Unit 4 - Manufacturing Processes and Fastners

MECHANICAL
ENGINEERING SCIENCE
UNIT - 4
Manufacturing processes and fasteners
Srinivasa Prasad K S
Department of Mechanical Engineering
MECHANICAL ENGINEERING SCIENCES
Manufacturing processes and Fasteners
Issues addressed …….
• Primary and secondary processes.

• Casting – sand and metal moulds.
• Forming – Forging, Rolling, drawing, deep drawing and extrusion.
• Rivets, Welding- electric arc, gas and resistance welding. Soldering
and brazing.
• Fasteners, cotter joint and couplings.
Manufacturing Process
“The Process of Converting Raw Materials Into Finished Products "or
Shaping of raw materials into finished products
Cost
Material
Use
NEED & CONCEPT OF MANUFACTURING PROCESS

The progress and the prosperity of human civilization are
governed and judged mainly by improvement and
maintenance of standard of living through availability or
production of ample and quality goods and services for
men’s material welfare in all respects covering housing,
clothing, medicine, education, transport, communication
and also entertainment.
NEED & CONCEPT OF MANUFACTURING PROCESS Cont…

The successful creation of men’s material welfare depends
mainly on
• Availability of natural resources (NR)
• Exertion of human effort (HE); both physical and mental
• Development and use of power tools and machines(Tools)
NEED & CONCEPT OF MANUFACTURING PROCESS Cont…

Production or manufacturing can be simply defined as
value addition processes by which raw materials of low
utility and value due to its inadequate material
properties and poor or irregular size, shape and finish are
converted into high utility and valued products with
definite dimensions, forms and finish imparting some
functional ability.
IMPORTANCE
• Today’s competitive manufacturing era of high industrial
development and research, is being called the age of
mechanization, automation and computer integrated
manufacturing
• Due to new researches in the manufacturing field, the
advancement has come to this extent that every different
aspect of this technology has become a full-fledged
fundamental and advanced study in itself.
• This has led to introduction of optimized design and
manufacturing of new products
IMPORTANCE Cont…
• New developments in manufacturing areas are deciding
to transfer more skill to the machines for considerably
reduction of manual labor.
• The scope of the subject manufacturing process is
extremely wide as it specifies the need of greater care for
man, machine, material and other equipments involving
higher initial investment by using proper safety rule and
precautions.
CLASSIFICATION OF MANUFACTURING PROCESS
Based on the property of metal
• Casting, Welding( Fusibility)
• Machining ( Divisibility)
• Metal Forming( Ductility/ Malleability)
• Non traditional Machining
Based on metal removal
• Cutting Process
• Non Cutting process
Another mode of classification is

Primary Manufacturing Processes-
Casting ,Forming, such as Forging, Rolling, Extrusion, etc.
Joining, such as Welding, Soldering,
Secondary Manufacturing Processes

Machining, Surface working, such as Heat Treatment, Coating, etc
Advanced Manufacturing Processes

Powder Metallurgy (PM)
Rapid Prototyping (RP) or 3-D Printing
CNC machines, machining centers, etc.
Die Casting, etc
PRODUCTION PROCESSES
• Casting
• Welding
• Machining
• Rolling
• Forging
• Extrusion
• Wire drawing
• Sheet metal working
METAL CASTING
INTRODUCTION
Metal casting involves pouring molten metal into a
mould containing a cavity of the desired shape to
produce a metal product.
The casting is then removed from the mould and

excess metal is removed, often using shot blasting,
grinding or welding processes.
The product may then undergo a range of

processes such as machining, heat treatment,
polishing and surface coating or finishing.
Foundry
Foundry is factory that produces castings.
Factory is a place where products (helpful to mankind) are manufactured.

