occur. This motion can be created by either moving the cutting tool
or moving the work piece.

2. Shearing: Machining is a shearing process, in which the cutting tools shears off
material from the work piece. This shearing occurs when the cutting tool is
applied to the work piece with sufficient force.

3. Chip formation: When material is removed from the work piece by the cutting
tool, it forms chips. The size and shape of the chips depends on a number of
factors, including the type of material being machined, the cutting tool geometry,
and the machining parameters.

5.4.2 Factors affecting machining processes

A number of factors affect the machining process, including:

1. Type of material being machined: The type of material being machined has a
significant impact on the machining process. Different materials have different
properties, such as hardness, toughness, and ductility. These properties affect the
machinability of the material, which is a measure of how easily the material can
be machined.

2. Cutting tool geometry: The geometry of the cutting tool also has a significant
impact on the machining process. The cutting tool geometry includes factors such
as the rake angle, clearance angle, and flank angle. These factors affect the chip
formation process and the surface finish of the work piece.
 3. Machining parameters: The machining parameters include the cutting speed, feed
rate, and depth of cut. These parameters control the rate at which material is
removed from the work piece and the surface finish of the work piece.

5.4.3 Types of machining processes

There are many different types of machining processes, but some of the most common
include:

1. Turning: Turning is a machining process in which a rotating work piece is

machined with a single-point cutting tool. Turning can be used to produce a
variety of shapes, including cylindrical, conical, and spherical shapes.

2. Drilling: Drilling is a machining process in which a rotating cutting tool is used to

create holes in a work piece. Drilling can be used to produce a variety of hole sizes
and depths.

3. Milling: Milling is a machining process in which a rotating cutting tool with

multiple teeth is used to remove material from a work piece. Milling can be used
to produce a variety of shapes, including flat surfaces, grooves, and slots.

4. Grinding: Grinding is a machining process in which a rotating abrasive wheel is

used to remove material from a work piece. Grinding can be used to produce very
accurate dimensions and surface finishes.

5.4.4 Applications of machining processes

Machining processes are used to produce a wide range of products, including:

1. Auto motive parts: Engine components, transmission components, and other

automotive parts are commonly machined.

2. Aerospace parts: Aircraft components, space craft components, and other aero
space parts are commonly machined.
 3. Medical devices: Surgical instruments, implants, and other medical devices are
commonly machined.

4. Electronic components: Semiconductor chips, circuit boards, and other electronic

components are commonly machined.

5. Consumer goods: Consumer goods such as appliances, tools, and toys are
commonly machined.

Machining processes are an essential part of modern manufacturing. By understanding

the principles of machining processes, engineers and manufacturers can produce high-
quality products with the desired shape, size, and surface finish.

5.5 Introduction to Computer Numerical Control (CNC)

Computer Numerical Control (CNC) machining is a manufacturing process in which
pre-programmed computer software dictates the movement of factory tools and
machinery.CNC machines can be used to create a wide variety of parts, from simple to
complex, with high precision and repeatability.
CNC machines work by following a set of instructions, or program that is created
using computer-aided design (CAD) software. The CAD program generates a G-code
file, which is a list of numerical instructions that tell the CNC machine how to move its
tools and axes. The G-code file is then uploaded to the CNC machine, which uses it to
control the machining process.
CNC machines can be used to perform a variety of machining operations, including:

1. Turning: Rotating a work piece while a cutting tool removes material to create a
desired shape

Milling: Using a rotating cutting tool to remove material from a work piece to create
a desired shape.

Routing: Using a rotating cutting tool to cut shapes out of materials such as wood
plastic, and metal

Drilling: Creating holes in work pieces.

 Grinding: Using an abrasive wheel to remove material from a work piece to achieve
a desired finish.

CNC machines are used in a wide variety of industries, including aerospace,

automotive, electronics, and medical. They are also used by hobbyist sand makers to
create their own projects.

5.5.1Advantages of using CNC machines

Advantages of using CNC machines are:

1. Accuracy and precision: CNC machines can produce parts with very high
accuracy and precision. This is because the machines are controlled by
computers, which can accurately follow the instructions in the G-code file.

2. Repeatability: CNC machines can produce identical parts over and over again.
This is because the machines are not affected by human error.

