MADE BY: ASHUTOSH UPADHYAY

EEE
SECTION-E
ROLL NO. 021
 INTRODUCTION
 TYPES OF MANUFACTURING PROCESS
 CUPOLA
 PATTERN
 TYPES OF PATTERN
 PATTERN ALLOWANCE
 GATING SYSTEM
 RISERS
 MOULDING
 CASTING
 WELDING
 FORGING AND SMITHYING
 Theprocess or methods involved in
conversion of raw materials into final usable
products is know as manufacturing process.
 Primary shaping process
 Machining processes
Machining is any of various processes in which
a piece of raw material is cut into a desired
final shape and size by a controlled material-
removal process.
 Theseprocesses are used effectively to
provide a good surface finish to the metal.
 Theseprocesses are used for joining of metal
surface .
 For
melting of cast iron in foundry, the
cupola furnace is used
A patter may be defined as a model of the
desired product called casting, constructed
in such a way that it can be used for forming
an impression called mould (cavity) in sand.
 Single piece pattern
it has no joint, parting or loose joints in its
construction. It has usually one board surface
that serve as a parting surface in the mould
 Thistype of pattern is formed in two pieces
where one of the pattern rest in the lower
part of the molding know as drag and other
in upper part of molding box know as cope.
 Itis made in these cases where casting
having a more complicated design and are
required to constructed in more than two
parts in order to facilitate easy molding.
 These patter are used where a rapid
production of small and accurate design on a
large scales.
 These core used in mass production of small
castings. Pattern of these casting are
connected to each other by means of garter
formed which provide suitable channel in sand
for edge the molten metal to these cavities.
 When the size of the casting is very large but
easy to shape and only few members are to
be made, it is uneconomical to make a large
solid pattern of that size.
 These patter are used for preparing moulds
of large circular casting, avoiding the use of
a solid patter of exact size.
A patter is always made layer than the
required size of the casting in order to allow
acting of certain parameters such as rapping,
shrinkage.
 Thevarious metal used for casting contract
after solidification in the mold.
 Thisallowance is provided on the pattern if
the casting is to be machined.
 Allpattern are given a slight toper on all
vertical surface parallel to the direction of
their withdrawal from the mould.
 This
allowance is provided in the pattern to
compensate for the rapping of the moulds
because the patter is to be rapped before
removing it from the mould.
 Theterm gate or gating system involve al the
passage through which molten metal enters
the molding cavity.
 Partingline gate
These are simplest both in nature and
construction.
 Inthis type of gate the entire molten metal
enters the mould cavity at the top due to
which leading t proper solidification of
casting from bottom to riser.
 In this molten metal enters mould cavity at
or near the bottom.
 The difficultly experienced with bottom gate
in deep and large casting can be removed by
using side gate.
Ariser is a passage made in the cope throug
which the molten metal rises up after the
mould is filled.
 Open riser
It has it’s top surface exposed to atmosphere
i.e. opened on top of cope or on the side at
the parting line.
 Thecores are defined as sand bodies to form
the hollow portions or cavities of desired
shape and size in a casting.
 Horizontal cores
It is assembled in the mould with it’s axis
horizontal.
 Itis assembled in the mould with it’s axis
vertical.
 Itis used to produce a blind hole in the
casting along the horizontal axis but apart
from horizontal core.
These are used when entire pattern is rapped
in the drag and core is required to be
supported from the top of the mould.
 Itemployed when a hole is desired to be
produced in the casting at such a position
that its axis fall either above or below the
parting line
 Floormolding
This method of molding is largely employed
for medium and large size articles.
 This method is employed for small casting
which are light in weight.
 This molds are prepared by the moulds are
prepared by the moulder bench.
 When fewer castings are required the moulds
are prepared in two or three boxes with the
use of molding board and then removed for
pouring.
 In this process, molding floor is dug in land of
rectangular shape and then lined with brick
work, particular a concert base is provided
at the bottom so as to withstand heavy
pressure of molten metal during pouring.
 Metallicpattern are used in this type of
molding process. A plaster mixture in
prepared consisting of 70 to 80% of plaster
and rest talc.
 Thisis process in which, the sand mixed with
a thermosetting resin is allowed to come in
contact with a heated metallic pattern plate
so that a thin and strong shell of mould is
formed around the pattern
 Thisprocess is basically a hardening process
for mould and cores the sand mixture used in
this process consist of pure silica sand free
from clay and sodium silicate liquid base
binders.
A casting made by pouring molten metal into
a mould of some metallic alloy is know s=as
permanent mould casting.
 This is also knows as gravity die casting.
 Since they are costly so they are
recommended for mass production.
 This process is based on the slodification of
molten metal by the chilling effect.
 It is used for casting metals like gold, silver,
aluminum, zinc etc. having low melting
point.
 Itis defined as the casting which uses
permanent mould (called die) and the
molten metal is introduced into it by means
of pressure of 7 to 700mpa.
 The casting produced under the process in
which molten metal is poured and allowed to
solidify under revolution is called as
centrifugal process.
 It is also knows as precession casting.
 This process is generally employed for the
production of rods, squares , pipes tubes,
sheets etc.
 It consist of pouring the molten metal into
the upper opening of a vertical metal mould.
 Itis a process of joining metal pieces
together by raising the temperature of the
piece to fusion and applying a mechanical
pressure to join them.
 Itis the simplest and probably the most
commonly used method of making la welds in
thin sheet using the principle of resistance
welding.
 Also knows as upset welding.
 It is wesd to join the metal pieces end to
end. In this process the metal pieces usually
bars and rods of the same cross section are
held in suitable clamps or vices with their
previously squared ends abutting against
each other.
 The high pressure oxygen-acetylene welding
is a process that use fuel gases and oxygen to
weld and cut.
 Oxygen fuel is one of the oldest welding
processes beside forge welding.
 Ita fusion or non-pressure welding method in
which a strong gas flame used to raise the
temperature of the end of the pieces to be
joinedto a heat sufficient to melt them.
 It is a very fast method of welding.
 It consist of holding the parts at a small
distance with their end faces opposite to
each other, bringing them closer at a fast
speed after switching on the current, thus
creating an arc between their end faces just
before they come in contact and completing
the weld under impact.