STEPS INVOLVED IN CASTING

Sand Casting Terminology
Concept of Gating and Risers

SAND CASTING PROCESS

FLOWCHART
SAND CASTING PROCESS

FLOWCHART
STEPS INVOLVED IN CASTING
•Pattern making
•Mould making
•Melting & Pouring
•Cooling & shakeout
•Sand reclamation
•Fettling, Cleaning & Inspection
PATTERN
The pattern is the principal tool during the casting
process. It is the replica of the object to be made by
the casting process, with some modifications.
The main modifications are the addition of pattern

allowances, and the provision of core prints. If the
casting is to be hollow, additional patterns called
cores are used to create these cavities in the finished
product.
Pattern allowances
• Shrinkage allowance
• Machining allowance
• Distortion allowance
• Draft allowance
Functions of the Pattern
1. A pattern prepares a mold cavity for the purpose of making a casting.
2. A pattern may contain projections known as core prints if the casting
requires a core and need to be made hollow.
3. Runner, gates, and risers used for feeding molten metal in the mold
cavity may form a part of the pattern.
4. Patterns properly made and having finished and smooth surfaces
reduce casting defects.
5. A properly constructed pattern minimizes the overall cost of the
castings.
Pattern Material
Wood, metals and alloys, plastic, plaster of Paris, plastic and
rubbers, wax, and resins.
Desirable properties of pattern material are:
1. Easily worked, shaped and joined
2. Light in weight
3. Strong, hard and durable
4. Resistant to wear and abrasion
5. Resistant to corrosion, and to chemical reactions
6. Dimensionally stable & should not cause distortion.
7. Unaffected by variations in temperature & humidity.
8. Available at low cost
9. Non hygroscopic
Types of Pattern
Solid pattern - A solid pattern is a model of the part as a single
piece. It is the easiest to fabricate, but can cause some difficulties
in making the mold. The parting line and runner system must be
determined separately. Solid patterns are typically used for
geometrically simple parts that are produced in low quantities.
Split pattern
Split pattern models the part as two separate
pieces that meet along the parting line of the mold.
Using two separate pieces allows the mold cavities
in the cope and drag to be made separately and the
parting line is already determined. Split patterns
are typically used for parts that are geometrically
complex and are produced in moderate quantities.
Match plate pattern
A match-plate pattern is similar to a split pattern,

except that each half of the pattern is attached to
opposite sides of a single plate.
The plate is usually made from wood or metal.

This pattern design ensures proper alignment of the
mold cavities in the cope and drag and the runner
system can be included on the match plate.
Match-plate patterns are used for larger production

quantities and are often used when the process is
automated.
Cope and drag pattern
A cope and drag pattern is similar to a match plate
pattern, except that each half of the pattern is attached to
a separate plate and the mold halves are made
independently.
Just as with a match plate pattern, the plates ensure

proper alignment of the mold cavities in the cope and
drag and the runner system can be included on the plates.
Cope and drag patterns are often desirable for larger

castings
Loose-piece pattern
Patterns with complicated shapes which cannot be

withdrawn easily.
Loose pieces remains attached with the main body

by using dowel pins.
Sweep pattern
Sweeps can be advantageously used for preparing moulds of large
symmetrical castings, particularly of circular cross section.
The full equipment consists of a base, suitably placed in the sand mass,
a vertical spindle and a wooden template called sweep.
The outer end of sweep carries the contour corresponding to the shape
of the desired casting. The sweep is rotated about the spindle to form
the cavity.
The hole made by the removal of spindle is patched up by filling the

sand.
PATTERN MAKING and CORE BOX MAKING
• The quality of the casting produced depends upon the

material of the pattern, its design, and construction.
• Pattern making is the first stage for developing a new casting.
• Pattern making is a highly skilled and precise process that is
critical to the quality of the final product.
• Pattern can be used for one or more casting.
• Cores are produced in conjunction with the pattern to form
the interior surfaces of the casting.
• These are produced in a core box, which is essentially a
permanent mould that is developed
SAND MOULD MAKING – Sand is expendable moulds.
The mould is formed in a mould box (flask), which is typically