3. Versatility: CNC machines can be used to perform a variety of machining opera-

tions. This makes them a very versatile tool for manufacturing.

4. Productivity: CNC machines can operate 24/7 without getting tired. This means
that they can produce parts much faster than manual machining processes.

Overall, CNC machines are a powerful tool for manufacturing a wide variety of parts
with high accuracy and precision. They are used ina wide range of industries and offer a
number of advantages over manual machining processes.

5.6 Introduction to 3D printing

3Dprinting, also known as additive manufacturing, is a process of creating a three-

dimensional object from a digital model. It works by adding material layer by layer
until the object is complete.
The first3D printer was invented in the 1980s, but the technology has only become
widely accessible in recent years. Today, there are many different types of 3D printers
available, ranging from small desktop models to large industrial machines.
 To 3D print an object, you first need to create a digital model. This can be done
using a variety of 3D modeling software programs. Once you have a digital model, you
can slice it into thin layers. This slicing process is done using a special software program
called a slicer.
Once the model is sliced, you can transfer the file to your 3D printer. The printer
will then read the file and start printing the object layer by layer.
3D printing can be used to create a wide variety of objects, including prototypes,
tools, toys, jewelry, and even medical implants. It is also becoming increasingly popular
for manufacturing finished products.

5.6.1 Benefits of 3D Printing

Here are some of the benefits of 3D printing:

1. It is possible to create complex objects that would be difficult or impossible to

make using traditional manufacturing methods.

2. 3D printing can be used to create custom objects, such as prosthetics and dental
implants.

3. 3D printing is relatively fast and efficient, which can save time and money on
manufacturing costs.

3. 3D printing can be used to produce objects from a wide variety of materials,

including plastics, metals, and ceramics.

4. Overall, 3D printing is a powerful and versatile technology that has the potential
to revolutionize many industries.

5.6.2 Examples of 3D printing

Here are some examples of how 3D printing is being used today:

1. In manufacturing, 3D printing is being used to create prototypes, tools, and

finished products. For example, Ford Motor Company is using 3D printing to
create prototype car parts.
 2. In the medical field, 3D printing is being used to create custom prosthetics, dental
implants, and other medical devices. For example, surgeons at the University of
Michigan have used 3D printing to create a custom skull implant for a patient with
a rare condition.

3. In education, 3D printing is being used to teach students about engineering,

design, and manufacturing. For example, many schools now have 3D printers
that students can use to create their own projects.

3D printing is a rapidly growing technology with the potential to change the way we
make things. It is an exciting time to be involved in this field.

5.7 Introduction to Smart manufacturing

Smart manufacturing is a technology-driven approach to manufacturing that uses data
to improve efficiency, productivity, and quality. It is enabled by a variety of emerging
technologies including the Industrial Internet of Things(IIoT),artificial intelligence
(AI), big data analytics, and cloud computing.
Smart manufacturing technologies connect machines, sensors, and people across the
manufacturing process, from product design to production to delivery. This
connectivity allows manufacturers to collect and analyze data in real time, and to use
this data to make more informed decisions about their operations.

5.7.1 Benefits of Smart Manufacturing

Some of the key benefits of smart manufacturing include:

1. Increased efficiency and productivity: Smart manufacturing technologies can

help manufacturers to automate tasks, optimize processes, and reduce waste. This
can lead to significant improvements in efficiency and productivity.

Improved quality: Smart manufacturing technologies can help manufacturers to

identify and correct quality problems early in the production process. This can lead to
significant improvements in product quality.
 Reduced costs: Smart manufacturing technologies can help manufacturers to reduce
costs in a number of ways, such as by reducing waste, improving efficiency, and
extending the life of equipment.

Increased agility: Smart manufacturing technologies can help manufacturers to be

more agile and responsive to changes in customer demand and market conditions.

Smart manufacturing is still in its early stages of development, but it has the potential
to revolutionize the manufacturing industry. It is already being adopted by a number of
leading manufacturers, and it is expected to become more widespread in the coming
years.

