casting

1. MANUFACTURING PRACTICES
By
Mr.NABAL SINGH
Assistant Professor,
Department of Mechanical Engineering,,
Jagannath University, Chaksu ,Jaipur
Mail ID:- nabaliitb10@gmail.com

2. Manufacturing
“The Process of Converting Raw
Materials Into Products”

3. Manufacturing processes
• Manu Factus : Latin for ‘made by hand’
• Definition:
• A Well organized method of converting raw material
to end product
• End Product: Value and utility added to output

5. Manufacturing a Product: General
Considerations
• Material Selection
• Processing Methods
• Final Shape and Appearance
• Dimensional and Surface Finish
• Economics of Tooling
• Design Requirements
• Safety and Environmental Concerns

6. Choosing Methods of Production
Use a Selection Chart

7. Economic and Technolgical defination
of Manufacturing

8. Survey of Manufacturing Processes
• Casting: expendable mold and permanent mold.
• Forming and Shaping: rolling, forging, extrusion, drawing, sheet
forming, powder metallurgy, molding
• Machining:
turning, boring, drilling, milling, planing, shaping, broaching, grinding,
ultrasonic machining, chemical machining, electrical discharge
machining (EDM), electrochemical machining, high-energy beam
machining
• Joining: welding, brazing, soldering, diffusion bonding, adhesive
bonding, mechanical joining
• Finishing: honing, lapping, polishing, burnishing, deburring, surface
treating, coating, plating

9. Casting Processes
Introduction of molten metal into a mold cavity; upon
solidification, metal conforms to the shape of the cavity.
Die Casting Sand Casting

10. Forming and Shaping Processes
Bulk deformation processes that induce shape changes
by plastic deformation under forces applied by tools
and dies.
Forging
Extrusion

11. Manufacturing Processes
for Plastics
• Plastics are shipped to manufacturing plants as
pellets or powders and are melted just before the
shaping process. Polymers melt at relatively low
temperatures and are easy to handle.
• Plastics can be molded and formed, as well as
machined and joined, into many shapes with
relative ease.

12. Injection Molding of Plastics

13. Materials

14. Properties of Materials
Mechanical Properties:
strength, toughness, ductility, hardness, elasticity, fatigue, cr
eep.
Behavior Under Loading:
tension, compression, bending, torsion, shear.
Physical Properties: density, specific heat, thermal
expansion, thermal conductivity, melting point, electrical
and magnetic properties.
Chemical Properties:
oxidation, corrosion, degradation, toxicity, flammability.

15. Types of Materials
Ferrous Metals: iron and steel.
Nonferrous Metals and Alloys:
aluminum, magnesium, copper, nickel, titanium, superallo
ys, beryllium, zirconium, low-melting alloys, precious
metals.
Plastics: thermoplastics, thermosets, elastomers.
Ceramics: glass, graphite, diamond.
Composite materials: reinforced plastics, metal-matrix
and ceramic-matrix composites, honeycomb structures.

16. Ferrous Metals: Applications
• Structural: building structures, concrete
reinforcement
• Automotive: chassis, engine parts, drive train, body
parts
• Marine: ship hulls, structure, engines
• Defense: tanks, weapons
• Consumer Products: appliances, recreational
vehicles, toys, utensils and tools

17. Nonferrous Metals: Applications
• Architectural: aluminum windows and doors
• Automotive: aluminum engine blocks, copper
wiring, mag wheels
• Marine: brass/bronze fittings, bearings, propellers
• Defense: brass shell casings
• Consumer Products: electrical
wiring, utensils, jewelry, electronics

18. Plastics (Polymers)
• Compared to metals, plastics have lower
density, strength, elastic modulus, and thermal
and electrical conductivity, and a higher
coefficient of thermal expansion
• The design of plastic parts should include
considerations of their low strength and
stiffness, and high thermal expansion and low
resistance to temperature.

19. Plastics: Applications
• Architectural: electrical and thermal insulation, weather
seals, carpets, wall coverings, paint
• Aerospace: electrical and thermal insulation, instrument
panels, upholstery, seals
• Automotive: body panels, instrument
panels, upholstery, electrical and thermal
insulation, seals, hoses, tires
• Consumer Products: toys, sporting
goods, appliances, tools, utensils, clothing, shoes, packaging