constructed in two halves to assist in removing the pattern.
The bottom half of the mould (the drag) is formed on a molding board.
Cores are required for making hollow cavity in the casting.
It require greater strength to hold their form during pouring. Cores are
formed using one of the chemical binding systems . After the core is
inserted, the top half of the mould (the cope) is placed on top. The
interface between the two mould halves is called a parting line.
MOULD MAKING
Mould designs include a gating system which is designed to carry molten
metal smoothly to all parts of the mould. The gating system typically includes
a sprue, gates, runners and risers.
The sprue is where the metal is poured.
Runners carry the molten metal towards the casting cavity through InGates.
Risers may have several functions including vents to allow gases to be
released, reservoirs prior to the casting cavity to aid progressive solidification,
and waste cavities to allow metal to rise from the casting cavity to ensure it is
filled and to remove the first poured metal from the casting cavity, thus
avoiding solidification problems
MELTING & POURING

The charge (Virgin metal and scrap) is weighed and introduced to the
furnace.
Alloys and other materials are added to the charge to produce the
desired melt.
Molten metal is transferred from the furnace to a ladle and cleaned and
held until it reaches the desired pouring temperature.
The molten metal is poured into the mould and allowed to solidify
Cooling and Shakeout
Once the metal has been poured, the mould is cooled.
Castings may be removed manually or using vibratory tables that shake the
refractory material away from the casting.
The casting are then heat treated for removing internal stresses and getting the
desired metallurgical properties.
Sand Reclamation
Fettling, Cleaning and Finishing

Gating system is removed, often using band saws, abrasive cut-off
wheels or electrical cut-off devices.
A ‘parting line flash’ is removed by grinding or with chipping hammers.
Castings may also need to be repaired by welding, brazing or soldering
to eliminate defects.
The casting may undergo additional grinding and polishing to achieve
the desired surface quality. The casting may then be coated using either
a paint or a metal finishing operation such as galvanising, powder
coating.
Advantages of Sand Casting
• Use is widespread; technology well developed.
• Materials are inexpensive, capable of holding detail and resist deformation
when heated.
• Process is suitable for both ferrous and non-ferrous metal castings.
• Handles a more diverse range of products than any other casting method.
• Produces both small precision castings and large castings of up to 1 tonne.
• Can achieve very close tolerances if uniform compaction is achieved. Mould
preparation time is relatively short in comparison to many other processes.
• The relative simplicity of the process makes it ideally suited to
mechanization.
• High levels of sand reuse are achievable
Limitations
• Typically limited to one or a small number of moulds
per box..
• Sand: metal ratio is relatively high.
• High level of waste is generated
Applications
Turbine vanes, Power Generators, Railways, Agricultural
Components, Construction equipments.
Casting Defects
Types
1. Gas Porosity: Blowholes, open holes, pinholes
2. Shrinkage defects: shrinkage cavity
3. Mold material defects: Cut and washes, swell, drops, metal
penetration, rat tail
4. Pouring metal defects: Cold shut, misrun, slag inclusion
5. Metallurgical defects: Hot tears, hot spot
Shift or Mismatch
The defect caused due to misalignment of

upper and lower part of the casting and
misplacement of the core at parting line
It is the enlargement of the mold cavity because

of the molten metal pressure, which results in
localized or overall enlargement of the casting.
Blowholes
When gases entrapped on the surface of the casting due to solidifying
metal, a rounded or oval cavity is formed called as blowholes. These
defects are always present in the cope part of the mold
Drop defect occurs when there is cracking on