5.7.2 Examples Smart Manufacturing Technologies

Here are some examples of how smart manufacturing technologies are being used
today:
1. Sensors are being used to collect data on the condition and performance of
machines. This data can be used to predict when maintenance is needed, and to
avoid unplanned downtime.
2. AI is being used to automate tasks such as quality inspection and process
optimization.
3. Big data analytics is being used to identify trends and patterns in manufacturing
data. This information can be used to improve decision-making and to identify
Opportunities for improvement

4. Cloud computing is being used to store and analyze manufacturing data. This
allows manufacturers to access their data from anywhere, and to scale their
operations up or down as needed.

Smart manufacturing is a complex and rapidly evolving field, but it has the potential
to transform the manufacturing industry. By using data to improve their operations,
manufacturers can become more efficient, productive, and agile.

5.8 Introduction to Thermal Engineering

Thermal engineering is a branch of mechanical engineering that deals with the
generation, conversion, and use of thermal energy. It is a broad field that encompasses
a wide range of applications, including power generation, heating and cooling, and
refrigeration.Thermalengineersusetheirknowledgeofthermodynamics,fluid mechanics,
and heat transfer to design and analyze systems that involve the transfer of heat energy.

5.8.1 Basic Principles of Thermal Engineering

The three fundamental principles of thermal engineering are thermodynamics, fluid

mechanics, and heat transfer.

1. Thermodynamics is the study of the relationships between heat, work, and energy.
It provides the foundation for understanding how thermal systems work.

2. Fluid mechanics is the study of the behavior of fluids, such as air and water .It is
important for understanding how fluids flow through and around thermal
systems.

3. Heat transfer is the study of how heat energy moves from one place to another. It
is essential for designing thermal systems that operate efficiently.

5.8.2 Applications of Thermal Engineering

Thermal engineering is used in a wide variety of applications, including:

1. Power generation: Thermal engineers design and operate power plants that
generate electricity from fossil fuels, nuclear energy, and renewable energy
sources such as solar and wind power.

2. Heating and cooling: Thermal engineers design and install heating, ventilation,
and air conditioning (HVAC) systems in buildings. They also design and
manufacture heating and cooling equipment, such as furnaces, air conditioners,
and refrigerators.

3. Refrigeration: Thermal engineers design and build refrigeration systems that are
used to preserve food and other perishable goods. They also design and
manufacture refrigeration equipment, such as compressors, condensers, and
evaporators.
 4. Other applications: Thermal engineering is also used in a variety of other
applications, such as the design of automotive engines, aircraft engines, and
industrial processes.

Thermal engineering is a broad and important field that plays a vital role in many
industries. Thermal engineers use their knowledge of thermodynamics, fluid
mechanics, and heat transfer to design and analyze systems that involve the transfer of
heat energy. Thermal engineering is a challenging but rewarding field that offers many
career opportunities.

5.9 Working principle of Boilers

The basic working principle of a boiler is to convert water into steam by using heat
energy. This is done by burning fuel in a furnace, which heats up the water in a closed
vessel. The heat causes the water to vaporize, and the steam then collected and used for
various purposes, such as generating electricity, heating buildings, or driving industrial
processes.
There are two main types of boilers: water tube boilers and fire tube boilers.

1. Water tube boilers have a series of tubes through which the water flows. The heat
from the furnace is transferred to the water through the walls of the tubes. Water
tube boilers are typically more efficient than fire tube boilers, but they are also
more complex and expensive to manufacture.

2. Fire tube boilers have a series of tubes through which the hot gases from the
furnace flow. The water surrounds the tubes, and the heat is transferred to the
water from the hot gases. Fire tube boilers are simpler and less expensive to
manufacture than water tube boilers, but they are also less efficient.

Both water tube boilers and fire tube boilers can be used to generates team or hot water.
The type of boiler that is used depends on the specific application.

5.9.1 Working principle of a boiler

Here is a more detailed explanation of the working principle of a boiler:

 1. Fuel is burned in the furnace, which heats up the air inside the furnace.

2. The hot air flows through the tubes in the boiler, transferring heat to the water
inside the tubes.

3. As the water heats up, it vaporizes and turns into steam.

4. The steam collects in the upper part of the boiler.

5. The steam is then piped out of the boiler and used for its intended purpose.

5.9.2 Applications of Boilers

Boilers are used in a wide variety of applications, including:

1. Electricity generation: Steam boilers are used to generate steam, which is then
used to drive turbines to generate electricity.

