Systems in

Mechanical
Engineering 202041
Mr. K. B. Bansode
 Course Objectives:

1. To identify the sources of energy and their

conversions
2. To explain the basic concept of engineering
thermodynamics and its application
3. To understanding the specifications of vehicles
4. To get acquainted with vehicle systems
5. To introduce manufacturing processes applying
proper method to produce components
6. To be able to select and compare domestic
appliances
 Course Outcomes
On completion of the course, learner will be able to
CO1: Describe and compare the conversion of energy from renewable and
non-renewable
energy sources
CO2: Explain basic laws of thermodynamics, heat transfer and their
applications
CO3: List down the types of road vehicles and their specifications
CO4: Illustrate various basic parts and transmission system of a road vehicle
CO5: Discuss several manufacturing processes and identify the suitable
process
CO6: Explain various types of mechanism and its application
 Unit V Introduction to
Manufacturing
Conventional Manufacturing Processes: Casting, Forging,
Metal forming (Drawing, Extrusion, etc.), Sheet metal
working, Metal joining, etc. Metal cutting processes and
machining operations- Turning, Milling and Drilling, etc.
Micromachining. Additive manufacturing and 3D Printing.
Reconfigurable manufacturing system and IOT, Basic CNC
programming: Concept of Computer Numerical
Controlled machines
 Manufacturing Process

It involves transforming a raw material from it’s original state to a finished

state by changing it’s shape or the properties of the material in a series of
steps.

Manufacturing Process

Raw Machine Finished

Material Tool Product

5
 Manufacturing Processes.

Deforming Machining Joining Surface Mat.

Primary Processes Processes Processes Finishing Properties
Shaping
Processes Modification
Processes
processes
Forging Turning Welding

Casting Honing Hot Working

Rolling Facing Soldering

Powder Lapping Cold Working

Sheet Metal
Metallurgy Working Drilling Brazing
Buffing Heat
Treatment
Processing Extrusion Milling Screwing
of Plastics
Plating Shot Peening
Shaping Riveting
Coating
Reaming Adhesive
Bonding Grinding 6
 Metal Casting
• Casting: It is a manufacturing process in which
part of desired shape is obtained by pouring
molten metal into cavity of required shape

• It is one of the oldest manufacturing process (around

6000 year old, Egyptians were first to use castings)

Castings

c
Investment Centrifugal
Sand Casting Die Casting Slush Casting
casting casting

7
Casting

8
Metal Casting: Sand Casting

9
 Metal Casting: Sand Casting
• Steps in Sand Casting:
1. Pattern Making:
• Pattern is replica of the part to be casted.
• Initially pattern has to be made using different manufacturing
process other than casting.
• Draft/Taper is provided on pattern for its easy removal from
sand mould
• Commonly used materials for pattern making are- Wood,
Plastic and metal

10
 Metal Casting: Sand Casting
• Steps in Sand Casting:
2. Mould Making:
• Mould is a container made from green sand and which has
cavity in which molten metal can poured.
• Mould box has two halves, the upper halve is called cope and
lower halve is called drag.

11
 Metal Casting: Sand Casting
• Steps in Sand Casting:
3. Core Making:
• Core is a device used in sand casting to produce hollow
castings
• Generally core is made from same material as that of the
mould i.e. sand
• Supporting elements called chaplets are used to support core

12
 Metal Casting: Sand Casting
• Steps in Sand Casting:
4. Metal Melting and Pouring:
• The raw material is melted using furnace. Furnace may be
operated on electricity or fuel
• The molten metal is poured into mould using ladle
• Pouring basin, sprue, runner, gate are used to guide molten
metal into the cavity

13
 Metal Casting: Sand Casting
• Steps in Sand Casting:
5. Solidification
• Metal is allowed to cool to room temperature
• During solidification the metal shrinks and the extra metal
required compensate this shrinkage is obtained from the riser
6. Finishing
• Undesired part which corresponds to gating system and riser
has to be cut from main casting
• The casted surface generally is rough and some finishing
operation like grinding, machining, polishing are required
7. Inspection
• Before dispatching the casted part has to be checked for
desired dimensions. The part which doesn’t meet expected
dimensions has to be scraped
• Castings are also checked for various undesirable defects
14
 Metal Casting: Sand Casting
Advantages of Sand Casting:
– Casting can be used to create complicated shapes
– Casting can be used to manufacture components made from brittle as
well as ductile material
– Casting can be used economically to create small as well as large
components
– Casting is a primary manufacturing process. Raw material supplied to
various other manufacturing process is obtained through the casting

15
 Metal Casting: Sand Casting

Disadvantages of Sand Casting:

– Casting can not be used to create very thin components (thickness <
6mm)
– Casting contains various defects such cracks, voids, foreign particle
inclusions which reduces strength of the component
– Casted components are brittle in nature as compared forged
components
– Surface finish of sand casted component is poor
– Man power and space requirement is high
– Risk of injury in metal handling is high

16
Forging

17
 Forging Process:
• Forging is the process of shaping heated metal by the
application of sudden blows (hammer forging) or steady
pressure (press forging) and makes use of the characteristic
plasticity of the material.