the upper surface of the sand and sand pieces
fall into the molten metal.
etal Penetration
These casting defects appear as an uneven and rough
surface of the casting. When the size of sand grains is
larges, the molten fuses into the sand and solidifies giving
us metal penetration defect.
They are very small holes of about 2 mm in size which appears on the surface of the
casting. This defect happens because of the dissolution of the hydrogen gases in the
molten metal. When the molten metal is poured in the mold cavity and as it starts to
solidify, the solubility of the hydrogen gas decreases and it starts escaping out the
molten metal leaves behind small number of holes called as pinholes.
kage Cavity
The formation of cavity in the casting due to
volumetric contraction is called as shrinkage cavity.
ot Tears or Hot Cracks
when the metal is hot it is weak and
the residual stress (tensile) in the
material cause the casting fails as the
molten metal cools down. The failure
of casting in this case is looks like
cracks and called as hot tears or hot
cracking.
Cold Shut
It is a type of surface defects and a line on the surface can be seen. When
the molten metal enters into the mold from two gates and when these two
streams of molten metal meet at a junction with low temperatures than
they do not fuse with each other and solidifies creating a cold shut (appear
as line on the casting). It looks like a crack with round edge
Causes
Poor gating system
Low melting temperature
• Lack of fluidity
Remedies
Improved gating system.
• Proper pouring temperature.
Misrun
When the molten metal solidifies before completely filling the
mold cavity and leaves a space in the mold called as misrun.
Causes
(i) Low fluidity of the molten metal.
(ii) Low temperature of the molten metal which decreases its
fluidity.
(iii) Too thin section and improper gating system.
Remedies
(i) Increasing the pouring temperature of the molten metal
increases the fluidity.
(ii) Proper gating system
(iii) Too thin section is avoided.
Properties of molding sand

Green strength
Dry strength
Permeability or porosity
Cohesiveness
Adhesiveness
Collapsibility
Flow ability
Refractoriness
1. Gravity Die casting
2.Manufacturing processes and Fasteners
Pressure die casting
Other types of
3. Investment casting processes
casting 2
1 3
Metal Forming
Plastic deformation with pressure, with or without the application of heat.
Forging , Rolling, Extrusion, Wire drawing and deep drawing.

Metal working methods

Hot working
It involves prior heating of the billet to a temperature above
(0.5Tm) Recrystallization temperature. This reduces strength and
increases ductility of the metal, permitting more extreme size
reductions and more complex shapes to be achieved in the
process. Advantages include reduction of ram force, increased ram
speed.
Cold working
It is generally used to produce finished form. Advantages of cold
extrusion include increased strength due to strain hardening, close
tolerances, improved surface finish, absence of oxide layers, and
high production rates.
Rolling
• It is the process of reducing the thickness or
changing the cross section of a long work piece by
compressive forces applied through a set of rolls.
• Most rolling is carried out by hot working, called
hot rolling, owing to the large amount of
deformation required.
• Hot-rolled metal is generally free of residual
stresses, and its properties are isotropic.
Forging
• It is the process of shaping heated metal by the application of sudden blows (i.e.,
hammer forging) or steady pressure (i.e., press forging) and makes use of the
characteristic of plasticity of the material
• A metal such as steel can be shaped in a cold state but the application of heat lowers
the yield point and makes permanent deformation easier
• Forging may be done by hand or machine.
• Forging by machine involves the use of dies and is generally used in mass-production.
Extrusion
A material is pushed through a die of the desired cross-section. This process has ability to
create very complex cross-sections,
•Hot extrusion
•Cold extrusion and warm extrusion
Drawing
Drawing is a process in which the material is pulled
through a die by means of a tensile force. Usually the
constant cross section is circular (bar, rod, wire, tube).
Deep Drawing
• Deep drawing is a sheet metal forming process.
• Metal sheets are largely used in manufacturing
industries due to its easy operation, light weight and
ability to be converted into various shapes.
• Sheet metal also provides good strength.
• There are various advantages of sheet metal
products which make it an versatile operation.
Welding
Welding
• Welding is a metallurgical joint of two metals pieces
together to produce essentially a single piece of metal.
• Welding is done with high temperature, with or without

pressure and with or without filler metals.
• Welding types : Fusion welding and Solid state welding
61
Fusion welding : Electric Arc welding

Steps involved in welding
• Step 1: Cleaning
• Step 2: Edge Preparation
• Step 3: Check for safety devices
• Step 4: Initial tack weld
• Step 5: Final welding
• Step 6: Excess material removal
Arc welding (Metal arc)
• Arc welding  fusion welding process  ends of the metal pieces joined by
electric arc. Used for welding steel, Al, Cu, Ti, Cu alloys, etc.
Arc welding equipment and accessories