2. Heating buildings: Steam boilers are used to heat water, which is then circulated
through pipes and radiators to heat buildings.

3. Industrial processes: Steam boilers are used to provide steam for a variety of
industrial processes, such as food processing, paper making, and textile
production.

Boilers are an essential part of many modern industries and play a vital role in our daily
lives.
5.10 Otto cycle
The Otto cycle is a thermodynamic cycle that describes the processes that occur in a
spark-ignition internal combustion engine. It is the idealized cycle for gasoline engines
and is also used in some other types of engines, such as small gas turbines.
The Otto cycle consists of four strokes:

1. Intake stroke: The piston moves down the cylinder, drawing in a mixture of air
and fuel.

2. Compression stroke: The piston moves up the cylinder, compressing the air-fuel
mixture.

3. Power stroke: The spark plug ignites the air-fuel mixture, causing it to combust.
The expanding gases push the piston down the cylinder, generating power.

4. Exhaust stroke: The piston moves up the cylinder, expelling the spent exhaust
gases.

The Otto cycle is a heat engine, which means that it converts heat energy into
mechanical energy. The heat energy comes from the combustion of the air-fuel mixture.
The Otto cycle is not a perfect heat engine, and some of the heat energy is lost to the
environment. However, the Otto cycle is a relatively efficient heat engine, and it is the
type of engine used in most cars today.

5.10.1 Working principle of Otto cycle

The Otto cycle can be visualized on a pressure-volume (PV) diagram. The four strokes
of the cycle are represented by the following four processes:

1. Process1-2: Isentropic compression: The air-fuel mixture is compressed by the

piston as it moves up the cylinder. This process is isentropic, which means that it
is reversible and there is no heat transfer to or from the system.

2. Process2-3: Constant volume heat addition: The spark plug ignites the air-fuel
mixture, and the heat energy from the combustion process causes the gas pressure
to increase. This process is constant volume, which means that the volume of the
gas does not change.
173Manufacturing Processes
3. Process 3-4: Isentropic expansion: The expanding gases push the piston down the
cylinder. This process is isentropic, just like the compression process.

4. Process4-1: Constant volume heat rejection: The exhaust valve opens, and the
spent exhaust gases are expelled from the cylinder. This process is constant
volume, just like the combustion process.

The net work output of the Otto cycle is equal to the area enclosed by the four processes
on the PV diagram. The thermal efficiency of the Otto cycle is the ratio of the net work
output to the heat energy added to the system. Thermal efficiency can be improved by
increasing the compression ratio of the engine.

5.10.2 Applications of Otto cycle

The Otto cycle is used in a variety of applications, including:

1. Gasoline engines in cars and trucks

2. Small gas turbines in airplanes and helicopters

3. Generators for producing electricity

4. Compressors for pumping air or other gases

5. The Otto cycle is a versatile and efficient heat engine, and it is widely used in a
variety of applications.

5.11 Diesel cycle

The Diesel cycle is a thermodynamic cycle that describes the combustion process in a
diesel engine. It is an ideal cycle, meaning that it represents the theoretical maximum
efficiency that a diesel engine can achieve.
The Diesel cycle consists of four strokes:

1. Intake stroke: The intake valve opens and the piston moves down, drawing air
into the combustion chamber.

2. Compression stroke: The intake valve closes and the piston moves up,
compressing the air in the combustion chamber.
 Figure 5.1:P V and T S diagram of diesel cycle

3. Power stroke: Fuel is injected into the compressed air and ignites due to the high
temperature and pressure. The combustion process drives the piston down,
producing work.

4. Exhaust stroke: The exhaust valve opens and the piston moves up, expelling the
exhaust gases from the combustion chamber.

The Diesel cycle can be represented on a pressure-volume PV) diagram, as shown

below:

5.11.1 PV diagram of the Diesel cycle

ThefourstrokesoftheDieselcyclearerepresentedbythefourlinesegmentsonthePV diagram:

1. Line 1-2:Intake stroke

2. Line 2-3:Compression stroke

3. Line 3-4:Power stroke

4. Line 4-1:Exhaust stroke

ThenetworkdonebytheDieselcycleisequaltotheareaenclosedbythefourline segments on
the PV diagram.
Diesel engines are more efficient than spark-ignition engines (such as gasoline
engines) because they operate at higher compression ratios. This is because the fuel in a
diesel engine is ignited by the heat of compression, rather than by a spark plug.
175Manufacturing Processes
Diesel engines are also more fuel-efficient than spark-ignition engines, especially at
high loads. This is because diesel engines burn fuel more completely than spark ignition
engines.