• In forging process the material is heated to a temperature at

which its elastic properties completely disappear. This
temperature is known as forging temperature and it varies
from material to material.

18
Working principle:

(a) Before forging (b) After forging

Forging process 19
 Working principle:
• In forging process, the material (billet) is
deformed into the desired shape
between two parts called dies. The
shape of the dies matches with desired
shape of the forged component.
• The forging press shown in figure
consists of a lower die fixed to the frame
(Anvil) while upper die is connected to
the ram. The hot material is kept on the
lower die.
• In mechanical press the ram is driven by
the crank shaft through the connecting
rod where as in hydraulic press the ram
is driven by the hydraulic cylinder. Materials used for forging:
• During the downward stroke of the ram, • Must be ductile material.
the upper die exerts sudden compressive • Examples: low and medium
force on the hot material. Due to this carbon steels, alloy steels,
sudden compressive force the hot stainless steels, copper alloys,
material is converted into the desired aluminum alloys etc.
shape.
20
 Classification
Based on types of dies used forging process are classified as:
1. Open die forging
2. Closed die forging

Open Die Forging process:

• In open die forging, the material or work
piece is deformed between two flat dies or
dies of very simple shape.

Closed Die Forging process:

• In closed die forging, the material or work
piece is deformed between two dies which
have the impression of the desired shape.
• when the two cavities are closed, the
cavity formed is of the desired final shape.

21
 Applications of Forging process:
1. Car axles, crankshafts, connecting rods, leaf springs, crane hooks, jet
engine turbine dies and blades.
2. Levers, flanges, propellers, hollow bodies, railway wheel disks, tank
bottoms.
3. Aircraft and rocket parts, knife blades, bolts, nuts, washers, collars, gear
blanks, etc.

22
Sheet metal Working

23
 SHEET METAL WORKING

Sheet metal working

is the process of manufacturing the components
from the sheet metal of thickness ranging from 0.1
mm to about 8 mm.

It is carried out by a machine tool called press

(Press working).

24
Sheet Metal Working
Sheet Metal Cutting (Shearing) Operations
• Piercing
• Punching
• Blanking
• Perforating
• Notching
• Lancing
• Slitting

Sheet Metal Forming Operations

• Bending
• Drawing & Deep Drawing
• Embossing
• Forming
• Coining (Squeezing)
25
 Metal Cutting (Shearing ) Processes:
Piercing- Producing a hole of any desired shape in metal.

Punching- Producing a circular hole in metal.

Blanking-
The metal punched out is the required component, called blank.
26
Difference between punching and
blanking

27
 Sheet Metal Forming
processes

• It is a process in which flat plate metal sheet is converted into

a desired shape without wasting the material.

• Bending
• Drawing and deep drawing
• Forming
• Coining
• Embossing

28
Bending

29
Drawing
process of forming a flat
metal sheet into a three dimensional
hollow shape.

Drawing

30
 Deep drawing
If the depth of hollow cup
exceeds the diameter of formed cup, the
process is called Deep Drawing.

Deep Drawing

31
Examples of Drawing operation

32
 Forming-
Process of flat metal sheet into a surface of a desired profile.

33
Example of Forming operation

34
Metal joining processes

35
 Metal Joining Processes
• Metal joining processes are used for various
industries: Construction, Shipping,
Automobile, Electronics etc
• They are broadly classified as;
– Welding
– Brazing
– Soldering

36
 Welding & its types
• A process of joining two similar or dissimilar materials (Metals & Non-metals), with
application of heat, with or without application of pressure, With or without use of
filler rod (Steel, Magnesium)

Filler
material
(Optional)
Application Heat
of pressure
(Essential)
(Optional)

Welding

37
Shielded Metal Arc Welding (SMAW)
• The arc temperature produce immense
heat with temp. ranging from 24000C to
40000C
• The electrodes are coated with a
shielding flux (Borax flux) of a suitable
composition.
• Heat is generated by an electric arc
between flux coated consumable metal
electrode and the work piece.