• AC or DC machine
• Electrode and electrode holder
• Chipping hammer
• Earthing clamps
• Wire brush
• Helmet
• Safety goggles, Hand gloves, etc.
• When two conductors of an electric circuit are touched
together momentarily and then instantaneously separated
slightly, assuming that there is sufficient voltage in the circuit
to maintain the flow of current, an electric arc is formed,
• Concentrated heat is produced throughout the length of the
arc at a temperature of about 3000 to 4000°C.
• In arc welding, usually the parts to be welded are wired as one
pole of the circuit, and the electrode held by the operator
forms the other pole.
• When the arc is produced, the intense heat quickly melts the
workpiece metal which is directly under the arc, forming a
small molten metal pool.
 At the same time the tip of the electrode at the arc also
melts, and this molten metal of the electrode is carried
over by the arc to the molten metal pool of the workpiece.
 The molten metal in the pool is agitated by the action of
the arc, thoroughly mixing the base and the filler metal.
 A solid joint will be formed when the molten metal cools
and solidifies.
 The flux coating over the electrode produces an inert
gaseous shield surrounding the arc and protects the
molten metal from oxidizing by coming in contact with the
atmosphere. Fig. illustrates the arc welding process.
Electrodes used for arc welding
• Non-consumable electrodes
• Does not consume during welding process

• Made of carbon, graphite or tungsten
• Consumable electrodes
• Consume during welding process

• Both rod and wire forms, electrode is consumed by the arc and
added to weld joint as filler metal. Made of mild steel, Al, lead-
bronze, phosphor-bronze, etc.
• Types  (1) Bare or non-coated electrodes
(2) Coated electrodes

Functions of coated electrodes.

•Protect molten metal from oxidation by producing gas
shield around the arc and weld pool
•Provide the formation of slag
•Controls the weld bead
•Stabilize the arc
Fluxes
Fluxes are added/coated over the surfaces of parent metal  protect
the weld metal from oxidation
Flux applied in the form of paste/powder/liquid/gas
Typical fluxes
• SiO2, TiO2, FeO, MgO, Al2O3 ,quartz sand, calcium oxide,
calcium fluoride, calcined borax, borax, lithium etc
• Produces a gaseous shield to prevent contamination.
Arc Welding
Gas Welding
Gas welding is a fusion welding method of welding, in
which a strong gas flame is used to rise the temperature
(3200 ˚C) of the work pieces so as to melt them
Gas Welding Setup (Oxyacetylene Gas Welding)
71
Gas Welding Flames
For complete combustion of acetylene, 2.5 volume of oxygen are

required for 1 volume of acetylene.
Oxygen to acetylene ratio varies from 0.95 to 1.5.
Depending on oxygen to acetylene gas ratio, it can be classified as

• Neutral Flame (0.95)
• Carburizing or reducing flames (0.95 to 1)
• Oxidizing Flame (1.15 to 1.5)
Gas Welding Flames
Advantages
• Process is simple and inexpensive
• Eliminates a skilled operator
• Temperature of the flame can be controlled
depending on the thickness and type of material
being welded
74
Disadvantages
• Acetylene gas is slightly costlier

• Not suitable for thick and high melting point metals
• Refractory metals like tungsten, molybdenum etc., and reactive metals like
zirconium, titanium etc., cannot be gas welded.
• Acetylene gas is highly explosive. Hence precautions should be taken during
its storage and welding.
75
Resistance Welding
Resistance heat is used for welding.
H = I2Rt
Where:
H = Heat generated in joule.
I = Electric current in ampere.
R = Electric resistance in Ohm.
t = Time of current flow in second.
Types of RW
– Spot welding,
– Seam welding
– Projection welding
– Flash welding
– Percussion welding
Resistance Welding
Because of high resistance of the material,
Heat is generated which in turn weld the material
Spot welding
Seam welding
Resistance Welding Cont…
Spot welding
Spot welding (also known as resistance spot welding) is a

resistance welding process. This welding process is used
primarily for welding two or more metal sheets together
by applying pressure and heat from an electric current to
the weld area.
Resistance Welding Cont…