5.11.2 Applications of Diesel Cycle

Diesel engines are used in a wide range of applications, including:

1. Automobiles

2. Trucks

3. Buses

4. Trains

5. Ships

6. Construction equipment

7. Power generation

Diesel engines are known for their reliability and durability, and they can operate for
long periods of time without requiring major maintenance.

5.11.3 Working principle of Diesel cycle

The Diesel cycle is a compression ignition cycle, meaning that the fuel is ignited by the
heat of compression rather than by a spark plug. This is achieved by compressing the air
in the combustion chamber to a very high temperature and pressure. When the fuel is
injected into the compressed air, it ignites spontaneously.

5.11.4 Four stages of Diesel Cycle

The Diesel cycle can be divided into four stages:

1. Compression: Air is drawn into the combustion chamber and then compressed by
the piston. This increases the temperature and pressure of the air.
 2. Combustion: Fuel is injected into the compressed air and ignites spontaneously.
The combustion process drives the piston down, producing work.

3. Expansion: The piston continues to move down, expanding the combustion gases.
This produces more work.

4. Exhaust: The exhaust valve opens and the piston moves up, expelling the exhaust
gases from the combustion chamber.

The Diesel cycle is a very efficient way to convert heat energy into mechanical work.
Diesel engines are typically more efficient than spark-ignition engines, and they can
also operate on a wider range of fuels.

5.12 Refrigeration and air-conditioning cycles

Refrigeration and air-conditioning cycles are thermodynamic cycles that use a
refrigerant to transfer heat from one location to another. They are used in a wide
variety of applications, including refrigerators, freezers, air conditioners, and heat
pumps.
The most common type of refrigeration and air conditioning cycle is the vapor
compression cycle. This cycle consists of four main components:

1. Compressor: The compressor compresses the refrigerant, increasing its

temperature and pressure. This process requires energy input.

Condenser: The condenser rejects heat from the refrigerant to the surrounding
environment, causing the refrigerant to condense into a liquid.

The hot, high-pressure refrigerant gas then enters the condenser, where it rejects
heat to the surrounding environment and condenses into a liquid. This process
releases heat to the environment.

Expansion valve: The expansion valve reduces the pressure of the refrigerant,
causing it to partially evaporate.

The liquid refrigerant then passes through an expansion valve, which reduces its
pressure. This causes some of the refrigerant to evaporate, which absorbs heat
from the surrounding environment.
177Manufacturing Processes
Evaporator: The low-pressure refrigerant vapor then enters the evaporator, where
it absorbs heat from the surrounding environment and completely evaporates.
This process cools the surrounding environment.

The refrigerant circulates through the cycle continuously, absorbing heat from the
evaporator and rejecting heat to the condenser.
Refrigeration and air conditioning cycles are very efficient at transferring heat. They
are used in a wide variety of applications to keep food fresh, cool homes and businesses,
and provide comfort in hot weather.
Here are some examples of how refrigeration and air-conditioning cycles are used:

1. Refrigerators and freezers: Refrigerators and freezers use refrigeration cycles to

keep food fresh by removing heat from the food and preventing it from spoiling.

2. Air conditioners: Air conditioners use refrigeration cycles to cool homes and
businesses by removing heat from the indoor air and rejecting it to the outdoor air.

3. Heat pumps: Heat pumps use refrigeration cycles to heat and cool homes and
businesses. They can transfer heat from a cooler location to a warmer location, or
vice versa.

Refrigeration and air-conditioning cycles are an essential part of modern life.They

helps us to keep food fresh, cool our homes and businesses, and provide comfort in hot
weather.

