Definition of Manufacturing

Manufacturing is the process of converting raw materials, components, or parts into

finished goods that meet a customer's expectations or specifications. It involves a series of
steps such as design, production, quality control, and distribution. Manufacturing plays a
crucial role in the economy by creating products that drive consumption, innovation, and
overall growth.

From the creation of everyday items to the development of advanced technology,

manufacturing encompasses a wide range of activities and industries. It is the backbone of
many economies and serves as a foundation for technological advancements and societal
progress. Whether it's the production of consumer goods or complex machinery and
equipment, manufacturing is essential for the well-being and advancement of societies
worldwide.
Importance of Manufacturing Towards
Technological Development
Technological Advancements Research and Development
Manufacturing plays a pivotal role in driving Manufacturing fosters a conducive
technological advancements. Innovations in environment for research and development,
manufacturing processes have led to the leading to the creation of new materials,
development of cutting-edge technologies processes, and products that fuel
such as automation, robotics, and additive technological progress in various industries.
manufacturing.

Economic Growth Global Competitiveness

Manufacturing contributes significantly to Manufacturing enhances a nation's global
technological development by stimulating competitiveness by driving the development
economic growth, which in turn provides the of advanced technologies and fostering a
necessary resources and incentives for skilled workforce, which propels
further advancements in technology and technological innovation on a global scale.
innovation.
Classification of
Manufacturing Processes
• Primary Processes: These include casting, forming, and machining.
Casting involves pouring molten metal into a mold, forming includes
processes like forging and extrusion, while machining involves cutting and
shaping materials.

• Secondary Processes: Such processes include welding, surface treatment,

assembly, and quality control. These processes add value to the primary
processes and enhance product functionality and aesthetics.

• Tertiary Processes: These cover activities like product design, research,

and development, which enable the optimization of manufacturing
processes and the creation of innovative products.
 Metal Casting Processes
Sand Casting Sand Moulds

Sand casting is a versatile metal casting process When it comes to sand casting, the use of sand
that involves creating a mold from a mixture of molds is crucial for accommodating the molten
sand and a bonding agent to form the desired shape. metal and facilitating the solidification process. The
This method is widely used for producing complex molds are carefully designed and prepared to ensure
metal parts of all sizes, from small components to the final product meets the required dimensional
large industrial machinery. accuracy and surface finish.
Type of Patterns and Moulding Sand
Properties
Type of Patterns Types of Moulding Sand and Their
Properties
Patterns in manufacturing are used to create the
shape and form of a product or part to be Moulding sand is a crucial component in casting
manufactured. There are various types of patterns, processes as it forms the mold cavity into which
including solid patterns, split patterns, and match- molten metal is poured. There are various types of
plate patterns. Each type serves specific needs in moulding sands, such as green sand, dry sand, and
the casting process, allowing for the creation of chemically bonded sand. Each type possesses
intricate and precise molds. unique properties in terms of permeability,
refractoriness, and collapsibility, impacting the
quality and characteristics of the final cast
Pattern Materials product.

The materials used for patterns vary based on the

complexity of the part, the expected production
volume, and the required surface finish. Common
pattern materials include wood, metal, and
plastics. Each material offers distinct advantages
and considerations in terms of durability, cost, and
ease of modification.

Pattern Allowances

Pattern allowances refer to the intentional

deviations from the nominal dimensions of a
pattern to account for various factors such as
Core Making and Elements of Gating
System
Core Making Elements of Gating System

Core making is a critical process in metal casting The gating system in metal casting refers to the
where a core, typically made of sand, is inserted arrangement of channels, runners, and gates
into the mold to create internal cavities and through which the molten metal is poured into the
complex shapes in the final casting. Cores are used mold cavity. It plays a crucial role in controlling
to create passageways, holes, and other features the flow of metal, preventing turbulence, and
that cannot be achieved with just the mold. The ensuring that the mold cavity is filled evenly to
cores are made using a mixture of sand and a produce high-quality castings. The elements of the
binder that can hold its shape until the molten gating system include the pouring basin, sprue,
metal is poured into the mold. Core making runners, gates, and risers. Each element is
requires precision and expertise to ensure that the designed to optimize the flow of metal, minimize
cores are dimensionally accurate and can defects, and facilitate the solidification of the
withstand the high temperatures and pressures casting in a controlled manner.
during casting.
 Description and Operation of Cupola
A cupola is a melting furnace used in foundries to melt iron and other metals. It consists of a vertical cylindrical
shaft furnace with a tuyere at the bottom. The process begins by charging the cupola with coke, limestone, and
iron scrap, followed by the ignition of a coke bed at the bottom. As the coke burns, it generates intense heat,
melting the iron scrap and other materials.

The molten metal is then tapped from the bottom of the cupola and poured into molds to create castings of
various shapes and sizes. The operation of the cupola involves precise control of airflow and temperature to
ensure the quality and consistency of the molten metal. The process requires skilled workers who understand the
intricacies of cupola operation.
Working principle of Special casting
processes

Shell Casting Pressure Die Casting Centrifugal Casting

Shell casting is a metal casting Pressure die casting is a Centrifugal casting is a process
process that uses a mold formed manufacturing process in which that uses centrifugal force to
from a thin-walled shell created molten metal is injected at high distribute molten metal into a
from a mixture of sand and resin. pressure into a metal mold. This mold. This rotational casting
The mold is heated so that it can process is suitable for high method is ideal for cylindrical or
be used multiple times. This volume production of detailed, symmetrical parts, as the
process is known for its high strength, and high precision centrifugal force ensures
accuracy and good surface parts. The high pressure ensures uniform distribution of the
finish, making it ideal for that the molten metal fills all the metal, resulting in high density
complex parts that require high parts of the mold and solidifies and low porosity in the final
precision and dimensional quickly, resulting in excellent part. It is commonly used for
stability. surface quality. pipes, cylinder liners, and other
similar components.
Casting Defects
Dimensional Inaccuracy Porosity
One of the common defects in casting is Porosity is a defect characterized by the
dimensional inaccuracy. This occurs when the presence of air or gas pockets within the
final cast product does not meet the required casting. This can weaken the structural
dimensions or specifications. It can be caused integrity of the product and compromise its
by issues such as incorrect mold dimensions, performance. Factors like improper gating,
thermal expansion, or shrinkage of the cast inadequate venting, or excessive metal
material. temperature can lead to porosity.

Surface Irregularities Incomplete Fusion

Surface irregularities, such as rough texture, Incomplete fusion occurs when the molten
cracks, or uneven surfaces, are detrimental to metal does not completely fuse with the
the appearance and functionality of the cast existing material during the casting process.
product. These defects can be caused by This leads to weak joints and structural
improper mold preparation, inadequate pouring weaknesses. Improper gating design and
techniques, or metal impurities. insufficient pouring temperature are common
causes of incomplete fusion.
Thank You