• Consumable electrodes usually

have a coating on its outer surface which
on melting release gases like hydrogen or
carbon dioxide to form a protective
covering around the molten pool from
from atmosphere contamination.

38
 Metal Cutting Processes
• In the present advanced technological society, we use hundreds
of equipments in our house, shops, industries, institutes and
many others
• The different manufacturing processes which are commonly
used in practice are shown in Fig. and according to the nature of
the process required, a typical type of machine tool is used.
• The following are the basic machine tools which are commonly
used in every workshop.
•  Lathe machine (for turning and reducing the
diameter).
•  Drilling machine (for generating hole).
•  Shaping machine (for producing flat surface).
•  Milling machine (metal is removed as work is fed
against a rotating multi-point cutter as per requirements).
•  Grinding machine (for producing smooth surfaces).
•  Numerically controlled machine (any machine
controlled by a computer).
Different Metal Cutting Processes
1. Lathe Machine
 Lathe operations
1. Turning – a. Straight Turning
b. Eccentric turning
c. Taper Turning
2. Facing
3. Parting off
4. Chamfering
5. Knurling
6. Grooving
7. Thread Cutting
8. Drilling
9. Reaming
10. Boring
 Turning ..
• machine length of job to reduce
diameter of Job
Operations on Lathe ..

• Cutting Tool: Turning Tool

• Feed:
in direction parallel to work piece axis
• Depth of Cut:
in direction perpendicular to work-
piece axis
 Turning ..
Cylindrical job

Workpiece
Operations on Lathe ..

Cutting
speed Depth of cut (d)
N
Machined
surface
Chuck Feed Chip
Tool
Depth of cut
 Turning ..
Cylindrical job
Operations on Lathe ..
 DRILLING MACHINE
This machine is commonly used for making hole of
required diameter in the blank work-piece. This process of
making hole is known as drilling.

The spindle is rotated by a

motor and transmitting
mechanism. The drill is press-
fitted into the spindle and work-
piece is fixed on the table. As
the drill is fed into work-piece,
the hole is created by removing
the material in the form of chips
 Milling Machine
It is a machine which removes excess materials
from the work pieces by a cutting tool called as
milling cutter. It is one of the important machines
of a tool room since almost all the operation can be
performed on it very accurately.

The milling cutter has multiple cutting edges, so it

removes metal at a very fast rate. The machine can
be mounted with a number of cutter at a time. So
milling machine finds wide application in
production work.
 Milling machine can be used to obtain:
A) Flat surfaces
B) Countoured surfaces
C) Slots
D) Internal and external threads
E) Gear cutting

Types of milling machine

• vertical milling machine
• Horizontal milling machine
 Micromachining
• The term micromachining usually refers to the
fabrication of micromechanical structures with
the aid of etching techniques to remove part
of the substrate or a thin film. Silicon has
excellent mechanical properties making it an
ideal material for machining.
• Micromachining usually refers to the
fabrication process of MEMS, microsensors
and microstructure in general. One usually
distinguishes between bulk and surface
micromachining.
 Micromachining continued

• The tool based traditional processes (micromilling

and microdrilling) and nontraditional processes
(micro EDM, micro ECM, ion/electron/laser beam),
degenerated from macroscale machining
processes, are more popular to produce
microcomponents in aerospace, transportation, oil
& gas, and medical industries.
 Abrasive Jet Machining
Definition:
In abrasive jet machining, a focused stream of
abrasive particles, carried by highpressure air or
gas is made to impinge on the work surface
through a nozzle and thework material is made to
impinge on the work surface through a nozzle and
workmaterial is removed by erosion by high
velocity abrasive particles.
 Additive manufacturing
• The term “additive manufacturing”
references technologies that grow three-
dimensional objects one superfine layer at a time.
Each successive layer bonds to the preceding layer
of melted or partially melted material. It is
possible to use different substances for layering
material, including metal powder, thermoplastics,
ceramics, composites, glass and even edibles like
chocolate.
• The journey from .stl file to 3D object is
revolutionizing manufacturing. Gone are the
intermediary steps, like the creation of molds or
dies, that cost time and money.
Fig. of additive manufacturing -3D
Printer
 Additive manufacturing processes
There are a variety of different additive manufacturing processes:
• Material Extrusion
• Material extrusion is one of the most well-known additive
manufacturing processes. Spooled polymers are extruded, or
drawn through a heated nozzle mounted on a movable arm. The
nozzle moves horizontally while the bed moves vertically,
allowing the melted material to be built layer after layer. Proper
adhesion between layers occurs through precise temperature
control or the use of chemical bonding agents
• Directed Energy Deposition
• The process of directed energy deposition (DED) is similar to
material extrusion, although it can be used with a wider
variety of materials, including polymers, ceramics and metals.
An electron beam gun or laser mounted on a four- or five-axis
arm melts either wire or filament feedstock or powder.
 Material Jetting
With material jetting, a print head moves back and forth,
much like the head on a 2D inkjet printer. However, it
typically moves on x-, y- and z-axes to create 3D objects.
Layers harden as they cool or are cured by ultraviolet
light.
• Binder Jetting
The binder jetting process is similar to material jetting,
except that the print head lays down alternate layers of
powdered material and a liquid binder.

