Manufacturing Processes - Department of Engineering Sciences

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Basic Mechanical Engineering
Prof. Yogiraj Deshmukh Assistant
Professor Department of Applied Sciences
Engineering
Hope Foundations International Institute of
Information Technology, I²IT
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UNIT III
Manufacturing Processes Introduction to
Manufacturing Processes and their Applications
(Casting, Forging, Sheet metal working and Metal
joining processes), Description of Casting
process Sand casting (Cope Drag). Sheet metal
Forming, (shearing, bending, drawing), Forging
(Hot working and cold working comparison),
Electric Arc welding, Comparison of Welding,
Soldering, Brazing
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
3
Manufacturing Process
It involves transforming a raw material from its
original state to a finished state by changing
its shape or the properties of the material in a
series of steps.
Raw Material
Machine Tool
Finished Product
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
4
Metal Casting

• Casting It is a manufacturing process in which
  part of desired shape is obtained by pouring
  molten metal into cavity of required shape
• It is one of the oldest manufacturing process
  (around 6000 year old, Egyptians were first to
  use castings)

Castings
Investment casting
Centrifugal casting
Sand Cascting
Die Casting
Slush Casting
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
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Basic terminology in SAND CASTING process

1. Mould
2. Pattern
3. Core
4. Mould box
5. Mould material
6. Pouring cup
7. Pouring basin
8. Sprue
9. Runner
10. Gate
11. Riser
12. Ladle

Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
6
Metal Casting Sand Casting

• Steps in Sand Casting
• Pattern Making

Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
7
Metal Casting Sand Casting

• Steps in Sand Casting
• 2. Mould Making

Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
8
Metal Casting Sand Casting

• Steps in Sand Casting
• 3. Core Making

Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
9
Metal Casting Sand Casting

• Steps in Sand Casting

4. Metal Melting and Pouring
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in
10
Metal Casting Sand Casting

• Steps in Sand Casting
• Solidification
• Finishing
• Inspection

Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
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Pouring Cup Pouring Basin Sprue
Riser
Mould
Split Flask
Locating Pins Runner Gate Crucible
Rammed Sand Cope
Molten Metal
Drag
Casting
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
12
Steps in sand moulding
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
13
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
14
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
15
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
16
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
17
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
18
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
19
Metal Casting Sand Casting

• Applications of Sand Casting
• Machine beds for various machines (Lathe,
  Drilling, Shaping, Milling)
• Automobile parts (Pistons, cylinder block, clutch
  and brake plates, Gearbox casing)
• Aircraft parts (Turbine and compressor blades,
  Engine casing)
• Casings used in various machines (Turbine,
  Generator, Compressors, Motors, Gear box, Pumps)
• Pulleys, Railway wagon wheels, Valves

Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in
20
References

• V. Ryan 2002 - 2018 www.technologystudent.com

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Thank you For further information please contact
Yogiraj Deshmukh yogirajd_at_isquareit.edu.in Depa
rtment of Applied Sciences Engineering Hope
Foundations International Institute of
Information Technology, I²IT Pune P-14, Rajiv
Gandhi Infotech Park, MIDC Phase I, Hinjawadi,
Pune 411 057 Phone - 91 20 22933441/2/3 www.is
quareit.edu.in info_at_isquareit.edu.in
Hope Foundations International Institute of
Information Technology, I²IT P-14, Rajiv Gandhi
Infotech Park, MIDC Phase I, Hinjawadi, Pune
411 057 Tel [phone]
www.isquareit.edu.in info_at_isquareit.edu.in