What is manufacturing

The word manufacturing is derived from the Latin, manu factus, which means made by hand. Manufacturing is not only the making of product; it is the integration of product demand, product design, material selection, manufacturing processing, product assembly, and management to produce a desired product at a competitive price at the desired time. Manufacturing is the use of machines, tools and labor to produce goods for use or sale. The term may refer to a range of human activity, from handicraft to high tech, but is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale. Such finished goods may be used for manufacturing other, more complex products, such as aircraft, household appliances or automobiles, or sold to wholesalers, who in turn sell them to retailers, who then sell them to end users the "consumers"

Manufacturing process
Manufacturing processing is the procedure by

which materials are formed into the desired

shapes. A sequence of operations and processes designed to create a specific product The process of turning materials into a product

Manufacturing process is the effective use of

the resources for the required product The resources are - Man - Material - Money - Machine

 In modern context it involves making products from raw material by using various processes, by making use of hand tools, machinery or even computers. Advance manufacturing engineering involves the following concepts 1. Process planning. 2. Process sheets. 3. Route sheets. 4. Tooling. 5. Cutting tools, machine tools (traditional, numerical control (NC), and computerized numerical control (CNC). 6. Jigs and Fixtures. 7. Dies and Moulds. 8. Manufacturing Information Generation. 9. CNC part programs. 10. Robot programmers. 11. Flexible Manufacturing Systems (FMS), Group Technology (GT) and Computer integrated manufacturing (CIM).

CLASSIFICATION OF MANUFACTURING PROCESSES

(1). primary shaping processes :

(1)Casting, (2) Powder metallurgy, (3) Plastic technology, (4) Gas cutting, (5) Bending and (6) Forging.

(2). secondary or machining processes are:

(1) Turning, (2) Threading, (3) Knurling, (4) Milling, (5) Drilling, (6) Boring, (7) Planning, (8) Shaping, (9) Slotting, (10) Sawing, (11) Broaching, (12) Hobbing, (13) Grinding, (14) Gear cutting, (15) Thread cutting and (16) Unconventional machining processes namely machining with Numerical Control (NC) machines tools or Computer Numerical Control (CNC) machines tools using ECM, LBM, AJM, USM setups etc.

Importance of safety

Different types of manufacturing processes 1 Casting 2 Molding 3 Forming 4 Machining 5 Joining 6 Rapid manufacturing 7 Unconventional machining processes
8 Powder metallurgy

Casting process

Casting is one of the oldest and best-known manufacturing processes. It consists of pouring a liquid material, usually a metal, into a mold and letting it cool and solidify into the desired shape.

Principle of casting It consist of introducing the molten metal into a cavity and mould of the desired shape and allowing it to solidify. Advantages - No limit to the sizes - Shape and intricacy of the article can be produced - It gives high strength and rigidity even to intricate part which are difficult to produce by other methods of manufacturing - Any shape can be casted - Avoids the problem which arise due to joining assembly together

Major area of casting process

Pattern making: This includes the modification of the desired part shape to include draft, shrinkage, and machining allowances as well as to provide the gating and risering design. The pattern has the shape of the casting, and it is used to make the cavity in the mold into which the metal is poured. Molding and core making: This includes the production of the molds and cores, the insertion of the ores in the mold, and the closing of the mold. Cores typically are sand masses that form the internal surfaces of the part, whereas the mold forms the external surface of the part. The use of cores permits the formation of irregularly shaped internal surfaces in castings, which is extremely difficult for the other forming processes. Melting: This includes the melting of the metal and the pouring of the molten metal into the mold cavity. Cooling and solidification: The cooling and solidification, which are determined by the mold material and riser location, affect the material properties and quality of the casting.

PATTERN

A pattern is a model or the replica of the object (to be casted).