5.13 IC engines
An internal combustion engine (ICE) is a heat engine in which the combustion of a fuel
occurs with an oxidizer (usually air) in a combustion chamber that is an integral part of
the working fluid flow circuit. In an internal combustion engine, the expansion of the
high-temperature and high-pressure gases produced by combustion applies direct force
to some component of the engine. The force is typically applied to pistons (piston
engine), turbine blades (gas turbine), a rotor (Wankel engine), or a nozzle (jet engine).
IC engines are used in a wide variety of applications, including:

1. Automobiles
5.14 Introduction to 2-Stroke engines178

2. Trucks

3. Buses

4. Motorcycles

5. Trains

6. Ships

7. Aircraft

8. Generators

9. Industrial machinery

5.13.1 Types of IC engines

There are two main types of IC engines: reciprocating engines and rotary engines.

1. Reciprocating engines have pistons that move up and down in cylinders. The
most common type of reciprocating engine is the four-stroke engine, which is
used in most automobiles and light trucks. Other types of reciprocating engines
include two-stroke engines, six-stroke engines, and diesel engines.

2. Rotary engines have a rotating rotor that moves around a stationary housing. The
most common type of rotary engine is the Wankel engine, which is used in some
Mazda sports cars.

5.13.2 Operating Principle IC Engines

The basic operating principle of all IC engines is the same. The engine first draws in a
mixture of air and fuel. The mixture is then compressed, ignited, and combusted. The
combustion produces high temperature and high pressure gases, which expand and
push the pistons or rotor. This motion is then converted into rotary motion by a
crankshaft, which can be used to drive a variety of machines and vehicles.
179Manufacturing Processes

5.13.3 Advantages and disadvantages of IC engines

IC engines have a number of advantages, including:

1. They are relatively simple and inexpensive to manufacture.

2. They are relatively efficient at converting fuel into mechanical energy.

3. They are very versatile and can be used in a wide variety of applications.

5.13.5 Disadvantages of IC Engines

IC engines also have a number of disadvantages, including:

1. They produce emissions that can pollute the air.

2. They are relatively noisy.

3. They can be relatively complex to maintain and repair.

IC engines are a mature technology that has been around for over 150years.They are
still the most common type of engine used in vehicles today. However, there is a
growing interest in developing new types of engines, such as electric vehicles and
hydrogen fuel cell vehicles, that are more efficient and produce fewer emissions.

5.14 Introduction to 2-Stroke engines

A two-stroke engine is a type of internal combustion engine that completes a power
cycle with two strokes of the piston during one crankshaft revolution. This is in contrast
to a four-stroke engine that requires four strokes of the piston to complete a power cycle
during two crankshaft revolutions.
Two-stroke engines are simpler and lighter than four-stroke engines, and they have
a higher power-to-weight ratio. This makes them ideal for applications where weight
and power are important, such as motorcycles, chainsaws, and lawnmowers.
However, two-stroke engines also have some disadvantages.

1. They are less fuel-efficient than four-stroke engines

2. Produce more emissions. Additionally,

 3. Use of a two-stroke oil mixture, which can be messy and inconvenient.

5.14.1 Working Principle of Two stroke Engine

A two-stroke engine works by using the crank case as a pump to move air and fuel in to
the combustion chamber. During the compression stroke, the piston moves up and
compresses the air-fuel mixture in the combustion chamber. At the top of the
compression stroke, the spark plug ignites the air-fuel mixture, which causes the piston
to move down.
As the piston moves down, it pushes the exhaust gases out of the exhaust port. At
the same time, the intake valve opens and the crankcase pump draws a fresh mixture of
air and fuel into the crankcase.
The piston then moves back up, compressing the fresh air-fuel mixture in the
crankcase. At the top of the compression stroke, the intake valve closes and the exhaust
valve opens. The piston then moves down again, pushing the fresh air-fuel mixture into
the combustion chamber and the exhaust gases out of the exhaust port.
This cycle repeats itself every time the crankshaft rotates once.

5.14.2 Advantages and Disadvantages of Two-Stroke Engines

1. Advantages:

(a) Simpler and lighter than four-stroke engines

(b) Higher power-to-weight ratio

(c) Less expensive to manufacture

Disadvantages:

(a) Less fuel-efficient than four-stroke engines

(b) Produce more emissions

(c) Require the use of a two-stroke oil mixture

(d) Can be noisy and smoky

(e) Applications of Two-Stroke Engines

181Manufacturing Processes
5.14.3 Applications of Two-Stroke Engines

Two-stroke engines are used in a wide variety of applications, including:

1. Motorcycles

2. Lawnmowers

3. Weed trimmers

4. Chainsaws

5. Snowblowers

6. Outboard motors

7. Generators

8. Air compressors

Two-stroke engines are still widely used in many applications, but they are being
phased out in some areas due to emissions regulations.