Seam welding
• Seam welding is the process of joining two similar or
dissimilar materials at the seam by the use of electric current
and pressure.
• The process is mostly used on metals since they conduct
electricity easily and can sustain relatively high pressures.
• It is one of the most common welding method used to join
metal sheets with a continuous weld.
• When two similar or dissimilar materials are pressed
together, there will be a slight gap between them due to
surface irregularities. In resistance seam welding, this gap
creates an electrical resistance between the two materials Continuous spot welding with roller electrodes.
and causes them to heat up at the seam.
LDERING
• Soldering is a method of joining similar or
dissimilar metals by the application of heat
and using a filler metal or alloy called solder.
• The molten filler metal is made to flow
between the two closely placed adjacent
surfaces by the capillary action.
• Soldering mainly requires the following-
1. Soldering Iron 2. Solder (alloy)
3. Flux
Soldering Process
1.Soldering gun
2.Filler material
3.Flux
Soldering Procedure
Work Preparation
• Work pieces should be perfectly clean.
• There should be no dirt, dust, rust, paint or grease.
• Cleaning can be done with a file or sandpaper.
Fluxing
• Flux depends on the material of work piece.
• It is applied with the help of brush.
• It avoids oxidation of molten metal, helps in flow of solder
Soldering Procedure Cont..
Tinning
• Soldering bit is cleaned; application of flux is done
over it.
• It is brought in contact of solder wire so the bit
carriers sufficient amount of molten solder over it.
• Filling the joint with molten solder and allow to
solidify
Classification of Solders
The solders can be classified into
1. Soft Solders (Temperature of melting 150 ˚C to 190 ˚C)

Generally composed of lead and tin
ii. Hard Solders (Temperature of melting 300 ˚C to 600 ˚C)

Generally composed of Copper and zinc
Fluxes
The main function of fluxes are

a. Remove oxide films from base part surfaces
b. Prevent oxidation during heating
c. Promote wetting of the faying surfaces
Faying surfaces are surfaces where parts are joined

together with adhesion or welding.
Classification of Fluxes
• Organic Fluxes
• Inorganic Fluxes
• Non Corrosive Fluxes
 Chemically unstable at higher temperature but non corrosive at room temperature: Lactic acid,
Benzoic acid, Stearic acid are used as flux
 Inorganic flux consists of mixture of zinc chloride and ammonia chloride
 Rosin fluxes which are non corrosive type fluxes, Rosin is a derivates of pipe trees gum. It is
highly electric conductive in nature
Advantages of Soldering
• Low cost and easy to use
• Soldered joints are easy to repair and rework.
• The soldered joint can last for a long time
• Leak proof joints can be produced
• Low energy is required.
Disadvantages of Soldering
• The strength of soldered joints is low.
• Cannot be used for high temperature applications
• Skilled and trained person is required
Brazing
Brazing is a joining process in which two similar or

dissimilar metals joined by a special filler metal
whose melting temperature is above 450 ˚C
Components in brazing
• Filler Metal (spelter)

• Flux
• Brazing Torch
• Filler metals in brazing is called spelter
• Aluminium – Silicon alloy are generally used for brazing alloys – with
melting point 550 ˚C – 780 ˚C
• Magnesium filler metals used for brazing magnesium alloys
• Silver and silver alloys are used to braze silver components.
• Copper and copper zinc alloys and copper tin alloys, melting range is
850 ˚C to 950 ˚C are used for brazing ferrous alloy, Nickel and copper –
nickel alloys
• Copper – Phosphorus alloys are used for brazing copper and its alloys.
Melting temperature 700 ˚C – 750 ˚C
• Nickel filler alloys are used for brazing Ni and Cobalt – base alloys.
Nickel braze joints can stand over 980 ˚C
Flux
Borax, boric acid, fluorides or chlorides are commonly used flux
Welding Torch
Oxyacetylene welding torch

