Manufacturing Processes (Part I)

Introduction:

In engineering practice, the knowledge of manufacturing processes plays an important role for mechanical engineers.  The following are the various manufacturing processes used in Mechanical Engineering.

1. Primary shaping processes.

The processes used for the preliminary shaping of the machine component are known as primary shaping processes. The common operations used for this process are casting, forging, extruding, rolling, drawing, bending, shearing, spinning, powder metal forming, squeezing, etc.

2. Machining processes.

The processes used for giving final shape to the machine component, according to planned dimensions are known as machining processes. The common operations used for this process are turning, planning, shaping, drilling, boring, reaming, sawing, broaching, milling, grinding, etc.

3. Surface finishing processes.

The processes that are used to provide a good surface finish for the machine component are known as surface finishing processes. The common operations used for this process are polishing, buffing, honing, lapping, abrasive belt grinding, barrel tumbling, electroplating, super finishing, etc.

4. Joining processes.

The processes used for joining machine components are known as joining processes. The common operations used for this process are welding, riveting, soldering, brazing, screw fastening, pressing, sintering, etc. Joints can be of following types:

·        Temporary joints,

·        Semi-permanent joints,

·        Permanent joints.

5. Processes effecting change in properties.

These processes are used to impart certain specific properties to the machine components so as to make them suitable for particular operations or uses. Such processes are heat treatment, hot-working, cold-working and shot peening.

Casting

It is one of the most important manufacturing processes used in Mechanical Engineering practice. The castings are obtained by remelting of ingots* in a cupola or some other foundry furnace and then pouring this molten metal into metal or sand moulds.

Engine blocks is major example of casting.

The various important casting processes are as follows:

1.      Sand mould casting.

The casting produced by pouring molten metal in sand mould is called sand mould casting. It is particularly used for parts of larger sizes.

2. Permanent mould casting.

The casting produced by pouring molten metal in a metallic mould is called permanent mould casting. It is used for casting aluminum pistons, electric iron parts, cooking utensils, gears, etc. The permanent mould castings have the following advantages:

(a) It has more favorable fine grained structure,

(b) The dimensions may be obtained with close tolerances,

(c) The holes up to 6.35 mm diameter may be easily cast with metal cores.

3. Slush casting. It is a special application of permanent metal mould casting. This method is used for production of hollow castings without the use of cores.

4. Die casting.

The casting produced by forcing molten metal under pressure into a permanent metal mould (known as die) is called die casting. A die is usually made in two halves and when closed it forms a cavity similar to the casting desired. One half of the die that remains stationary is

known as cover die and the other movable half is called ejector die. The die casting method is mostly used for castings of non-ferrous metals of comparatively low fusion temperature. This process is cheaper and quicker than permanent or sand mould casting. Most of the automobile parts like fuel pump, carburetor bodies, horn, heaters, wipers, brackets, steering wheels, hubs and crank cases are made with this process. Following are the advantages and disadvantages of die casting:

Advantages

(a) The production rate is high, ranging up to 700 castings per hour.

(b) It gives better surface smoothness.

(c) The dimensions may be obtained within tolerances.

(d) The die retains its trueness and life for longer periods. For example, the life of a die for zinc base castings is up to one million castings, for copper base alloys up to 75 000 castings and for aluminum base alloys up to 500 000 castings.

(e) It requires less floor area for equivalent production by other casting methods.

(f) By die casting, thin and complex shapes can be easily produced.

(g) The holes up to 0.8 mm can be cast.

Disadvantages

(a) The die casting units are costly.

(b) Only non-ferrous alloys are casted more economically.

(c) It requires special skill for maintenance and operation of a die casting machine.

5. Centrifugal casting. The casting produced by a process in which molten metal is poured and allowed to solidify while the mould is kept revolving, is known as centrifugal casting. The metal thus poured is subjected to centrifugal force due to which it flows in the mould cavities. This results in the production of high density castings with promoted directional solidification. The examples of centrifugal castings are pipes, cylinder liners and sleeves, rolls, bushes, bearings, gears, flywheels, gun barrels, piston rings, brake drums, etc.

Casting Design

An engineer must know how to design the castings so that they can effectively and efficiently render the desired service and can be produced easily and economically. In order to design a casting, the following factors must be taken into consideration:

1. The function to be performed by the casting,

2. Soundness of the casting,

3. Strength of the casting,

4. Ease in its production,

5. Consideration for safety, and

6. Economy in production.

In order to meet these requirements, a design engineer should have a thorough knowledge of production methods including pattern making, moulding, core making, melting and pouring, etc. The best designs will be achieved only when one is able to make a proper selection out of the various available methods. However, a few rules for designing castings are given below to serve as a guide:

1. The sharp corners and frequent use of fillets should be avoided in order to avoid concentration of stresses.

2. All sections in a casting should be designed of uniform thickness, as far as possible. If, however, variation is unavoidable, it should be done gradually.

3. An abrupt change of an extremely thick section into a very thin section should always be avoided.

4. The casting should be designed as simple as possible, but with a good appearance.

5. Large flat surfaces on the casting should be avoided because it is difficult to obtain true surfaces on large castings.

6. In designing a casting, the various allowances must be provided in making a pattern.

7. The ability to withstand contraction stresses of some members of the casting may be improved by providing the curved shapes e.g., the arms of pulleys and wheels.

8. The stiffening members such as webs and ribs used on a casting should be minimum possible in number, as they may give rise to various defects like hot tears and shrinkage, etc.

9. The casting should be designed in such a way that it will require a simpler pattern and its moulding is easier.

10. In order to design cores for casting, due consideration should be given to provide them adequate support in the mould.

11. The deep and narrow pockets in the casting should invariably be avoided to reduce cleaning costs.

12. The use of metal inserts in the casting should be kept minimum.

13. The markings such as names or numbers, etc., should never be provided on vertical surfaces because they provide a hindrance in the withdrawal of pattern.

14. A tolerance of ± 1.6 mm on small castings (below 300 mm) should be provided. In case more dimensional accuracy is desired, a tolerance of ± 0.8 mm may be provided.

In next blog, more topics like forging processes will be discussed.

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