5.15 Introduction to 4-Stroke engines

A four-stroke engine is an internal combustion engine in which the piston completes

four separate strokes while turning the crankshaft. A stroke refers to the full travel of
the piston along the cylinder, in either direction. The four separate strokes are termed:

1. Intake: The intake valve opens and the piston moves down the cylinder, drawing
in a mixture of air and fuel.

2. Compression: Both the intake and exhaust valves are closed, and the piston moves
up the cylinder, compressing the air-fuel mixture.

3. Power: The spark plug ignites the air-fuel mixture, causing it to expand rapidly
and drive the piston down the cylinder. This is the only stroke that produces
power to turn the crankshaft.
 4. Exhaust: The exhaust valve opens and the piston moves up the cylinder, pushing
out the spent exhaust gases. Once the exhaust stroke is complete, the cycle begins
again with the intake stroke.

Four-stroke engines are the most common type of internal combustion engine used in
automobiles, trucks, and other motor vehicles. They are also used in many other
applications, such as lawn mowers, generators, and boats.
Four-stroke engines are more efficient than two-stroke engines, and they produce
fewer emissions. They are also quieter and more reliable. However, four-stroke engines
are also heavier and more complex than two-stroke engines.

5.15.1 Advantages of four-stroke engines

1. More efficient than two-stroke engines

2. Produce fewer emissions

3. Quieter and more reliable

4. Longer lifespan

5.15.2 Disadvantages of four-stroke engines

1. Heavier and more complex than two-stroke engines

2. More expensive to manufacture

5.15.4 Applications of four-stroke engines

1. Automobiles

2. Trucks

3. Buses

4. Motorcycles

5. Lawnmowers

6. Generators
183Manufacturing Processes
7. Boats

8. Airplanes

9. Industrial machinery

Four-stroke engines are a versatile and efficient type of internal combustion engines
that are used in a wide variety of applications.

5.16 Introduction to SI/CI Engines

Spark-ignition (SI) and compression-ignition (CI) engines are the two most common
types of internal combustion engines. They are used in a wide variety of applications,
including cars, trucks, buses, boats, and generators.
SI engines are generally powered by gasoline, and they use a sparkplug to ignite the
air-fuel mixture in the combustion chamber. The spark plug creates a high-voltage
electrical spark that ignites the mixture, causing it to burn rapidly and expand. This
expansion drives the piston down, which in turn rotates the crankshaft.
CI engines are generally powered by diesel fuel, and they rely on the heat of
compression to ignite the air-fuel mixture. In a CI engine, the air is compressed to a
very high temperature and pressure, which causes the diesel fuel to ignite
spontaneously when it is injected into the combustion chamber. This combustion
process also drives the piston down and rotates the crankshaft.
Here is a table that summarizes the key differences between SI and CI engines:

Table 5.1:Differences between SI and CI engines

Characteristic SI engine CI engine
Fuel Gasoline Diesel
Ignition method Spark plug Compression
Compression ratio 8:1 to 12:1 14:1 to 25:1
Air-fuel ratio 14.7:1 18:1 to 25:1
Efficiency 25% to 35% 30% to 40%
Emissions Relatively low Relatively high
Noise Relatively low Relatively high
Cost Relatively low Relatively high
5.17 Electric and Hybrid Vehicles184

5.16.1Applications of SI and CI engines

SI engines are commonly used in cars, trucks, buses, motorcycles, and boats. They are
also used in some small generators. CI engines are commonly used in heavy-duty
trucks, buses, construction equipment, and agricultural equipment. They are also used
in large generators and marine engines. Advantages and disadvantages of SI and CI
engines:

1. SI engines

(a)Advantages:

i. Relatively low cost

ii. Relatively low emissions

iii. Smooth and quiet operation

Disadvantages:

i. Lower efficiency than CI engines

ii. Less torque than CI engines

iii. Requires higher octane fuel

2. CI engines:

(a) Advantages:

i. Higher efficiency than SI engines More torque than SI engines Can

run on a variety of fuels, including diesel, biodiesel, and vegetable
oil

(b) Disadvantages:

i. Relatively higher cost

ii. Relatively higher emissions

iii. Noisier and rougher operation than SI engines

185Manufacturing Processes

Overall, SI and CI engines have different strengths and weaknesses. The best type of
engine for a particular application depends on a variety of factors, including fuel costs,
emissions requirements, and performance requirements.