OBJECTIVES OF A PATTERN

1 Pattern prepares a mould cavity for the purpose of making a casting. 2 Pattern possesses core prints which produces seats in form of extra recess for core placement in the mould. 3 It establishes the parting line and parting surfaces in the mould. 4 Runner, gates and riser may form a part of the pattern. 5 Properly constructed patterns minimize overall cost of the casting. 6 Pattern may help in establishing locating pins on the mould and therefore on the casting with a purpose to check the casting dimensions. 7 Properly made pattern having finished and smooth surface reduce casting defects.

PATTERN MATERIAL 1. Wood 2. Metal 3. Plastic 4. Wax etc. FACTORS EFFECTING SELECTION OF PATTERN MATERIAL 1. Number of castings to be produced. Metal pattern are preferred when castings are required large in number. 2. Type of mould material used. 3. Kind of molding process. 4. Method of molding (hand or machine). 5. Degree of dimensional accuracy and surface finish required. 6. Minimum thickness required. 7. Shape, complexity and size of casting. 8. Cost of pattern and chances of repeat orders of the pattern

TYPES OF PATTERN The types of the pattern and the description of each are given as under. 1. One piece or solid pattern 2. Two piece or split pattern 3. Cope and drag pattern 4. Three-piece or multi- piece pattern 5. Loose piece pattern 6. Match plate pattern 7. Follow board pattern 8. Gated pattern 9. Sweep pattern 10. Skeleton pattern 11. Segmental or part pattern

PATTERN ALLOWANCES
1.Shrinkage allowance 2.Machining allowance 3.Draft or taper allowance 4.Rapping allowance 5.Distortion allowance

Cores and core print

Cores are compact mass of core sand that when placed in mould cavity at required location with proper alignment does not allow the molten metal to occupy space for solidification in that portion and hence help to produce hollowness in the casting. Types of cores 1. Horizontal 2. Vertical 3. Balanced 4. Wing 5. Hanging core 6. Cover core

Sand Natural and synthetic sand Main constituents 1. Silica sand 2. Binder (organic group are dextrin, molasses, cereal binders, linseed oil and resins like phenol formaldehyde, urea formaldehyde etc) 3. Moistures 4. Additives (coal dust, corn flour, dextrin, sea coal etc.) Types of sands 1. Green sand 2. Loam sand 3. Facing sand 4. Baking sand 5. System sand 6. Parting sand 7. Core sand

Properties of the moulding sand 1.Permeability 2.Cohesiveness 3.Adhesiveness 4.Plasticity 5.Refractoriness 6.Chemical resistivity 7.Flowability 8.Binding property 9.Green strength

Mould making

Mould

FACTORS CONTROLING GATING DESIGN The following factors must be considered while designing gating system. (i) Sharp corners and abrupt changes in at any section or portion in gating system should be avoided for suppressing turbulence and gas entrapment. Suitable relationship must exist between different crosssectional areas of gating systems. (ii) The most important characteristics of gating system besides sprue are the shape, location and dimensions of runners and type of flow. It is also important to determine the position at which the molten metal enters the mould cavity. (iii) Gating ratio should reveal that the total cross-section of sprue, runner and gate decreases towards the mold cavity which provides a choke effect. (iv) Bending of runner if any should be kept away from mold cavity. (v) Developing the various cross sections of gating system to nullify the effect of turbulence or momentum of molten metal. (vi) Streamlining or removing sharp corners at any junctions by providing generous radius, tapering the sprue, providing radius at sprue entrance and exit and providing a basin instead pouring cup etc.

CLASSIFICATION OF MOLDING PROCESSES Molding processes can be classified in a number of ways. Broadly they are classified either on the basis of the method used or on the basis of the mold material used. (i) Classification based on the method used (a) Bench molding. (b) Floor molding, (c) Pit molding. (d) Machine molding. (ii) Classification based on the mold material used: (a) Sand molding: 1. Green sand mould 2. Dry sand mould, 3. Skin dried mould. 4. Core sand mould. 5. loam mould 6. Cement bonded sand mould 7. Carbon-dioxide mould. 8. Shell mould. (b) Plaster molding, (c) Metallic molding. (d) Loam molding

Casting process review

Casting defects