Advantages
• Much heat is not involved in the process. Hence low thermal distortions.
• Easily automated process
• Dissimilar parts can be joined
Disadvantages
• Flux residual must be removed after brazing, otherwise
which may cause corrosion
• Large and thick sections cannot be brazed efficiently
• Relatively expensive filler materials
91
Comparison between soldering, brazing
Soldering Brazing
Filler metal is called solder Filler metal is called spelter
Melting point of filler metal is below Melting point of filler metal is above 450 ˚C
450 ˚C but below melting point of work piece
Soldered joint strength is low Brazed joint strength is high

Solder is cheaper process Brazing is costlier process
(Economical Process)
Usually suitable for join metals with Suitable process for joining metals for
small thickness larger thickness
92
Fasteners
• Fasteners are small to large pieces of hardware that is
used to affix or join objects together.
• Fasteners are everywhere. From Smartphone to Sydney
or Golden gate bridge.
• From rivets, nuts, bolts, screws to paper clip, split clip
and nails are all considered to be fasteners.
• Did you know, a Boeing 747-400 has six million parts, half of
which are fasteners. Around 3 million different types of nuts
and bolts, rivets and screws.
• There are 18,038 iron parts and more than 25,00,000
fasteners (rivets) used to hold the Eiffel tower together.
• Examples of fasteners are wood screw, machine screws, sheet
metal screws, self drilling sheet metal screws, hex bolts, flange
bolts etc.
Square Screws or trapezoidal treads are used

Riveting Joint
• It is a semi permanent joint.
• Riveting is a forging process that may be used
to join parts together by way of a metal part
called a rivet.
• Rivets are used in construction and sheet
metal industry.
• One of the end is preformed and other end are
formed using a forming tool over the
connection, joining the parts securely.
Lap joints.
Butt joints.

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MECHANICAL

• Primary and secondary processes.

NEED & CONCEPT OF MANUFACTURING PROCESS

NEED & CONCEPT OF MANUFACTURING PROCESS Cont…

NEED & CONCEPT OF MANUFACTURING PROCESS Cont…

Another mode of classification is

Secondary Manufacturing Processes

Advanced Manufacturing Processes

The casting is then removed from the mould and

The product may then undergo a range of

Foundry is factory that produces castings.

Factory is a place where products (helpful to mankind) are manufactured.

STEPS INVOLVED IN CASTING

Concept of Gating and Risers

SAND CASTING PROCESS

SAND CASTING PROCESS

The main modifications are the addition of pattern

A match-plate pattern is similar to a split pattern,

The plate is usually made from wood or metal.

Match-plate patterns are used for larger production

Just as with a match plate pattern, the plates ensure

Cope and drag patterns are often desirable for larger

Patterns with complicated shapes which cannot be

Loose pieces remains attached with the main body

The hole made by the removal of spindle is patched up by filling the

• The quality of the casting produced depends upon the

The mould is formed in a mould box (flask), which is typically

MELTING & POURING

Fettling, Cleaning and Finishing

The defect caused due to misalignment of

It is the enlargement of the mold cavity because

Drop defect occurs when there is cracking on

Properties of molding sand

Plastic deformation with pressure, with or without the application of heat.

Forging , Rolling, Extrusion, Wire drawing and deep drawing.

Metal working methods

• Welding is done with high temperature, with or without

• Welding types : Fusion welding and Solid state welding

Fusion welding : Electric Arc welding

Arc welding equipment and accessories

• Does not consume during welding process

• Consume during welding process

(2) Coated electrodes

Functions of coated electrodes.

Gas Welding Setup (Oxyacetylene Gas Welding)

For complete combustion of acetylene, 2.5 volume of oxygen are

Oxygen to acetylene ratio varies from 0.95 to 1.5.

Depending on oxygen to acetylene gas ratio, it can be classified as

• Acetylene gas is slightly costlier

Spot welding (also known as resistance spot welding) is a

Resistance Welding Cont…

The solders can be classified into

1. Soft Solders (Temperature of melting 150 ˚C to 190 ˚C)

ii. Hard Solders (Temperature of melting 300 ˚C to 600 ˚C)

The main function of fluxes are

Faying surfaces are surfaces where parts are joined

Brazing is a joining process in which two similar or

• Filler Metal (spelter)

Borax, boric acid, fluorides or chlorides are commonly used flux