5.17 Electric and Hybrid Vehicles

Electric and hybrid vehicles are becoming increasingly popular as people look for ways
to reduce their environmental impact and save money on fuel.

5.17.1 Components of Electric and Hybrid Vehicles

These vehicles use a variety of components to propel them, including:

1. Internal combustion engine (ICE): Electric hybrid vehicles have a conventional

ICE, which powers the vehicle when the battery is depleted or when the vehicle
needs more power than the battery can provide.

2. Electric motor(s): Electric and hybrid vehicles have one or more electric motors,
which are powered by batteries. The electric motor(s) can propel the vehicle on
their own, or they can work in conjunction with the ICE to improve fuel efficiency
and performance.

3. Battery pack: Electric and hybrid vehicles have a battery pack, which stores the
electrical energy that powers the electric motor(s).The battery pack can be
charged by plugging the vehicle into an external power source, or by regenerative
braking.

4. Power control unit: The power control unit manages the flow of power between
the ICE, the electric motor(s), and the battery pack. It ensures that the right
amount of power is being used at the right time.

5. Regenerative braking system: The regenerative braking system captures energy

that is lost during braking and converts it into electrical energy, which is stored in
the battery pack. This helps to improve the fuel efficiency of the vehicle.

In addition to these main components, electric and hybrid vehicles also have a variety of
other components, such as a transmission, cooling system, and climate control system.
5.17 Electric and Hybrid Vehicles186

5.17.2 How Electric and Hybrid Vehicles Work?

Electric and hybrid vehicles work in different ways, but they both use the combination
of an ICE and an electric motor to propel the vehicle.
In an electric vehicle, the electric motor is the only source of power. The battery pack
is charged by plugging the vehicle into an external power source, and the electric motor
uses the stored electrical energy to propel the vehicle.
In a hybrid vehicle, the ICE and the electric motor(s) work together to propel the
vehicle. The ICE can power the vehicle directly, or it can be used to generate electricity
to power the electric motor(s).The battery pack can also be charged by regenerative
braking.
The specific way that the ICE and electric motor(s) work together in a hybrid vehicle
depends on the type of hybrid system. There are three main types of hybrid systems:

1. Parallel hybrid systems: In a parallel hybrid system, the ICE and electric motor(s)
can power the vehicle independently or in conjunction with each other.

2. Series hybrid systems: In a series hybrid system, the ICE powers a generator,
which in turn powers the electric_motor .The ICE, does not directly power the
wheels.

3. Plug-in hybrid systems: Plug-in hybrid systems have a larger battery pack than
other types of hybrid systems. This allows the vehicle to travel further on electric
power alone. Plug-in hybrid systems can be plugged into an external power source
to charge the battery pack.

5.17.3 Benefits of Electric and Hybrid Vehicles

Electric and hybrid vehicles offer a number of benefits, including:

1. Reduced emissions: Electric and hybrid vehicles produce less tailpipe emissions
than conventional gasoline-powered vehicles. This helps to improve air quality
and reduce greenhouse gas emissions.

2. Improved fuel efficiency: Electric and hybrid vehicles are more fuel-efficient than
conventional gasoline-powered vehicles. This can save you money on fuel costs.
187Manufacturing Processes

3. Reduced noise: Electric vehicles are much quieter than conventional gasoline
powered vehicles. This can make for a more pleasant driving experience.

4. Performance: Electric and hybrid vehicles can offer excellent performance, thanks
to the instant torque provided by the electric motor(s).
Electric and hybrid vehicles are becoming increasingly popular as people look for ways
to reduce their environmental impact and save money on fuel. These vehicles offer a
number of benefits, including reduced emissions, improved fuel efficiency, reduced
noise, and excellent performance.