MANUFACTURING PROCESS Prof. Kiran Gore Unit -3

What is ‘Manufacturing’?  Process of converting raw material in to finished goods, with the combination of 3 element i.e. MAN, MACHINE & MATERIAL. MFG. PROCESS FINISHED GOODS MAN MACHINE MATERIAL

Contents  Casting  Metal forming process ( Forging )  Sheet metal working  Metal joining process

Casting process

One of the Oldest mfg process. Is the process in which molten metal is poured into the prepared mould or cavity which conforms to the shape of desired component & then allowing the metal or alloy to cool & solidify.

A plant where the casting are produced is known as ‘foundry’ or ‘foundry shop’ Foundry

BASIC TERMINOLOGY IN CASTING PROCESS

1.mould The cavity which confirms the shape of the component to be manufactured & in to which molten metal is to be poured is called as the mould.

Open mold & closed mould

Mould making

It is the model or replica of the object to be cast. 2. Pattern

Materials for pattern making 1.Wood 2.Metal 3.Plastic 4.Plaster of Paris or gypsum cement 5.wax

3.Casting A component manufactured is called as ‘Casting’

Difference between pattern and casting pattern casting

Core Core is an obstruction which when positioned in the mould, does not permit the molten material poured to fill the space occupied by the core, hence to produced hallow casting.

Core

5. Mould box Mould box is the combination of two halves, upper half & lower half. The upper half is called as a cope & lower half is called as a drag.

Mould box DRAG COPE

Mould box

6. Mould material  Mould material is one out of which mould is made.  Mould can be made of wax, plaster of parries, ceramics etc.

7. Sprue  It is the channel through which metal is brought in to the parting plane where it enters the runner & gate.  It may be square or round in shape.

8. Runner

9.Gate

9) Gate  A gate is channel which connects the runner with the mould cavity through which molten flows to till fill the mould cavity.  For large components more than one gates are used

10. Riser

Ladle are used to carry the molten metal from the furnace to the molding box 10) Ladle

Casting processes Following are the various casting processes which are commonly used 1.Sand mould casting 2.Metallic mould casting 3. Centrifugal casting 4. Investment casting 5. Continuous casting

1. Sand mould Casting  Most common method of casting  It is the casting process in which the castings are made using sand mould

1. Pattern making 2. Sand mixing 3. Mould making 4. Core making 5. Melting and pouring of metal 6. Cooling and solidification of casting 7. Cleaning & finishing 8. Inspection Steps in Sand casting

1) Pattern making Make the of pattern wood, metal or plastic.

2) Sand mixing Select a particular sand, test it & prepare the necessary sand mixtures for mould & core making.

3) Mould making  Process of making the cavity  In sand casting mould is made of sand  The pattern is kept in a flask and the moulding sand is pressed (ramming) around the pattern. The pattern is then taken out. The cavity formed due to removal of pattern is mould.

4) Core making With the help of patterns prepare the mould & required cores.

5.Melting and pouring of metal  Melt the molten metal or alloy to be cast.  Pouring the molten metal in to the mould.  Remove the casting from the mould after solidification of metal.

6. Cooling and solidification of casting

7) Cleaning Clean the part.

8. finishing finish the part

9) Inspection Test & inspect the casting & remove the defects, if any.

 The components of intricate shapes which are difficult to produced by other manufacturing process can be produced by casting process. Advantages of casting process

intricate shapes

 In casting process there is no restriction on size of components. Advantages of casting process

 The casting process is economically suitable for both the small quantity job production as well as the mass production. Advantages of casting process

 In casting process the cost of component is very low. Advantages of casting process

 The components of thickness less than 6mm cannot be manufactured by casting process. Limitation of casting process

 Casting process requires large man power as compared to other manufacturing process. Limitation of casting process

 Casting process require large space as compared to other manufacturing process.

Limitation of casting process  In casting process, the environmental pollution is very high.

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