• Powder Bed Fusion

Powder Bed Fusion (PBF) technology is used in a variety
of AM processes, including direct metal laser sintering
(DMLS), selective laser sintering (SLS), selective heat
sintering (SHS), electron beam melting (EBM) and direct
metal laser melting (DMLM).
 Additive manufacturing materials
It is possible to use many different materials to create 3D-
printed objects. AM technology fabricates jet engine parts from
advanced metal alloys, and it also creates chocolate treats and other
• Thermoplastics food items.
• Metals
• Ceramics
• Biochemicals
• Additive manufacturing applications-
• Aerospace
AM excels at producing parts with weight-saving, complex geometric
designs. Therefore, it is often the perfect solution for creating ight, strong
aerospace parts.
• Automotive
• CNN reported that the McLaren racing team is using 3D-printed
parts in its Formula 1 race cars.
 Healthcare
At the New York University School of Medicine, a clinical
study of 300 patients will evaluate the efficacy of patient-
specific, multi-colored kidney cancer models using additive
manufacturing
Product Development
As the potential for AM's design flexibility is realized, once
impossible design concepts are now being successfully re-imagined.
Additive manufacturing unleashes the creative potential of designers
who can now operate free of the constraints under which they once
labored.
 NUMERICALLY CONTROLLED MACHINES
(NC OR CNC MACHINES)

• The operations which can be carried out by CNC

(Computerised Numerically Controlled)
machines are mounting the job or machine,
rotation of spindle, movement and operations of
different tools in sequence as per the
requirements of the job, tool changing, ON and
OFF operations and releasing the finished job.
For the operations as mentioned above, a
programme is done on a tape and fed to the
machine through computer. This method helps to
change the programme if required with minimum
time and cost
 Classification of CNC-Controlled Systems
According to the operations carried out, the systems are
classified as follows :

• 1. Point to Point System : In this system, the operation is

carried out at selected point on the job. During operation, it has no
effect on the work-piece during its motion from one point to
another point. It is generally used for drilling and reaming
operations.
• 2. Straight Cut System : In this operation, the tool is
moved continuously along a straight path for required cut and for
required time. The example of this system is turning on the lathe.
The finishing of the job depends upon the speed of the job and feed
rate.
• 3. Continuous Path System : In this system, simultaneous
movement of tool along different axes takes place to produce
desired contour. This is used for curved surfaces and different
profiles (as cam profile). The motion of the tool is controlled on
more than one axis simultaneously and continuously.
Fig. Continuous Path System
 Advantages and Disadvantages of
NC-MachinesAdvantages
•  It provides high degree of accuracy and
reliability.
•  The flexible programming permits quick changes
in the geometry and dimensions, if required.
•  Human errors are totally eliminated.
•  The production is increased with minimum scrap.
•  Idle time is required and machine utilization time
is increased.
•  It is best suited for mass production.
• Disadvantages
•  The initial cost is high.
•  Not suitable for low volumes.
•  Highly trained programmers are required.
 UNIT 5
• What is casting? Explain with sketch sand casting.
• What is forging? State its advantages and disadvantages
• Write short notes on drawing and extrusion metal forming process.
• Explain with sketch different types of sheet metal working processes.
• What is welding? Write short notes on arc welding.
• Compare TIG and MIG welding.
• Explain with sketch shielded metal arc welding.
• Draw the block diagram of lathe machine.
• Write short notes on different parts of lathe machine.
• Explain with sketch different operation performed on lathe machine.
• Draw block diagram of sensitive drilling machine.
• Draw sketches of different operation performed on drilling machine.
• Write a short notes with figure
• Horizontal milling
• Vertical milling.
• Explain with sketch different operation performed on milling machine.
• Write short notes on
• Micromachining
• Additive manufacturing
• 3D printing
• IOT
• CNC Programming